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This application is a continuation of PCT/ES00/00181 filed May 18, 2000.
DESCRIPTION
Object of the Invention
The invention relates to an elliptic valve assembly with compound movement, the novel characteristics of which are that the valve have elliptic heads and in that the motion they describe in the opening and closing process is a combined motion, with a lateral rotation movement in addition to the linear displacement.
The object of the invention is to provide automobile engine manufacturers with a cylinder head with novel valves, in both their configuration and their movement, by which an improved filling of the engine cylinders is obtained as a result of a greater passage section towards the cylinder as compared to conventional valves with a circular head.
BACKGROUND OF THE INVENTION
In cylinder heads with circular section valves and an opening and closing mechanism implying a linear displacement, it is common that the passage section between the valve and the chamber is limited by the characteristics of the head itself, whether hemispherical, flat or Heron type.
As is known, valves are the closing elements placed between the interior of the cylinders and the inlet and exhaust ducts of the head of an internal combustion engine, so that as any other closing element at the moment when it allows passage it is obstructing the inlet or outlet of the passing fluid, but are necessary to block the connection between the various parts during the remaining cycles.
Conventional valves with a circular head, whether they are driven directly by the cams or by rockers, are mechanical elements with a to-and-fro rocking motion, for which they require two forces to perform their function: one to open, and another to close them returning them to their original closed position.
Once the valve is open it must be closed once again, following the camshaft arrangement, for which a spring is required to exert a force allowing an acceleration identical to that of the lift or displacement to carry out the aforementioned function. In practice the situation is otherwise, as when the valve is lifted the force required must provide the required acceleration to the mass while opposing the action of the spring which will return the valve to its original position.
A number of embodiments exist which are based on different valve systems with alternating motion, among which the following may be cited:
MIESSE engine, with a single pipe for inlet and exhaust which may be used for both by the displacement of a partition in the form of a piston.
SPHINX engine with ring valves, which is actually an improvement on the KNICHT runner, port type.
HEWITT engine, in which the conventional valves are replaced by synchronized pistons.
FISHER engine, which lacks valves but includes ports which in turn are controlled by an ingenious pistons system, which may be seen as a combination of the aforementioned system.
Examples of devices which include valves which, in addition to a linear displacement, also move their head laterally are among others U.S. Pat. No. 4,309,966 and Japanese Patent JP 60006011, although in the first case the valve is circular and in the second it is a perfect ellipse with its head coupled to the shaft in a non-eccentric manner, which prevents the devices disclosed in these documents from providing an ideal passage section and thereby an optimum inlet and exhaust flow to the cylinders.
DESCRIPTION OF THE INVENTION
The valve cylinder head object of the invention provides a solution to the problems presented by conventional valve heads, as in addition to providing new characteristics which result in an improved performance of the engine in which the valve head is installed.
More specifically, the novelty of the cylinder head of the invention is an improved filling of the cylinders, increasing the passage section of conventional valves. That is, using the same mechanical base the innovation of the valve head of the invention lies in an operation similar to that of a runner, with the resulting increased filling of this solution as well as a structural simplicity which can be assimilated in current manufacturing processes without requiring great changes.
This increased passage section by which an improved cylinder fill is attained is achieved by the use of valves with an elliptic head, whose opening and closing motion is complemented by a lateral rotation motion. This latter motion requires the valves to be internally guided by a pair of lugs placed diametrically opposite each other on the corresponding shaft. These lugs move along symmetrical helical tracks made for such purpose in the valve shaft housing, thereby enabling the rotation which is determined to be between 50° and 65°.
To allow the insertion of the valves, the machining of these symmetrical helical tracks which make up the guide will be as far as the bottom end of said valves, and complemented by a metal retainer threaded in the position corresponding to said bottom end in order to prevent leaks through said tracks.
In addition, it should be remarked that the valves are complemented by springs similar to those used in circular valve heads with alternate motion, which springs allow to control the usual opening/closing movement and that of the lateral rotation.
The use of the cylinder head with elliptic valves with compound motion, in accordance with the above, will provide a higher efficiency than any other multi-valve system currently employed, as the application of the system will imply an improved filling of the cylinders; in addition by giving the valves a rotation movement a runner-like passage section is achieved, free of obstacles, allowing the mixture to enter more quickly into the cylinders in the inlet process, thereby allowing a greater sweep of the gases in the exhaust process, thereby achieving their exhaust as well as a greater thermodynamic efficiency.
That is, by achieving an improved filling the volumetric coefficient of the inlet is increased, providing a higher specific power and an improved combustion of the fuel, with the ensuing reduced emission of CO and NO type gases.
Obtaining a higher engine torque at lower revolutions allows manufacturing engines with improved usage capacity at all revolutions.
Considering that the industrialization of the elliptic valve head object of the invention does not require significant changes with respect to current heads, as relates to the size and use of the same movement distribution systems (camshaft), and inlet and exhaust ducts, this will allow a great improvement with a simple application as all other elements are readily applicable as there are no costly innovation processes required in the manufacture production lines.
DESCRIPTION OF THE DRAWINGS
These and further characteristics of the present invention will become clearer in view of an accompanying set of drawings of a preferred embodiment of the invention, where for purposes of illustration only the following is shown:
FIG. 1 shows a sectional view of part of the cylinder head with the elliptic head valve object of the invention, revealing all of the main and innovative characteristics of the invention.
FIG. 2 shows a plan view of the elliptic outline of the valve head incorporated in the cylinder head of the invention, shown in its end rotation positions at an angle between 50° and 65°.
PREFERRED EMBODIMENT OF THE INVENTION
In view of the above described figures one can see a part of a cylinder head ( 1 ) on which is mounted a valve ( 2 ) with a head ( 3 ) having an elliptical configuration, placed on the passage of the inlet or exhaust duct ( 4 ), with the corresponding rocker ( 5 ) acting on the top end of said valve ( 2 ).
In this part of the head ( 1 ) can also be seen an ignition plug ( 6 ) and the top part ( 7 ) of the cylinder where the combustion occurs.
One of the novel characteristics of the invention is based on the elliptic configuration of the head ( 3 ) of valve ( 2 ), as well as the establishment of a special guide ( 8 ) in the housing of the shaft of the valve ( 2 ), which guide ( 8 ) is provided with two tracks ( 9 ) symmetrically arranged and having a helical configuration, in which slide and are guided corresponding lugs ( 10 ) provided for such purpose diametrically opposite each other in the shaft of valve ( 2 ). FIG. 1 shows said valve in two positions, one closed and, in a broken line, one open. In each position is shown the situation of the lug ( 10 ) in the corresponding track ( 9 ) in guide ( 8 ). FIG. 2 shows that the valve head has an elliptical configuration with opposing edge areas, one area being narrower than the other area, and that the valve shaft is eccentrically joined to the valve head at the narrower edge area.
These tracks ( 9 ) are machined as far as the bottom end, at which point is provided a metal retainer ( 11 ) which is threaded in to prevent leaks through said tracks ( 9 ) of the guide ( 8 ).
Furthermore, the valve is complemented by a pair of coil springs ( 12 ) mounted between a cavity of the cylinder head ( 1 ) and a top cap ( 13 ) which acts as a stop, aided by a set key ( 14 ).
In accordance with the above described characteristics, the valve ( 2 ) undergoes a two-fold motion, as it has a linear motion, as is conventional, and in addition a simultaneous rotation with an amplitude between 50° and 65°, as shown in FIG. 2, with the double axial and rotational motion guided by the sliding of the lugs ( 10 ) of the shaft of valve ( 2 ) on the tracks ( 9 ) of guide ( 8 ) made for such purpose in the housing of said valve shaft. | The invention aims at achieving better filling of the cylinders located in the body of the valve ( 1 ) by implanting valves ( 2 ) with an elliptical head ( 3 ) whose linear opening/closing movement is complemented by a lateral rotation with a 55° amplitude, said rotational movement being accomplished by using a guide ( 8 ) having two symmetrical and helicoidal tracks ( 9 ) on which two pivots ( 10 ) that are provided for said purpose can slide on points diagonally opposite to the stem pertaining to the corresponding valve ( 2 ). The overhead with the composite movement elliptical valves can be used in all internal combustion engines such as spark ignition or compression ignition internal combustion engines regardless of the number of cylinders and their utilization. | 5 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/843,256 filed Sep. 8, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to mechanical jars that perform impact-related forces on a tool string downhole in hydrocarbon wells, water wells, or other well applications.
[0004] 2. Description of the Related Art
[0005] Well operations often require the use of devices that provide an “impact” on a tool string or a downhole production device. Certain types of downhole tools require the shearing of screws or pins to either set or release a device. A downhole packer or bridge plug, for example, may be run into a wellbore on wireline and then set in place within the is wellbore by shearing screws on the run-in tool. To do this, an impact load will need to be delivered to the run-in tool that is sufficient to cause shearing to occur. In other applications, a device that is being installed in or removed from a production string by wireline or coiled tubing may require impacts to properly install or remove it. For example, gas-lift valves are typically installed in and removed from the pocket of a gas-lift mandrel by a wireline tool. Removing the gas lift valve from the pocket requires the application of an impact force to unseat the valve from the pocket.
[0006] Typically, a mechanical, hydraulic or spring-type jarring tool is used to deliver the impact forces for these situations. With these tools, the impact force is predetermined and calibrated at the surface prior to running the jarring tool in to the wellbore. However, the actual impact force that will be delivered while in the hole will vary depending upon the various well environments and geometries that exist. One important aspect of wellbore geometry is wellbore angle or deviation. Wellbore deviation applies increased friction forces on the tool string and thereby results in reduced impact forces being applied by the jarring tool. In particular, spring jars require pre-set calibration at the surface by manually applying torque to the spring mechanism prior to running the tool in. However, this is not optimal where the wellbore angle is unknown or if wellbore angle changes along the length of the wellbore.
SUMMARY OF THE INVENTION
[0007] An intelligent downhole impact jar device is described that is able to sense well bore angle or deviation and alter the effective jar impact load based upon the sensed information. In an exemplary embodiment, the impact jar device includes a jarring portion for creating jarring impacts within a wellbore toolstring. The jarring portion is adjustable so that jarring forces of various levels can be produced. The device also includes a sensor for determining a wellbore condition, principally the angle of deviation of the surrounding wellbore, and generating a signal indicative of the wellbore condition. In addition, the impact jar device includes a controller to receive the signal from the sensor and adjust the jarring portion to produce a jarring impact of suitable force to match the wellbore condition. For example, if the wellbore is deviated and the jarring force provided by the impact jar will be reduced by the deviation, the controller will adjust the jarring assembly so as to correspondingly increase the force of the jarring impact the jarring assembly will create, thereby increasing the effective jarring force to compensate for the wellbore deviation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For detailed understanding of the invention, reference is made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings in which reference characters designate like or similar elements throughout the several figures of the drawings.
[0009] FIGS. 1A-1C present a side, cross-sectional view of an exemplary intelligent impact jar tool constructed in accordance with the present invention, and in a run-in position.
[0010] FIGS. 2A-2B present a side, cross-sectional view of the impact jar tool of FIGS. 1A-1B , now with the jar having been actuated in preparation for a jar impact.
[0011] FIGS. 3A-3B depict the impact jar tool of FIGS. 1A-1B and 2 A- 2 B during jarring.
[0012] FIGS. 4A-4B illustrate the impact jar tool now being adjusted for downhole angle.
[0013] FIG. 5 is an illustration of an exemplary controller constructed in accordance with the present invention.
[0014] FIG. 6 is a diagram depicting operational steps taken by the controller to adjust the impact jar jarring force to compensate for deviations in wellbore deviation angle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] FIGS. 1A-1D illustrate an exemplary intelligent impact jar device 10 , which is adapted to be secured within a production string (not shown) in a wellbore. The jar device 10 includes an outer tubular housing, generally indicated at 12 , that defines a bore 14 along its length. The bore 14 includes upper and lower enlarged diameter upsets 16 , 18 proximate its upper end 20 . The upper end 21 of the housing 12 has a reduced diameter neck 23 . The housing 12 is attached at its lower end 22 to a lower end sub 24 .
[0016] Disposed radially within the bore 14 of the housing 12 is an impact anvil 26 having a reduced diameter shaft portion 28 , an enlarged diameter anvil portion 30 and a retaining portion 32 . An equalizing passage 34 is defined within the impact anchor 26 and extends between port openings 36 , 38 , and 40 . The retaining portion 32 of the anvil 26 carries a release bearing 42 having a collar 44 and ball bearings 46 . The release bearing 42 is removably secured to the retaining portion when the ball bearings 46 reside within a complimentary annular relief 50 , which is visible in FIG. 3B . The upper end of the anvil 26 is affixed to a top sub 48 , which has a connection suitable for attaching the jar device 10 to a desired wireline or coiled tubing running arrangement (not shown).
[0017] The release bearing 42 is secured by threading or similar fashion to spring housing 52 , which resides within bore 14 . Within the spring housing 52 is a compressible spring 54 . In a currently preferred embodiment, the spring 54 is made up of stacked Belleville washers. However, a coiled spring or fluid spring may be used as well. A spring compression member, or rod, 56 is disposed within the spring housing 52 as well and extends through the lower axial end of the spring housing 52 . The lower end of the compression rod 56 is secured to the spindle of rotary motor 58 . The motor 58 is secured within the bore 14 below the spring housing 52 . Spring 60 is disposed between the spring housing 52 and the motor 58 . A battery pack or other power supply 62 provides power for the motor 58 to operate. The upper end of the compression rod 56 has an enlarged compression head 64 that is located above the spring 54 . Compression of the spring 54 by the spring compression rod 56 and affixed head 64 pre-tensions the release bearing 42 upon the retaining portion 32 of the impact anvil 26 . The compression rod 56 also includes a screw shaft 65 , which is the portion that is affixed to the rotary spindle of the motor 58 . Rotation of the screw shaft 65 in one direction by the motor 58 will shorten the screw shaft 65 and cause the compression head 64 to compress the spring 54 . Rotation of the screw shaft 65 in the opposite direction will uncompress the spring 54 . When the spring 54 is compressed by the motor 58 , the jar force provided by the tool 10 is increased due to increased spring loading and pre-tensioning. Conversely, when the spring 54 is uncompressed, by operation of the motor 58 in reverse, the jar force provided by the tool 10 is decreased.
[0018] During run-in, the jar device 10 is in the configuration shown in FIG. 1A-1C . In order to cause the jar device 10 to create an impact, the top sub 48 is pulled upwardly, drawing the anvil 26 upwardly with respect to the housing 12 to place the anvil 26 in tension. When the anvil 26 reaches the position shown in FIGS. 2A-2C , the ball bearings 46 of the release bearing 42 will encounter the enlarged diameter upset 16 . The ball bearings 42 will move radially outwardly into the upset 16 and allow the retaining portion 32 of the anvil 26 to be move out of the relief 50 on the retaining portion 32 . As a result, the retaining portion 32 is released from attachment to the release bearing 42 and spring housing 52 (see FIG. 3B ). This release will happen very quickly, as the anvil 26 is pulled upwardly in tension. When the anvil 26 is released from the release bearing, the enlarged portion 30 of the anvil 26 will strike against the upper end 20 of the bore 14 , as shown in FIG. 3A . This striking action creates the jarring impact that the tool 10 is intended to deliver. The presence of the equalizing passage 34 and ports 36 , 38 , 40 will permit the anvil 26 to move within the bore 14 of the housing 12 without hindrance by fluid pressure differentials that might otherwise prevent the desired impact jar from occurring.
[0019] Following the jar impact described above, the tool 10 must be reset before a second impact can be performed. To reset the tool, the anvil 26 is moved axially downwardly with respect to the housing 12 . The retaining portion 32 is reinserted into the release bearing 42 and urge the release bearing 42 and affixed spring housing 52 axially downwardly within the housing 12 . This downward movement of the anvil 26 will be resisted by the compression spring 60 , which will compress during the downward movement. As the release bearing 42 enters the lower upset 18 , the ball bearings 46 of the release bearing 42 can move radially outwardly into the upset 18 , thereby allowing the retaining portion 32 to be moved within the release bearing 42 to a point wherein the ball bearings 46 will become aligned with its relief 50 . At this, point the spring 60 may decompress to urge the spring mandrel 52 and anvil 26 axially upwardly with respect to the housing 12 . The release bearing 42 will move out of the enlarged diameter upset 18 and is into a restricted diameter portion 66 of the bore 14 located between the upper and lower upsets 16 , 18 , thereby securing the anvil 26 to the release bearing 42 and the spring housing 52 . Following this resetting, the jarring tool 10 may be again actuated to cause an impact jar, as described previously.
[0020] The jar device 10 is also capable of self-adjustment to alter the amount of impact force that is delivered by the jar device 10 . A controller 68 is operably associated with the motor 62 and governs the adjustment of the impact jar force via adjustment of the compression spring 54 by compression rod 56 and motor 62 . Upon receipt of a suitable command from the controller 68 , the motor 62 will rotate the screw shaft 65 in order to adjust the jarring force (either increase or decrease) that will be provided by the tool 10 . In a currently preferred embodiment, depicted schematically in FIG. 5 , the controller 68 comprises a circuit board 69 having an on-board inclinometer 70 that is capable of detecting the angle from the vertical at which the tool 10 is oriented. Inclinometers of this type are available commercially from a number of commercial sources, including various suppliers of MEMS (microelectromechanical systems) devices, such as Analog Devices of Norwood, Mass. In a currently preferred embodiment, the inclinometer 70 is a spring system made of silica. The controller 68 is also provided with a processor 72 that receives the data obtained by the inclinometer 70 and determines the amount of adjustment that is needed to be made to the compressible spring 54 to compensate in the loss effective jarring force resulting from the deviation angle of the surrounding wellbore. The controller 68 is also capable of providing a command signal to the motor 58 to cause the motor 58 to operate in a particular manner.
[0021] The controller 68 is preprogrammed at the surface with the parameters necessary to allow the controller 68 to determine the amount of frictional losses upon the impact jar device 10 as a result of deviations in the angle of the surrounding wellbore as measured by the inclinometer 70 . These parameters will likely include the weight of the jar tool 10 and associated components as well as the coefficient of friction for the material making up the surrounding wellbore or wellbore casing (either measured or obtained from widely-available reference sources).
[0022] Exemplary operation of the controller 68 to adjust the impact force of the jar tool 10 is depicted schematically in FIG. 6 . According to step 82 of the process 80 , the inclinometer 70 detects the angle of deviation of the surrounding wellbore from the vertical and transmits this information to the controller 68 . In step 84 , the controller 68 determines an approximated amount of impact force loss due to the angular deviation. The determination of force loss may be done by applying known frictional coefficients and friction determination equations to calculate, from the detected angle of deviation and the known material of the surrounding wellbore, a friction force loss amount. For example, if the surrounding wellbore is lined with iron casing sections, an approximate kinetic frictional coefficient (μ) of 0.20 (obtained from published source materials) can be used by the controller 68 to determine the amount of force that is necessary to overcome the frictional losses from the angled deviation of the wellbore. In this example, if the inclinometer 70 were to determine that the impact jar tool 10 were deviated, say 10 degrees from the vertical, the friction force loss due to the deviation could be determined by the equation:
F 1 =Nμ where:
F 1 is the friction force loss (i.e., the frictional force resisting motion of the impact jar tool 10 ); N is the component of force exerted upon the wellbore surface by the weight of the tool 10 ; and μ is the coefficient of friction.
[0026] In step 86 , the controller 68 provides a command to the motor 58 to increase the compression of the spring 54 by rotation of the screw shaft 65 to cause the compression head 64 to compress the spring 54 , thereby creating a pre-tension condition upon the impact anvil 26 . As the spring 54 is axially compressed (see FIG. 2B ), the force with which the impact anvil 26 will impact the upper end 20 of the bore 14 of housing 12 will be correspondingly increased. This process may be repeated by the controller 68 , as illustrated by arrow 88 in FIG. 6 , to provide for a constantly updating, iterative process that is repeated in accordance with a programmed timed cycle.
[0027] The necessary wiring and programming needed to accomplish the above-described steps 82 , 84 , and 86 will be apparent to those of skill in the art of programming microprocessors. The controller 68 is preferably programmed with the desired parameters prior to running the tool 10 into a wellbore. To do this, a serial interface port 90 is provided which allows the controller 68 to be connected up to a programming computer at the surface of the well prior to running the tool 10 into the well.
[0028] Those of skill in the art will recognize that, although the present invention is shown and described in a limited number of forms herein, it is amenable to various changes and modifications without departing from the scope and spirit of the invention. | An intelligent downhole impact jar device is described that is able to sense well bore angle or deviation and alter the effective jar impact load based upon the sensed information. The impact jar device includes a jarring portion for creating jarring impacts within a wellbore toolstring. The jarring portion is adjustable so that jarring forces of various levels can be produced. The jarring portion is adjusted in response to sensed wellbore conditions, such as the angle of deviation of the surrounding wellbore. | 4 |
This application is a continuation of application Ser. No. 07/827,304, filed Jan. 29, 1992, now abandoned, which is a division of application Ser. No. 07,552,700 filed Jul. 16, 1990, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates generally to a method for pretreating continuous textile material having a tufted carpet web and, more particularly, to an improved method for pretreating carpet goods before a dyeing process.
A method and apparatus for pretreating a continuous textile web is disclosed in DE-AS 16 35 004. This document describes guiding a carpet web through a basin of a padding machine or foulard filled with a wetting agent. The wetting agent is squeezed out in a specified manner, and then a dyeing liquid is immediately applied to the web.
Various problems have occurred when tufted carpet webs are pretreated, and subsequently dyed according to the above-described prior art. To lengthen the useful lifetime of the tufting needles used in the ever faster-running tufting machines, larger and larger quantities of finishes or spinning oils must be applied to the fibers. Among their other uses, these finishes and spinning oils are used as lubricants in the carpet tufting process. The finishes and spinning oils remain on the carpet goods and, in conventional dyeing processes, very often result in an uneven fixation of the dye, thus producing cloudy patches and a sandwich effect on the dyed carpet goods. The sandwich effect occurs when the fiber tips are dyed to a lesser degree than the remaining material. The foam used to dye the carpet goods dyes the fiber tips particularly well, and thus, the sandwich effect and the cloudy patches are avoided. However, the finishes and the spinning oils on the carpet web destroy the dyeing foam in the steaming machine and thus the result is a cloudy coloration on the carpet goods.
Problems are caused not only by the quantity of finishes or spinning oils used, but also by the type of finishes or spinning oils that are used. Of course, the price per kilogram of these processing aids is very important. Therefore, inexpensive finishes are often applied to the fibers. Although these inexpensive finishes are effective during the tufting operation, they cause considerable problems during the subsequent dyeing process.
Further problems can occur during the storage of the tufted, untreated carpet material (rolls having a width of 4 to 5 m, for example) over a long period of time. Amongst other things, the carpet edges become damp and then dry out again, which causes the finishes and spinning oils present at the edges to become altered in comparison to the finishes and spinning oils at the middle of the carpet. This nonuniformity may vary the color of the carpet material and result in uneven carpet dyeing over the width of the carpet surface.
When a pretreatment process is carried out in the padding machine, such as disclosed in DE-AS 16 35 004, the finishes and the spinning oils accumulate in the trough of the padding machine and are then subsequently picked up again by the carpet web in a nonuniform manner, thereby interfering with the coloration. When the known technique is used, obstinate coating agents, such as the above-mentioned finishes and spinning oils, cannot be effectively removed.
SUMMARY OF THE INVENTION
The invention is directed to providing a method for pretreating continuous textile material before a dyeing process occurs that avoids the above-mentioned problems and disadvantages of the prior art.
The invention solves these problems and avoids these disadvantages by providing a method for pretreating a continuous textile web having at least one tufted side that includes the following steps. The web to be pretreated is guided essentially vertically through a wedge-shaped gap filled with a preparatory agent from the top of the gap to the bottom. The preparatory agent is applied to the textile web as the web passes through the gap. The preparatory agent is wiped off the web at a lower end of the gap. The web is conducted through air for a predetermined dwell time before the web is hydroextracted to a predetermined moisture content.
Due to the special type of application of the preparatory agent of the invention, in which the web is guided through a vertical gap, only a comparatively small quantity of the preparatory agent comes into contact with the web. The preparatory agent is constantly being resupplied. If the preparatory agent were not continuously resupplied to the gap, as in the present invention, the amount of the agent available in the gap would be used up in a few seconds. Harmful quantities of chemicals, such as finishes and spinning oils derived from preceding treatment steps, cannot collect in such a small quantity of liquid, which is resupplied again and again over such a short time period. This is unlike the situation that occurs in larger baths, such as found in the trough of a padding machine, or even in a roller vat.
Since the chemicals, particularly the finishes and spinning oils, are generally not easily removed, the preparatory agent should be given a period of time to become effective. If the preparatory agent is a rinsing agent, it can partially dissolve the chemicals found on the web during the dwell time it remains on the web and, moreover, can penetrate efficiently between the fibers. The result is a textile material that is thoroughly prepared for the subsequent application of the liquid dye.
The present invention is not directed merely to the idea of pretreating or prewashing a carpet web, but rather concerns a particular type of preparatory agent application in which the web comes into contact with only a small amount of the preparatory agent and then is subjected to a dwell time to increase the effectiveness of the preparatory agent. The preparatory agent can be a rinsing agent to remove the chemicals, for example the above-mentioned finishes and spinning oils, present on the web from preceding manufacturing steps. However, it is also possible to apply other types of preparatory agents.
It has been shown that dwell times of approximately 30 to 90 seconds are expedient to partially dissolve and then thoroughly remove the chemicals present on the web, such as finishes and spinning oils.
The first machine found in man continuous-dyeing installations is a preliminary steamer. In this machine, the textile material is prepared for the dyeing operation, and any creases or markings resulting from storage are removed. However, it is not possible to very successfully remove such markings when dry material is steamed. If, however, the web is steamed, in accordance with a technique of the invention, after the water is extracted and before the dyeing process, then the material conducted to the steaming machine arrives with a controlled moisture content. This process results in much improved crease removal and, additionally, the material acquires a particularly advantageous bulk.
According to another aspect of the invention, an apparatus is provided for pretreating a continuous textile web having at least one tufted side that includes an applicator for applying a preparatory agent to the web. The applicator includes means for defining a gap to be filled up to a predetermined filling level with a preparatory agent. The gap is arranged to extend across the width of a web to be treated in the applicator and has a top end inwardly tapering toward its bottom end. At least one member seals the bottom end of the gap such that the member may exert pressure on at least one side of a web conducted through the gap. At least one counter-member extends across the width of the web conducted through the gap. The counter-member faces the sealing member such that the sealing member elastically presses against the web and the counter-member as the web is guided through the bottom end of the gap. The pretreatment apparatus also includes a hydroextraction device disposed downstream from the applicator in the direction of travel of a web conducted through the applicator and a dwell apparatus arranged between the applicator and the hydroextraction device. The dwell apparatus conducts the web as it emerges from the applicator through the surrounding air before it is fed to the hydroextraction device.
Use of an applicator that constitutes the first component of the installation and has a vertical gap sealed at the bottom through which a web is guided from the top of the gap to the bottom is disclosed in French Patent 1 381 081.
The dwell apparatus in which the dwell time is developed may include a first row of deflecting rolls and a second row of deflecting rolls disposed above the first row in a vertical direction. The deflecting rolls of the first row may be horizontally offset from the rolls of the second row, whereby a web conducted over the first and second rows of deflecting rolls is guided in vertically extending loops.
The hydroextraction device may be formed by a suction gap because use of a suction gap exerts a minimum of stresses on the fibrous structure of the tuft.
As already mentioned, the steaming machine is arranged downstream from the hydroextraction device and improves the quality of the material and prepares it for the subsequent dyeing operation.
A though the invention is not limited to a method in which the pretreatment and dyeing installation is operated in a continuous mode and the web is immediately subject to the dyeing operation before it leaves the steaming machine, such a method is preferred.
Further features, advantages, and embodiments of the invention are apparent from consideration of the following detailed description, drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWING
The sole drawing FIGURE illustrates a side view of an apparatus for pretreating carpets constructed according to the principles of the present invention.
DETAILED DESCRIPTION
The apparatus 100 is used to pretreat, before dyeing, a web 10 that consists of a carpet material having a tufted side. The web 10 is conducted in the direction indicated by the arrows through the apparatus 100. The web 10 sequentially passes through the following devices: an applicator A containing the preparatory agent; a detainment station in the form of a dwell apparatus B; a hydroextraction device in the form of a suction device C; and a steaming machine D.
The applicator A comprises a vertical gap 2 that extends over the width of the web 10. This gap 2 is filled up to a filling level 3 with a liquid preparatory agent that is continuously supplied from supply conduits 21. The quantity of liquid contained in the gap 2 is small; if the working width of the gap is 4 m, the quantity of liquid is about 25 liters. The web 10 is guided vertically over guide rolls 5 and 6 from the top to the bottom and through the gap 2. The web absorbs the preparatory agent in the gap 2, which is subsequently wiped off from both sides of the web 2 by two inflatable tubes 7 disposed below the gap 2. The inflatable tubes 7 extend across the width of the web 10. These tubes 7 define and seal the bottom end of gap 2 so that no significant quantities of the preparatory agent can run downward and out of the gap 2.
The web 10 is next led over the driven deflecting roll 8, which provides the necessary amount of tension to guide the web 10 through the gap 2, as well as over a compensator 9, before feeding the web 10 into the dwell apparatus B. In the embodiment shown in the FIGURE, the dwell apparatus B includes a series of four upper deflecting rolls 11, which are all arranged at the same height and parallel to one another. The dwell apparatus B also includes a series of three deflecting rolls 12 spaced vertically below and horizontally offset from the deflecting rolls 11. The web is guided over the deflecting rolls 12 in vertically extending loops in the manner illustrated in the FIGURE.
The fabric web 10 then arrives in the hydroextraction device C, which includes a suction device 13. The suction device 13 comprises a suction tube 14 disposed below a horizontal section of the web 10 and a pressure element 15 disposed above the suction device. A spray device 16 can also be arranged at a point beyond the suction device 13. The hydroextraction device C can also comprise several suction devices 13 which are connected together in series with spray devices 16. The suctioning of the web 10 in the suction device 13 produces a residual moisture content of 30% to 70%. The tension required to bring the web 10 between the suction tube 14 and the pressure device 15 is produced by a driven roll 17 located beyond the suction tube 14.
The web 10 then runs over a compensator 18 and into the steaming machine D. In the embodiment shown in the FIGURE, the web 10 only forms an upright loop in the steaming machine D. After leaving the steaming machine, the web 10 passes a driving roll which conducts the web through the end of the pretreatment apparatus 100 to begin the dyeing operation.
The following example describes the use of the pretreatment apparatus 100. First, assume a carpet material having a tufted pile of 6.6 nylon and an adhesive-bonded (nonwoven) backing with a fabric weight of 700 g/m 2 is to be treated in the apparatus 100. An aqueous preparatory agent having a chemical concentration of 0.5 g/l of washing and wetting agents is applied in the applicator A in a quantity of approximately 400% of the dry material. The web is then detained in the dwell apparatus B for about one minute. After passing through the suction device, the web has a residual moisture content of approximately 50%. With this residual moisture, the web enters the steamer D, where it is also detained for about one minute. After the subsequent dyeing and fixation procedure, a carpet web results that has no cloudy patches and does not exhibit a sandwich effect. | An undyed carpet web is pretreated by applying a liquid preparatory agent in a gap of an applicator. Subsequent to the application of the preparatory agent, the carpet web is detained in a dwell apparatus. The web is then suctioned off in a hydroextraction device and steamed in a steaming machine before the dyeing operation begins. | 3 |
INTRODUCTION
[0001] Today, reception devices for television programs are able to receive media contents from a plurality of sources. Hybrid Broadcast Broadband TV (HbbTV) is both an industry standard (ETSI TS 102 796) and promotional initiative for hybrid digital TV to harmonise the broadcast, IPTV, and broadband delivery of entertainment content to the end consumer through connected TVs (smart TVs) and set-top boxes. The HbbTV consortium, regrouping digital broadcasting and Internet industry companies, establishes a standard for the delivery of broadcast TV and broadband TV to the home, through a single user interface, creating an open platform as an alternative to proprietary technologies. Products and services using the HbbTV standard can operate over different broadcasting technologies, such as satellite, cable or terrestrial networks.
[0002] HbbTV allows for digital television content from a number of different sources to be shown including traditional broadcast TV, Internet, and connected devices in the home. To watch hybrid digital TV, consumers will need a hybrid IPTV set-top box with a range of input connectors including Ethernet, as well as at least one tuner for receiving broadcast TV signals. The tuner in a hybrid set-top box can be digital terrestrial television (DVB-T, DVB-T2), digital cable (DVB-C, DVB-C2) or digital satellite (DVB-S, DVB-S2) compatible.
[0003] As a consequence, the hybrid IPTV set-top box has the choice of activating a broadcast communication means or an IP communication means to obtain the channel requested by the user. By broadcast communication, we understand the transmission of the same content to many devices, via the cable, the satellite, or radio waves antenna. This also includes multicast over IP, in which a particular content is available on an IP network and can be accessed at the same time by a plurality of devices (one to many). By IP communication, we understand the transmission on request by a device via an IP network (one to one). This choice should be transparent for the user and the reception device should determine which communication means is available for a given channel and in case the channel is available on both communication means, the quality available on each means.
[0004] On the transmission side, the cost for rendering a channel accessible is not the same if it is available on broadcast or IP. On broadcast, the bandwidth per channel is usually wider and the decision to include a channel into a broadcast feed is determined by the broadcaster. The setting-up of the feed is more complicated since the allocation of the frequency for a given service should be precisely described in tables (Program Association Table PAT, Program Map Table PMT). These tables describe the content of the different transponders since a service is composed of a plurality of elementary streams (audio, video, data, caption, access control) identified by a Packet Identifier PID and a plurality of services are transmitted by the same transponder. Changing the distribution of these services is therefore cumbersome.
[0005] On the other side, IP transmission is simple since the reception device sends a request to an IP transmission center to obtain a given channel. The IP transmission center prepares and sends the requested channel to the reception device using the IP protocol. This channel uses the Internet connection of the user. Dedicated packets, forming the requested channel, are sent to the reception device. The drawback of this solution is the bandwidth which is required since this bandwidth increases linearly with the number of users. It is therefore more advantageous to address a large audience with a broadcast communication. However, with the increase of available channels, the available frequencies and services are not sufficient to satisfy the demand, and some more confidential channels will only be accessible via IP communication. The decision to use one or the other communication means is generally based on audience survey results.
[0006] As the demand for different channels evolves with time, there is also a need for a mechanism that enables a flexible modification of the channels made accessible to users from broadcast means to IP means and vice versa
BRIEF DESCRIPTION OF THE INVENTION
[0007] The aim of the present description is to propose a different approach to allocate a channel to either the broadcast communication means or the IP communication means and to allow for a certain amount of flexibility in such allocation.
[0008] Accordingly, there is proposed a method to optimize the transmission of a set of television channels to at least a reception device having a device identifier, said reception device having at least a broadcast communication means and IP communication means, this method comprising the steps of:
selecting, by a reception device, a channel having a channel identifier received via either the broadcast communication means from a broadcast transmission center or the IP communication means from an IP transmission center, transmitting, by the reception device to a control center, a status message comprising at least the selected channel, receiving, by the control center, status messages from a plurality of reception devices, calculating by the control center, from the status messages, a cost per channel based at least on the number of reception devices having selected said channel, allocating the channels having the highest cost to the broadcasting transmission center and allocating the other channels to the IP transmission center, transmitting a response message to the reception devices, said response message comprising an allocation list describing, for each channel, to which communication means said channel is allocated.
[0015] A set of channels (or services according to the DVB recommendation) is delivered to a broadcast transmission center and an IP transmission center. The control center is in charge of allocating the channels to each transmission center. For that purpose, each transmission center has access to all the channels and selects only the one specified by the control center for transmission.
[0016] According to one aspect of this method, the control center receives from the reception devices, the channel identifiers of the channels currently in use. This information serves to determine the number of concurrent receptions of one channel are requested and as a consequence, what is the most appropriate way to transmit the channels to the users.
[0017] According to another aspect of the invention, there is provided a method for changing the allocation of channels to each transmission center, in a flexible way. In particular, this method allows for a channel which were allocated to the broadcast transmission center to be re-allocated to the IP transmission center and vice versa.
[0018] The method also allows for the available bandwidth of the broadcast transmission center to be optimized.
BRIEF DESCRIPTION OF THE FIGURES
[0019] The present invention will be better understood thanks to the enclosed drawings in which:
[0020] FIG. 1 illustrates a system in which an embodiment as the present invention may be deployed;
[0021] FIG. 2 illustrates a reception device suitable for use in the system of FIG. 1 .
DETAILED DESCRIPTION
[0022] FIG. 1 illustrates the different elements forming a transmission system. On one side, a backbone BB carries all channels available for transmission. This backbone BB is connected to at least one broadcast transmission center BTC and at least one IP transmission center IPTC. It is understood that a plurality of broadcast transmission centers can be used, connected to the backbone, to address a subset of reception devices. This is particularly the case in IP mode, in which an IP transmission center prepares a subset of channels forming an IP channel stream, this stream being transmitted to a local IP transmission front-end in charge of selecting one channel selected by the user and transmitting this channel to the user. These IP transmission front-ends are located close to the users, in particular in the telephone switches or wherever the IP connection of one user is multiplexed.
[0023] The transmission system comprises a control center CC whose is to collect the user's behavior and to determine which transmission center is the most appropriate. For this purpose, the control center is connected to Internet and is able to receive messages from and send messages to the reception devices. At the startup of a reception device, a request is sent the control center CC to obtain the list of allocated channels. This list is stored in the reception device and used each time a selection is made by the user. The list contains a description of the transmission means used for a specific channel. The reception device can then select the correct transmission means to receive the channel. According to an embodiment, the list also contains additional details that can speed-up the setting up of the transmission means. In the case of broadcast transmission, the list will contain the transponder identifier, i.e. the central frequency around which the channel is modulated. In the case of IP transmission, the list contains the IP address of the IP transmission center in charge of transmitting this channel.
[0024] According to the invention, the reception devices STB1, STB2, STBn communicate the selection made by the user to the control center. This selection comprises at least an identifier of the current main channel or alternatively of a secondary channel such as one currently recorded or in PIP function. A message is generated by a reception device, said message containing an identifier of the current channel and of the other channels currently used, if any. This message can be sent to the control center at each channel change, or at regular intervals (e.g. every 15 min), or on request of the control center.
[0025] The control center is in charge of counting the number of reception devices currently using one particular channel. In view of the repetition of the messages sent by the reception devices (in case it is sent every 15 min.) the control center should be able to discard the messages repeating the same information. For that purpose, different solutions are proposed.
[0026] A first solution is to associate the message with a unique identification of the reception devices. The control center keeps a table containing, for each unique identification, an identifier of the current channel (Device_ID, Channel). In the case that several channels are used by a single reception device, the message will contain an identifier of each channel used (Device_ID, Channel1, Channel2, Channel3). Once this table is populated, the control center can count the number of times each channel appears. The unique identification can be the unique address of the reception device stored in the reception device and added into the message, or the physical address of the reception device (IP address) obtained by the communication protocol.
[0027] Another solution is to use a session number, allocated to a specific reception device by the control center when the reception device first connects to the control center. This session number is valid for a limited time period (e.g. 1 hour) and this time period is updated each time the control center receives a message (Session_ID, Channel) from the reception device. The message may contain this session number allowing the control center to populate the table (Session_ID, Channel, Expiration_Time). In the case that multiple channels are used by a single reception device, the message may contain an identifier of each channel used (Session_ID, Channel1, Channel2, Channel3). Each time a message is received, the expiration time is moved ahead by a predefined value. When the control center counts the entries per channel, it will discard the entries for which the expiration time is behind the current time.
[0028] It is also possible not to discard the messages, but on the contrary, to count each message for example over a regular interval, such as 15 minutes. In this case, every 15 minutes, the number of reception devices for each channel is updated and the allocation tables can be updated accordingly.
[0029] Thanks to the messages received from the reception devices, the control center can have, for each channel, the number of reception devices currently using said channel. This information is used to calculate a cost per channel, this cost being directly related to the number of reception devices using this channel.
[0030] According to a first embodiment, the cost is the number of reception devices. The control center may sort the channels by cost. The channels having the highest costs are then allocated to the broadcast transmission center until the total available bandwidth is full. For example the broadcast transmission center has a capability of 100 MHz. In the allocation to the broadcast transmission center, the bandwidth of each channel will be taken into account. The channels are then sorted by bandwidth, from the ones with the largest bandwidth to the ones with the smallest. The channels are so allocated for broadcast transmission in order to fill the maximum bandwidth (100 MHz). The first channels, the sum of whose cumulated bandwidths does not exceed 100 Mhz are hence broadcast. The other channels are then handled by the IP transmission center. The control center prepares an allocation list describing, for each channel, which transmission center is used. This allocation list is then sent to the reception devices.
[0031] In one embodiment, illustrated by the table below, the cost can take into account the bandwidth used by this channel and the number of users accessing it over the Internet (Unicast cost).
[0000]
Number of
Channel_ID
customers
Bandwidth
Unicast Cost
27
250.000
3.5 Mbps
875k
18
135.000
4.5 Mbps
607.5k
134
65.000
3.5 Mbps
227k
7
60.000
5.5 Mbps
330k
[0032] In the case illustrated above, the unicast cost of the channel 18 can be C_18=135′000×4.5=607.5 k and the unicast cost for the channel 7 is C_7=60′000×5.5=330 k. The sorting of the unicast cost will take into account a combination of the number of devices and the bandwidth. In this case, channel 18 will have a higher cost than channel 7, and for this reason channel 7 will be selected for broadcast with priority over channel 18
[0033] This list can take some priority channels into account, i.e. channels which are always sent by one specific transmission means. In the case that a provider has contracted a guarantee with the distributor that a channel will always be sent via broadcast, this channel is always part of the broadcast channels.
[0034] In one embodiment, the control center may include a “suboptimal channel” in the list of broadcast channels, when this helps to deal with fractions of bandwidth that would otherwise be wasted. For example, in a system where the maximum bandwidth is 100 Mhz, if the first 19 channels account for 98 Mhz and the 20th channel would occupy 4 Mhz, the control center can decide to broadcast the next channel (e.g. 21 st or 22 nd , . . . ) whose bandwidth is <=2 Mhz (which is the residual available bandwidth).
[0035] The allocation list is established on a regular basis. The section of the list that refers to the broadcast transmission center is sent to the broadcast transmission center and the section that refers to the IP transmission center is sent to the IP transmission center. These transmission centers will then filter the set of channels to keep only the ones mentioned in their respective lists. To facilitate the detection of changes in the allocation list, the same can contain a version indication. Each time the allocation list is changed by the control center, the version indication is updated. This version indication helps the reception devices to detect whether a modification was made compared to the list received previously. If not, the reception device simply ignores the list. When a change occurs in the list, the control center sends this list at least to the reception devices that are currently tuned on one channel affected by a change and to the broadcast and IP transmission centers. It is not desirable that this list change too often. This is why the control center waits a certain time, preferably when a change in the cost ranking is detected, to see if the change is stable or only due to some transient user's behavior. If after a certain time, the cost ranking is stable and one channel should be moved from one transmission means to the other, the control center may decide to change the list.
[0036] According to a preferred embodiment, the change occurs in two steps. We take the example of moving the channel A from broadcast transmission means to IP transmission means and the channel B from IP transmission means to broadcast transmission means. The first step is to free one channel on the broadcast transmission center and to copy channel A to the IP transmission center. According to a preferred embodiment, channel A is analyzed to detect content suitable for the transition. A channel usually contains a main section and an auxiliary section. The main section is the user's expected content such as a film, a sport event, a documentary etc. The auxiliary content is mainly the advertisement section. The control center detects the auxiliary section or waits until this happens, to send an allocation list comprising a change. When an auxiliary section is detected, channel A can be changed from broadcast to IP. This is done by sending the updated allocation list to the broadcast transmission center and the IP transmission center. In order to allow for a smooth change, the IP transmission center can be informed first to include channel A into its offer and to keep channel A in the broadcast transmission center. During this transition period, channel A will be available via both transmission means. Concurrently, the updated list is sent to the reception devices, allowing them to change during the auxiliary section of channel A from broadcast to IP.
[0037] After this transition period, which can be defined to be long enough to have the time to inform all reception devices, the second step can take place. Channel B is analyzed in order to detect an auxiliary section. Once found, the allocation list is changed and an updated list is sent to the broadcast transmission center to replace channel A by channel B. At that time, if a reception device has not switched to the IP transmission means, it will no longer be able to receive this channel. Once the broadcast center has confirmed that channel B is on air, the control center sends the updated list to the reception devices containing the new allocation for channel B. At that time, the IP center still continues to propose channel B to the reception devices.
[0038] After the expiration of the transition phase, the IP transmission center is informed by the control center to deactivate channel B.
[0039] In order to make this scenario easier and to minimize the number of communications, the control center could also send the two updated allocation tables together with a validity period (one per list) indicating from when to when each list is valid.
[0040] According to a first embodiment, there is no synchronization of the content during or at the end of re-allocation of a channel. Contents of these channels are transmitted and viewed according to the technical constraints of the transmission means.
[0041] According to a second embodiment, a synchronization of the content is made during or at the end of the re-allocation of a channel. In this embodiment, the channel contains means for identifying specific places within that content. These means can be for example an index of I-frames, marks that are integrated in the stream or a time-stamp. When a channel is moved from one transmission means to another, the means for identifying a specific place are used to store the place where a channel stopped being transmitted by a specific transmission means. Content is then transmitted by the other transmission means from that stored place. A buffer is preferably integrated in the reception means to store a part of the content and to facilitate the transition between the transmission means. It should be noted that a short part of the content could always be stored, not only during transition.
[0042] An allocation list may further comprise additional information. The reception device can send not only the current channel but also the physical reception constraint. In the case that a reception device can only receive a maximum bandwidth of 4 Mbps via IP, moving channel 7 of the list above from broadcast to IP can have a negative consequence for this reception device. The control center may further calculate the impact of this change on the reception devices and in the case that a large number of devices cannot afford this higher bandwidth, may decide to keep channel 7 on the broadcast transmission center even if the number of devices is less than for other channels. For this reason a limit may be set in the control center, for example 10%, so that a change may be blocked if more than 10% of the devices would not be able to follow this change.
[0043] It is to be noted that a reception device is not necessarily a set-top box. It can be a computer or even a mobile device. The latter can obtain content via DVB-H (broadcast) or via the data link (3G, 4G or Wifi). Similarly, the content is not necessarily limited to audiovisual content but could be generic data content that could be alternatively broadcast over a satellite or sent over a unicast data link.
[0044] FIG. 2 illustrates a reception device in which two transmission means are shown. The IP transmission means IP_TM is in charge of the reception of a channel in IP mode and the data is passed to an IP processing module that produces, for example, a TS packet stream. The same is valid for the broadcast reception means BD_TM, with the received data being passed to a broadcast processing module BD_PR. This module produces a TS packet stream. In the illustrated embodiment, two buffers are shown BP_PU and IP_BU, one per transmission means. The buffers are present to achieve a seamless transition between the two transmission means. It is known that the transmission time is different per transmission means. If one compares the output of the broadcast processing module with the output of the IP processing module, the content can have up to 500 ms difference in time. The buffers will be then used to resynchronize both contents for example by detecting a packet header identifying an I-frame. When the change should occur, the buffer of the other transmission means is analyzed to detect at which position the same packet is present. Once detected, the pointer of the buffer is modified so that both outputs of the processing modules are synchronized. The selection module (SL) can then switch from one source to the other one and pass the content to the decompression module PR. | A method to optimize transmission of a set of television channels to a reception device having at least a broadcast interface and an IP interface, comprising: selecting by a reception device a channel having a channel identifier received via either the broadcast communication means from a broadcast transmission center or the IP communication means from an IP transmission center; transmitting by the reception device to a control center a status message comprising at least the selected channel; receiving, by the control center, status messages from a plurality of reception devices; calculating by the control center, a cost per channel based at least on the number of reception devices selecting said channel; allocating the channels having the highest cost to the broadcast transmission center and allocating the other channels to the IP transmission center; and transmitting to the reception devices an allocation list describing to which interface each channel was allocated. | 7 |
BACKGROUND OF THE INVENTION
[0001] 2. Field of the Invention
[0002] The invention relates to an improved fuel injection nozzle for an internal combustion engine.
[0003] 2. Description of the Prior Art
[0004] One injection nozzle known for instance from German Patent Disclosure DE 100 58 153 A1 has a needle body which has at least one first injection port and at least one second injection port and includes both a first nozzle needle and a second nozzle needle. The first nozzle needle is embodied as a hollow needle, and the second nozzle needle is disposed coaxially to and in the first nozzle needle. With the aid of the first nozzle needle, the injection of fuel through the at least one first injection port can be controlled, while the second nozzle needle serves to control the injection of fuel through the at least one second injection port. The needle body includes a first control chamber, in which a first control face is disposed. This first control face is drive-coupled to the second nozzle needle and is oriented such that a pressure prevailing in the first control chamber generates pressure forces at the first control face that introduce closing forces into the second nozzle needle. Communicating with this first control chamber is a control line, with which the pressure in the first control chamber can be controlled.
[0005] In the known injection nozzle, the needle body furthermore includes a pressure chamber to which a fuel supply line is connected. In this pressure chamber, the first nozzle needle has at least one pressure step, which when the pressure chamber is subjected to pressure introduces opening forces into the first nozzle needle. If a low pressure prevails in the fuel supply line, then closing forces, generated by a suitable closing spring, are generated predominantly at the first nozzle needle. For opening the first nozzle needle, a high pressure is generated in the fuel supply line and, in the first nozzle needle by way of its pressure step, this high pressure generates sufficiently high opening forces. The first nozzle needle is thus directly controlled by the pressure applied to its pressure step so that the first nozzle needle is pressure-controlled.
[0006] The second nozzle needle is likewise equipped with a pressure step, but only when the first nozzle needle is opened is it acted upon by the high pressure and is capable of generating forces operative in the opening direction of the second nozzle needle. As long as a suitable high pressure prevails in the first control chamber, the closing forces predominate in the second nozzle needle. If with the first nozzle needle opened, the pressure in the first control chamber is lowered via the control line, then the opening forces predominate at the second nozzle needle. Thus the second nozzle needle is not controlled directly by the pressure applied to its pressure step but rather indirectly via the pressure in the first control chamber. Accordingly, the second nozzle needle in this case is servo-controlled.
[0007] To enable the second nozzle needle to open quickly, the pressure in the first control chamber drops correspondingly fast. As a result, the second nozzle needle is given a relatively high stroke speed. At certain engine operating points, it is necessary for the injection to be terminated again only briefly after the opening of the second nozzle needle. This can result in configurations in which the second nozzle needle closes too early, for instance if because of its high stroke speed it bounces back from a stop that defines the maximum opening stroke of the second nozzle needle. To attain optimal emissions and power values for the engine, however, it must be possible to predetermine the opening and closing instants of the injection nozzle as exactly as possible.
OBJECT AND SUMMARY OF THE INVENTION
[0008] The injection nozzle of the invention has the advantage over the prior art that upon opening of the second nozzle needle, a lesser stroke speed is established for that nozzle needle, so that no bouncing, or only reduced bouncing, of the second nozzle needle occurs. As a result, the end of injection for the fuel injection through the at least one second injection port, or through all the injection ports, can be predetermined with greater accuracy. This is attained by means of the invention in that the first control chamber is connected for communication to a suitable pressure source directly or indirectly via a first coupling path. As a result, the pressure in the control chamber cannot drop so sharply, since hydraulic fluid, in particular fuel, permanently continues to flow in via the first coupling path. It is also of particular significance in the present invention that now both nozzle needles are servo-controlled. For that purpose, a second control face is provided, which is embodied on the first nozzle needle or is drive-coupled to it and which is disposed in the first control chamber, where it can be acted upon by a pressure acting in the closing direction of the first nozzle needle. The pressure in the first control chamber thus controls both the first nozzle needle and the second nozzle needle. A second coupling path has particular significance here; it likewise connects the first control chamber to the pressure source for communication and is controlled as a function of the stroke of the first nozzle needle. The control of the second coupling path is designed such that beginning at the closing position of the first nozzle needle, the second coupling path is open up to a predetermined prestroke of the first nozzle needle and is blocked beyond a stroke of the first nozzle needle that goes beyond the prestroke. As a result of this design, the first control chamber is supplied with replenishing hydraulic fluid upon the opening of the first nozzle needle, until the prestroke is attained, both through the first coupling path and through the second coupling path. Beyond the prestroke, or in other words when the second coupling path is blocked, the supply of hydraulic fluid to the first control chamber is then effected only via the first coupling path. As a consequence, the pressure in the first control chamber, upon opening of the control line that communicates with the first control chamber, initially drops to a first value and then, when the prestroke is reached, drops to a second value that is less than the first. These pressure values can be designed such that at the first pressure value, only the first nozzle needle opens, while at the second pressure value, the second nozzle needle opens as well. The expense for achieving the servo control of the two nozzle needles is comparatively slight as a result.
BRIEF DESCRIPTION OF THE DRAWING
[0009] The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of preferred embodiments, taken in conjunction with the sole drawing FIGURE which shows a longitudinal section, greatly simplified, through a basic illustration of a preferred exemplary embodiment of the injection nozzle of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] In FIG. 1 , an injection nozzle 1 of the invention has a needle body 2 , which protrudes with a nozzle tip 3 into a combustion chamber 4 or a mixture-forming chamber 4 of an internal combustion engine, in particular a Diesel engine. In the region of the nozzle tip 3 , the needle body 2 includes at least one first injection port 5 and at least one second injection port 6 . Typically, a plurality of first injection ports 5 are provided, in particular arranged in a ring. Correspondingly, a plurality of second injection ports 6 may be provided, also expediently arranged in a ring.
[0011] In the needle body 2 , a first nozzle needle 7 is supported with an adjustable stroke. To that end, the needle body 2 includes a first needle guide 8 , which has a first guide cross section 9 . In the closing position shown here, the first nozzle needle 7 is seated in a first seat 10 , which has a first seat cross section 11 . The first nozzle needle 7 is equipped with at least one pressure step 12 , which is oriented toward the injection ports 5 , 6 . This pressure step 12 is embodied by providing that the first guide cross section 9 is larger than the first seat cross section 11 .
[0012] On the side remote from the first seat 10 , the first nozzle needle 7 is braced on a transmission body 13 , which in this case has a disklike or sleevelike shape. The transmission body 13 is in turn braced, on a side remote from the nozzle needle 7 , on a coupling sleeve 14 . The first nozzle needle 7 , the transmission body 13 , and the coupling sleeve 14 here form a first needle combination 15 , which is supported as a unit, with an adjustable stroke, in the needle body 2 . Since in operation of the injection nozzle 1 , solely pressure forces are transmitted among the individual components of the first needle combination 15 , that is, among the first nozzle needle 7 , the transmission body 13 , and the coupling sleeve 14 , the individual components 7 , 13 , 14 of the first needle combination 15 can rest quasi-loosely against one another. It is equally possible for the individual components 7 , 13 , 14 to be secured to one another. It is equally possible for at least two of the components, such as the transmission body 13 and the coupling sleeve 14 , to be combined into a one-piece component.
[0013] The first nozzle needle 7 is assigned a restoring spring 16 , by way of which the first needle combination 15 is braced on the needle body 2 . The restoring spring 16 may introduce a restoring force, operative in the closing direction represented by an arrow 17 , which can be introduced into the first nozzle needle 7 . The opening direction is correspondingly represented by an arrow 18 . The restoring spring 16 is braced here on the transmission body 13 , which thus transmits the restoring force to the first nozzle needle 7 .
[0014] The first nozzle needle 7 is embodied as a hollow needle and serves in its interior to support a second nozzle needle 19 , which is coaxial with the first nozzle needle 7 . Accordingly, the first nozzle needle 7 includes a needle guide 20 , which has a second guide cross section 21 . The second nozzle needle 19 , in the closing direction shown here, is seated in a second seat 22 , which is disposed between the at least one first injection port 5 and the at least one second injection port 6 and has a second seat cross section 23 . In the preferred embodiment shown here, it may be expedient also to equip the second nozzle needle 19 with at least one pressure step 24 , which is oriented toward the injection ports 5 , 6 . Correspondingly, this pressure step 24 is embodied by providing that the second seat cross section 23 is smaller than the second guide cross section 21 .
[0015] On a side remote from the injection ports 5 , 6 , the second nozzle needle 19 is braced on a transmission bolt 25 , which in turn is braced on a coupling rod 26 . The second nozzle needle 19 , the transmission bolt 25 , and the coupling rod 26 again form a common, adjustable-stroke unit, that is, a second needle combination 27 . If in conventional operation of the injection nozzle 1 , solely pressure forces occur inside the second needle combination 27 , then once again the members of the second needle combination 27 , that is, the second nozzle needle 19 , the transmission bolt 25 and the coupling rod 26 , may rest loosely against one another. Once again, it may be expedient for at least two of the components 19 , 25 , 26 to be secured against one another or to be produced as a one-piece component.
[0016] The needle body 2 furthermore includes a first control chamber 28 , in which both a first control face 29 and a second control face 30 are disposed. The first control face 29 is a component of the second needle combination 27 and is embodied here on the coupling rod 26 . In another embodiment, the first control face 29 may also be embodied directly on the second nozzle needle 19 . The first control face 29 is oriented away from the injection ports 5 , 6 , so that pressure exerted on the first control face 29 transmits a force acting in the closing direction 17 on the second needle combination 27 , which force is thus introduced into the second nozzle needle 19 . In a distinction from this, the second control face 30 is embodied on the first needle combination 15 and is likewise oriented away from the injection ports 5 , 6 . Accordingly, pressure exerted on the second control face 30 leads to the introduction of a force effected in the closing direction 17 into the first needle combination 15 and thus into the first nozzle needle 7 .
[0017] The first control chamber 28 communicates with a control line 31 , with the aid of which the pressure in the first control chamber 28 can be controlled. In the preferred embodiment shown here, this control line 31 is embodied as an outlet line, and will therefore henceforth be called the outlet line 31 . The outlet line 31 here contains a control valve 32 , which has two connections and two switching positions and can accordingly be embodied on the order of a 2/2-way valve. In the first switching position, shown here, the outlet line 31 is blocked (blocked state). In the other switching position, the outlet line 31 communicates with a return line 33 , which leads to a return 34 , not shown here, which is relatively pressureless and in this sense forms a pressure sink 34 (open state). The return or the pressure sink 34 is for instance a reservoir, and in particular a fuel tank.
[0018] The needle body 2 furthermore includes a second control chamber 35 , which is connected via an inlet line 36 to a pressure source 37 . This pressure source 37 is for instance a high-pressure fuel line, which serves to supply fuel at high pressure to the injection valve 1 . Typically, the high-pressure fuel line 37 supplies a plurality of such injection valves 1 simultaneously with fuel on the so-called common rail principle. This common high-pressure fuel line 37 is then supplied by a common high-pressure fuel pump, not shown. Alternatively, it is equally possible to provide a separate a high-pressure fuel line 37 and/or a separate high-pressure fuel pump for each injection nozzle 1 .
[0019] In the second control chamber 35 , there is a third control face 38 , which is exposed to the pressure prevailing in the second control chamber 35 . The third control face 38 is again oriented away from the injection ports 5 , 6 and embodied on the first needle combination 15 . The pressure engaging the third control face 38 thus conducts a force, operative in the closing direction 17 , into the first needle combination 15 and hence into the first nozzle needle 7 .
[0020] According to the invention, a first coupling path 39 is now provided, which directly or indirectly connects the control chamber 28 to the pressure source 37 (high-pressure fuel line). In the special embodiment shown here, this first coupling path 39 includes at least one transverse bore 40 , which radially penetrates a cylindrical portion 41 in the first needle combination 15 , in this case the coupling sleeve 14 . The positioning of the transverse bore 40 is selected such that it is open toward the second control chamber 35 . In addition, radially between the first needle combination 15 and the second needle combination 27 , an annular chamber 42 is formed, which is open toward the first control chamber 28 and into which the transverse bore 40 discharges. In this way, a communicating connection is created between the control chambers 28 and 35 through the annular chamber 42 and the transverse bore 40 , and this connection also communicates via the inlet line 36 with the high-pressure fuel line 37 , or in other words the pressure source 37 . It is clear that a plurality of such transverse bores 40 may also be provided, which can be expediently distributed over the circumference on the axial portion 41 of the coupling sleeve 14 . The first coupling path 39 here thus connects the first control chamber 28 directly to the second control chamber 35 and hence indirectly to the pressure source 37 .
[0021] Alternatively, the first coupling path 39 may be formed by a line which connects the first control chamber 28 directly to the pressure source 37 or directly to the inlet line 36 and thus indirectly to the pressure source 37 . This line could then discharge for instance axially into the first control chamber 28 .
[0022] In addition, a second coupling path 43 is provided, which likewise connects the first control chamber 28 directly or indirectly to the pressure source 37 (high-pressure fuel line). In the preferred embodiment shown here, the second coupling path 43 includes at least one longitudinal groove 44 , which is open toward the first control chamber 28 and which, when the first nozzle needle 7 is closed, protrudes into the second control chamber 35 . This longitudinal groove 44 is embodied here in the cylindrical portion 41 of the coupling sleeve 14 . The longitudinal groove 44 , given a suitably shaped first nozzle needle 7 , could also be embodied directly on the first nozzle needle 7 . Alternatively, it is equally possible for the longitudinal groove 44 to be embodied not on the first needle combination 15 but rather on the needle body 2 , specifically in a wall 45 radially defining the first control chamber 28 . In that case, the longitudinal groove 44 would be axially open toward the second control chamber 35 and would be radially open toward the first control chamber 28 . The longitudinal groove 44 has an end 46 remote from the first control chamber 28 . The needle body 2 also has a wall portion 47 which axially defines the second control chamber 35 . This wall portion 47 and the end 46 of the longitudinal groove 44 form control edges, which cooperate with one another to open and block the second coupling path 43 . In this way, a control, whose mode of operation will be described in further detail hereinafter, for the second coupling path 43 is integrated with the injection nozzle 1 . It is clear that preferably a plurality of such longitudinal grooves 44 are provided, in particular distributed over the circumference of the axial portion 41 .
[0023] Alternatively, the second coupling path 43 may for instance also be formed by a line, which is connected directly to the pressure source 37 or directly to the inlet line 36 and hence indirectly to the pressure source 37 . This line could then discharge radially into the first control chamber 28 and could be controlled by the outer jacket of the axial portion 41 as a function of the stroke of the first needle combination 15 .
[0024] Expediently, the first coupling path 39 is disposed or embodied such that is always open, in all the stroke positions of the nozzle needles 7 , 19 . In this way, when the control valve 32 is closed, filling of the first control chamber 28 and thus a pressure buildup in the first control chamber 28 can be assured in any arbitrary relative position of the nozzle needles 7 , 19 to one another and relative to the needle body 2 .
[0025] Furthermore, the first coupling path 39 is expediently more severely throttled than the inlet line 36 , so that via the first coupling path 39 , a pressure drop is made possible.
[0026] Expediently, the coupling paths 39 and 43 are adapted to one another such that the first coupling path 39 is more severely throttled than the second coupling path 43 .
[0027] The second coupling path 43 is controllable as a function of the stroke of the first nozzle needle 7 . An axial spacing between the end 46 of the longitudinal groove 44 and the wall portion 47 defines a prestroke 48 , upon which the second coupling path 43 is switched for the sake of opening and closing.
[0028] The inlet line 36 is expediently disposed such that in all the stroke positions that occur of the nozzle needles 7 , 19 , it is always open and can feed the second control chamber 35 .
[0029] A slaving means 49 is embodied between the first needle combination 15 and the second needle combination 27 . This slaving means 49 is designed such that the first needle combination 15 , upon closure, entrains the second needle combination 27 or at least the second nozzle needle 19 in the closing direction 17 .
[0030] When the nozzle needles 7 , 19 are open, the injection ports 5 , 6 are supplied with fuel at high pressure via a fuel supply line 50 . To this end, this fuel supply line 50 is connected to the pressure source or high-pressure fuel line 37 . The fuel supply line 50 discharges into a nozzle chamber 51 , from which an annular chamber 52 leads to the injection ports 5 , 6 . The first sealing seat 10 is disposed between the at least one first injection port 5 and the annular chamber 52 , so that the first nozzle needle 7 controls the supply of fuel to the at least one first injection port 5 . The second sealing seat 22 is disposed between the at least one second injection port 6 and the annular chamber 52 , so that when the first nozzle needle 7 is open, the second nozzle needle 19 controls the fuel injection through the at least one second injection port 6 .
[0031] The injection nozzle 1 of the invention functions as follows:
[0032] In the outset position shown in FIG. 1 , the control valve 32 is in the blocking position shown, so that the outlet line 31 is not in communication with the pressure sink 34 . Since the first control chamber 28 moreover communicates, at least via the first coupling path 39 and at short strokes of the first valve combination 15 , indirectly with the pressure source 37 via the second coupling path 43 , the high fuel pressure can build up in the first control chamber 28 . Accordingly, the first control face 29 can introduce a relatively strong closing force into the second needle combination 27 and a resultant force operative in the closing direction 17 is created in the second nozzle needle 19 .
[0033] The second control face 30 introduces a relatively strong closing force into the first needle combination 15 . Moreover, the high fuel pressure also prevails in the second control chamber 35 , so that via the third control face 38 as well, a relatively strong closing force can be introduced into the first needle combination 15 . The restoring force of the restoring spring 16 is operative as well. While the pressure forces on the second control face 30 and the third control face 38 and the restoring forces of the restoring spring 16 act in the closing direction 17 , the high fuel pressure at the pressure step 12 of the first nozzle needle 7 generates a force acting in the opening direction 18 .
[0034] Overall, a resultant force operative in the closing direction 17 can thus build up in the first nozzle needle 7 as well. Consequently, the first nozzle needle 7 is seated in the first seat 10 , and the second nozzle needle 19 is seated in the second seat 22 .
[0035] For opening the first nozzle needle 7 , the control valve 32 is adjusted into the open position, and as a result the outlet line 31 is opened and thus communicates with the pressure sink 34 . Accordingly, a pressure drop occurs in the first control chamber 28 . As a result of this pressure drop, a first pressure value can develop in the first control chamber 28 . Since the outlet line 31 has a throttling action, and since via the coupling paths 39 , 43 , replenishing hydraulic fluid permanently flows into the first control chamber 28 when line 31 is open, the first pressure value is indeed less than the high fuel pressure, but is at least greater than the pressure of the pressure sink 34 . At the same time, the pressure also drops in the second control chamber 35 . The pressure decrease at the second control face 30 and the third control face 38 leads to reduced closing forces in the first needle combination 15 . The involved components of the injection nozzle 1 are adapted to one another in such a way that in the first nozzle needle 7 , a resultant force operative in the opening direction 18 is established and the first nozzle needle 7 lifts from the first seat 10 .
[0036] As a consequence, an injection of fuel occurs through the at least one first injection port 5 .
[0037] As soon as the first nozzle needle 7 lifts from the first seat 10 , the high fuel pressure is essentially applied to the pressure step 24 of the second nozzle needle 19 as well. The components of the injection nozzle 1 here are adapted to one another in such a way that in the second needle combination 27 , a resultant force acting in the closing direction 17 continues to result, even though the pressure in the first control chamber 28 has been reduced to the first pressure value, and the pressure step 24 of the second nozzle needle 19 is acted upon by the high fuel pressure. For instance, for this purpose, the pressure step 24 of the second nozzle needle 19 is made relatively small. A restoring spring, not shown here, may also be provided, which is braced on the second needle combination 27 , for instance on the first control face 29 , and introduces a corresponding closing force into the second needle combination 27 . Accordingly, even when the first nozzle needle 7 is opening, the second nozzle needle 19 remains in the second seat 22 .
[0038] If the control valve 32 is open long enough, then beginning at the outset position, in which the first nozzle needle 7 is seated in the first seat 10 , the first needle combination 15 executes the predetermined prestroke 48 . As soon as this prestroke 48 has been executed, the control edges, that is the axial end 46 of the longitudinal groove 44 and the wall portion 47 are radially aligned with one another, and as a result the second coupling path 43 is blocked. Because of the blocking or closure of the second coupling path 43 , not as much replenishing hydraulic fluid flows into the first control chamber 28 , so that the pressure there continues to drop, to a second pressure value. In any case, the second pressure value is less than the first pressure value that prevails when the second coupling path 43 is open. Since as before, the first coupling path 39 allows a replenishing flow of hydraulic fluid into the first control chamber 28 , the second pressure value is also higher than the pressure of the pressure sink 34 . The adaptation of the components of the injection nozzle 1 for this state is selected in such a way that the second pressure value at the first control face 29 can now introduce only such slight pressure forces that a resultant force operative in the opening direction 18 is established at the second needle combination 27 , or at the second nozzle needle 19 . Consequently, the second nozzle needle 19 lifts from the second seat 22 . Accordingly, a fuel injection through the at least one second injection port 6 now takes place in addition.
[0039] It is notable here that the first coupling path 39 limits the pressure drop in the first control chamber 28 to the aforementioned second pressure value, so that for the opening stroke of the second nozzle needle 19 or of the second needle combination 27 , only a comparatively low opening speed results. In particular, a hard impact against a stop face, such as an axial wall 53 of the first control chamber 28 , and hence bouncing of the second needle combination 27 can be avoided.
[0040] Furthermore, it is fundamentally possible to design the second needle combination 27 such that it moves in damped fashion against the stop (wall 53 ), which can be achieved for instance by suitable contouring of the first control face 28 .
[0041] As soon as the first nozzle needle 7 has exceeded the prestroke 48 , the kinematics of the first needle combination 15 change as well. For one thing, the reduced pressure force at the second control face 30 has an effect on the balance of forces at the first needle combination 15 . As a result of the blocked second coupling path 43 , the replenishing medium flowing into the second control chamber 35 via the inlet line 36 can now flow out of the second control chamber 35 only via the first coupling path 39 , so that in the second control chamber 35 , a pressure increase occurs. This pressure increase increases the closing force of the third control face 38 , which likewise affects the balance of the forces that engage the first needle combination 15 . Depending on the design, a damping or braking of the first nozzle needle 7 or the first needle combination 15 can be attained.
[0042] If only an injection through the at least one first injection port 5 is wanted, then the control valve 32 must be returned to the blocking position shown in good time, before the first nozzle needle 7 reaches the predetermined prestroke 48 . The axial length of the prestroke 48 can thus be selected as a function of the opening times for the first nozzle needle 7 .
[0043] To close the nozzle needles 7 and 19 , the control valve 32 is shifted to the closing position shown. The result is a sharp pressure increase in both the first control chamber 28 and the second control chamber 35 , with the consequence that the balance of forces at the first needle combination 15 is reversed again, resulting in a force in the closing direction 17 that drives the first needle combination 15 ahead in the closing direction 17 . Since with the second nozzle needle 19 open, the high fuel pressure engages the second seat cross section in the opening direction 18 as well, it can happen that the balance of forces at the second needle combination 27 , despite the high pressure at the first control face 29 , does not produce closing force, or only a relatively slight resultant closing force. In this case, the slaving means 49 assures that the first needle combination 15 carries the second needle combination 27 , or at least the second nozzle needle 19 , along with it. As soon as the first nozzle needle 7 arrives in the first seat 10 , the pressure downstream of the first seat 10 drops abruptly, so that then the second needle combination 27 , or the second nozzle needle 19 , moves into the second seat 22 as well.
[0044] The foregoing relates to a preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | An injection nozzle for an internal combustion engine, having a first nozzle needle for controlling the fuel injection through a first injection port, a second nozzle needle for controlling the fuel injection through a second injection port, a first control chamber in which a first control face drive-coupled to the second nozzle needle for introducing closing forces is disposed, and a control line for controlling the pressure in the first control chamber. Especially exact instants of the end of injection can be attained if in the first control chamber, a second control face is disposed that is drive-coupled to the first nozzle needle; a first coupling path connects the first control chamber directly or indirectly to a pressure source; a second coupling path connects the first control chamber directly or indirectly to the pressure source; and the second coupling path is controlled as a function of the stroke of the first nozzle needle such that it is blocked beyond a prestroke of the first nozzle needle. | 5 |
[0001] The present application claims priority from U.S. application Ser. No. 60/518,582 filed Nov. 7, 2003 and entitled Inchworm Robot for Minimally Invasive Cardiac Interventions, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Heart surgery, particularly the types addressed here (e.g., epicardial electrode placement, atrial ablation) is typically done via either an open approach, or a minimally invasive approach using hand-held rigid endoscopic tools.
[0003] Several recent development efforts center around robots intended to perform heart surgery, among other procedures. A commercially available robotic system for cardiac surgery is the da Vinci System available from Intuitive Surgical of Mountain View, Calif. That system is teleoperative, meaning that the motions of the surgeons hands on input devices are mirrored by laparoscopic manipulators located within the body. While such a system can offer superior dexterity to conventional laparoscopic instruments, it requires some form of stabilization for the heart, requires collapsing a lung, has a limited operative field, and is bulky and expensive.
[0004] Closed-chest endoscopic visualization of the epicardium was first described by Santos et al. (Ann Thorac Surg 1977; 23: 467-470); subsequent reports have utilized the technique for evaluation of blunt chest trauma, pericardial effusion and lung cancer staging. Lattouf et al have utilized the technique for epicardial implantation of left ventricular pacing leads. In each of these reports, endoscope access required thoracotomy with breach of the left pleural space. Direct access to the pericardial space via subxiphoid puncture is an increasingly practiced technique during catheter ablation procedures. In these reports, once access was achieved, catheter manipulation was guided solely by fluoroscopy. We are aware of cursory attempts at standard pacing lead implantation using this approach which have failed due to inability to achieve fixation.
[0005] The challenges of minimally invasive access are further complicated by the goal of avoiding cardiopulmonary bypass, and this goal necessitates surgery on a beating heart. Thus instrumentation is needed that allows stable manipulation of an arbitrary location on the epicardium while the heart is beating. See, for example, published application number 20040172033. Local immobilization of the heart is the approach generally followed with endoscopic stabilizers such as the Endostab device and the endo-Octopus device, which operate with pressure or suction. However, the resulting forces exerted on the myocardium can cause changes in the electrophysiological and hemodynamic performance of the heart, and there has been discussion in the literature regarding the care that must be taken to avoid hemodynamic impairment [Falk, et al., Endoscopic coronary artery bypass grafting on the beating heart using a computer enhanced telemanipulation system. Heart Surg Forum 2: 199-205, 1999]. As an alternative, several researchers in robot-assisted endoscopic surgery are investigating active compensation of heartbeat motion by visually tracking the epicardium and moving the tool tips accordingly [ avu o{haeck over (g)}lu MC, et al., Robotics for telesurgery: second generation Berkeley/UCSF laparoscopic telesurgical workstation and looking towards the future applications. Industrial Robot 30: 22-29, 2003; Ortmaier T J. Motion compensation in minimally invasive robotic surgery. Ph.D. dissertation, Technical University of Munich, Germany, 2003.], but this research problem remains open. The motion of the beating heart is complex. In addition to the challenges of modeling or tracking the heart surface, active compensation will require considerable expense for high-bandwidth actuation to enable manipulation in at least three degrees of freedom over a relatively large workspace (See Cavusoglu, supra).
BRIEF SUMMARY
[0006] The prior art solutions address a problem that exists only because the tools are held by a surgeon or a robot that is fixed to the table or standing on the floor. The present disclosure takes a different approach. Rather than trying to immobilize the heart surface to stabilize it in the fixed frame of reference of a table-mounted robotic device, we mounted the device in the moving reference frame of the beating heart. That task was accomplished with a miniature crawling robotic device designed to be introduced into the pericardium through a port, attach itself to the epicardial surface, and then, under the direct control of the surgeon, travel to the desired location for treatment. The problem of beating-heart motion was largely avoided by attaching the device directly to the epicardium. The problem of access was resolved by incorporating the capability for locomotion.
[0007] Improved access and precise manipulation are not the only benefits of this approach. Port access for minimally invasive cardiac surgery has typically been transthoracic, largely to accommodate the rigid endoscopes generally used for both manual and robot-assisted procedures. Transthoracic access to the heart requires deflation of the left lung, general endotracheal anesthesia, and differential lung ventilation. A variety of current and upcoming procedures, however, can conceivably be performed transpericardially, without invasion of the pleural space, with appropriate instrumentation. Examples include, but are not limited to cell transplantation, gene therapy for angiogenesis, epicardial electrode placement for resynchronization, epicardial atrial ablation, intrapericardial drug delivery, and ventricle-to-coronary artery bypass, among others.
[0008] The ability of the device to move to any desired location on the epicardium from any starting point enables minimally invasive cardiac surgery to become independent of the location of the pericardial incision. Use of the device also allows a subxiphoid transpericardial approach to any intrapericardial procedure, regardless of the location of the treatment site. As a result, deflation of the left lung is no longer needed, and it becomes feasible to use local or regional rather than general anesthetic techniques. These advantages have the potential for opening the way to ambulatory outpatient cardiac surgery. The opportunity for “synergy” (e.g. multiple procedures during a single operative session) may prove particularly valuable. The techniques disclosed herein are applicable to other organs within a living body and need not be limited to the human heart, which is merely our first application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For the present disclosure to be easily understood and readily practiced, the present disclosure will now be described, for purposes of illustration and not limitation, in connection with the following figures wherein:
[0010] FIG. 1 is a forward isometric view of the distal body and proximal body which, together with the control wires and suction lines, makeup one embodiment of the robot;
[0011] FIG. 2 is a rearward isometric view of the distal and proximal bodies of FIG. 1 ;
[0012] FIGS. 3A-3D illustrate forward locomotion of the robot;
[0013] FIGS. 4A-4C illustrate side to side turns of the robot;
[0014] FIG. 5A illustrates another embodiment of a robot and control system according to the present disclosure while FIG. 5B illustrates a washer-like support spacer;
[0015] FIG. 6A is an example of one type of end effector, a semicircular needle, retracted into a recessed storage location in the distal body while FIG. 6B illustrates the needle in operation;
[0016] FIGS. 7A and 7B are an example of another type of end effector;
[0017] FIG. 8 illustrates a self contained embodiment of the device of the present disclosure;
[0018] FIGS. 9A and 9B illustrate one example of a streamlined device of the present disclosure;
[0019] FIGS. 10A and 10B illustrate another example of a streamlined device of the present disclosure;
[0020] FIGS. 11A and 11B illustrate an embodiment of a device of the present disclosure having stabilization struts; and
[0021] FIG. 12 is a conceptual illustration of the robot maneuvering on the surface of a heart to perform a procedure.
DETAILED DESCRIPTION
[0022] One embodiment of a robot constructed according to the present disclosure is illustrated in FIGS. 1 and 2 . FIGS. 1 and 2 illustrate a prototype device 10 designed and constructed in the Medical Instrumentation Lab at Camegie Mellon University, which will now be described for purposes of illustration and not limitation. The device 10 consists of two glass-filled polycarbonate shells forming a distal body 12 and a proximal body 14 , each body having a 13 mm circular footprint and a height of 14 mm. That size allows the device 10 to fit within a standard 20 mm diameter cannula or port. Each of the body sections 12 , 14 is equipped with an independent suction line 16 , 18 and suction pad 20 , 22 , respectively, for gripping to biological tissue. The suction lines 16 , 18 and suction pads 20 , 22 illustrate one type of means for prehension.
[0023] The translation and rotation of the body sections 12 , 14 relative to one another are controlled from an external control system, in this embodiment a handle 15 (shown in FIGS. 3A-3D and FIGS. 4A-4C ), by manually adjusting the lengths of three nitinol wires 24 , 25 , 26 running along the longitudinal axis of the device 10 . The super-elasticity of nitinol allows the wires to support tension and compression (i.e. pulling and pushing) without permanently deforming. That eliminates the need for shape restoring components (like springs) that are required in some other systems. The axes of these wires 24 , 25 , 26 intersect the body sections 12 , 14 at the perimeter of a 10 mm diameter circle at 120-degree intervals. The wires 24 , 25 , 26 are fixed to the distal body 12 and pass freely through the proximal body 14 out to the handle 15 of the device. Between the proximal body 14 and the handle 15 , the wires 24 , 25 , 26 are contained within sheathes 24 ′, 25 ′, 26 ′, respectively, e.g. flexible plastic tubing, whose ends are attached to the proximal body 14 and the handle 15 . The three independently actuated wires 24 , 25 , 26 provide three degrees of freedom between the distal body 12 and the proximal body 14 , two angular and one tanslational. The two angular degrees of freedom allow the device 10 to adapt to the curvature of the heart (or other organ) as well as turn laterally (i.e. yaw).
[0024] The sheaths 24 ′, 25 ′, 26 ′ prevent bowing of the wires 24 , 25 , 26 so as to transmit the forces applied to the wires 24 , 25 , 26 , respectively, at the handle 15 to either proximal body 14 or distal body 12 and ensure that the length of wires 24 , 25 , 26 between the handle 15 and proximal body 14 remains constant. Thus, when the length of a wire exiting its sheath at the handle is changed, the length of that wire between the proximal body 14 and the distal body 12 changes by the same amount.
[0025] Inchworm-like locomotion is achieved by alternating the suction force exerted by the two body sections, while changing the lengths of the wires at the fixed handle, as shown in FIGS. 3A-3D . The configuration of the sheaths 24 ′, 25 ′ 26 ′and enclosed wires 24 . 25 , 26 does not affect the locomotion of the device 10 as long as there is slack between the handle 15 and the proximal body 14 , some of which will be taken up with each forward step. In the figure, the heavy black line indicates which suction pad is active. Note that the configuration of the sheaths and enclosed wires between the handle 15 and proximal body 14 changes with each forward step, but the lengths remain constant.
[0026] Between FIGS. 3A and 3B , while the proximal suction pad 22 is turned on, the wires 24 , 25 , 26 are moved forward causing distal body 12 to move forward by the same amount. In FIG. 3C , the proximal suction pad 22 is turned off and the distal suction pad 20 is turned on. In FIG. 4D , the compression in the sheaths 24 ′, 25 ′, 26 ′ is released, causing the proximal body 14 to “catch up” with the distal body 12 . Another forward step can now be taken by repeating the process. Turning can be achieved by differentially changing the lengths of the side wires as shown in FIGS. 4A-4C . The actuation of the wires at the handle may be performed manually, along with the opening and closing of the valves to the suction lines.
[0027] Another embodiment is illustrated in FIG. 5 . In FIG. 5 , components having similar functions and construction to those of FIGS. 1 and 2 have like reference numbers. The embodiment of FIG. 5 differs from the previous embodiment in several ways. For example, between the proximal body 14 and distal body 12 the wires 24 , 25 , 26 may be attached to a support spring 27 by eyelets 28 to prevent the wires 24 , 25 , 26 from bowing during turning and to ensure that the wires maintain an equal distance from one another. The support spring 27 may have a very low spring constant (e.g. k=0.012 N/mm) such that the restoring force is negligible as compared to that of the wires 24 , 25 , 26 . As an alternative to the spring 27 and eyelets 28 , a plurality of flat, washer-like structures 31 (See FIG. 5B ) may be provided to maintain the proper spacing between wires 24 , 25 , 26 . The plurality of washer-like structures 31 may be separated from one another by springs (not shown).
[0028] A 1.6 mm diameter commercial fiberscope 29 , running longitudinally through the length of the device, may be fixed on the distal body 12 to provide visual feedback, with or without the use of an adjustable mirror 40 . The images from the fiberscope 29 may be captured with a digital video camera 42 and displayed as a part of the graphical user interface (GUI) 44 , both of which are part of a control system 46 . The control system 46 may include sensors 48 for monitoring the vacuum supplied by suction lines 16 , 18 , electronically controlled valves 50 for determining which suction pad 20 , 22 is operative, and vacuum source 52 . The control system 46 may also include motors 54 for controlling movement of wires 24 , 25 26 . A computer 55 may be provided to control the various components in response to information input by the surgeon via the GUI 44 to control locomotion and other functions. Such a design allows for the motors 54 , solenoid valves 50 , etc. to be located outside the device 10 . It is anticipated that the robot 10 may be either a disposable device or a reusable, sterilizable device.
[0029] In the embodiment of FIG. 5 , the suction pads 20 , 22 are connected to the bodies 12 , 14 by means of flexible feet 56 , 58 , respectively. That enables the suction pads 20 , 22 more freedom to conform to the surface of the organ. Meshes (not shown) may cover the bottom of the suction pads to keep out large particles, while suction filters 60 may be provided to remove fluids and small particles.
[0030] An aspect of the present invention is changing the frame of reference of the robot from that of the surgeon to that of the moving organ. The exact form and construction of the robot used to bring about that change of reference is not critical to this aspect of the invention. For example, although in the disclosed embodiments locomotion is achieved through the advancement of wires, either manually or through the activation of motors, others means of locomotion may be provided such as local (i.e. positioned on the robot) electric motors (operated with or without a tether), local ultrasonic motors (operated with or without a tether), as well as pneumatic actuators (typically operated with a tether). The means for prehension in the disclosed embodiment is suction. Alternative means of prehension may include synthetic gecko foot hair [Sitti M, Fearing RS (2003) Synthetic gecko foot-hair micro/nano-structures as dry adhesives. J Adhesion Sci Technol 17(8): 1055-1073] or a “tacky” foot. The actuation for treatment may include all the same alternatives as for locomotion. Finally, the device may operate with a tether having wires and pneumatic lines as disclosed above, with a tether having electric wires for local motors or video from a camera, or the device may operate without a tether. Tetherless models could be powered by a battery, the transcutaneous charging of a coil, etc., and could be controlled by local computing or through radio frequency transmissions. It will be understood by those of ordinary skill in the art that changing the frame of reference of the robot from that of the surgeon to that of the moving organ can be brought about by a wide variety of robots designed so as to be able to move within a loosely bounded body cavity. A loosely bounded body cavity refers to that space surrounding an organ such as, for example, the peritoneal space surrounding the liver, the pleural space surrounding the lungs, the pericardial space surrounding the heart, etc., in addition to the space within certain organs such as the heart or stomach.
[0031] FIG. 6A illustrates an end effector (tool), which in this example is a needle 30 carried within a recess 32 in distal body 12 . Distal body 12 also carries a means for providing images such as a fiberscope or camera, with or without some combination of lenses, mirrors, fiberoptics, etc. The needle 30 may used to perform epicardial electrode lead placement for cardiac resynchronization therapy (CRT) via subxiphoid videopericardioscopic access. A robot 10 equipped with the needle 30 can perform a minimally invasive suturing technique that can be used with a variety of epicardial pacing leads, both permanent and temporary.
[0032] Needle 30 is a high-strength needle for suturing that has a drive shaft (not shown) that runs along the long axis of the device 10 , entered laterally and located below the midline of distal body 12 . At the distal (working) end of this drive shaft is the needle 30 which is a segment (roughly 5 mm) that is bent 90° with respect to the drive shaft, forming the radius of a circle. The needle 30 will then terminate in a semicircular suturing portion. The lower half of the front end of the distal body 12 has a semicircular channel 32 into which the needle 30 recedes when it is not in use, protecting both the cardiac tissue and the needle 30 .
[0033] The proximal end of the suture thread 36 remains outside the body. The distal end of the thread 36 is connected to a sharpened cap 38 , which will fit snugly over the end of the needle 30 . When the surgeon has positioned the distal body 12 at a desired work site, suturing will be performed by advancing the needle 30 from its recessed storage channel 32 (see FIG. 5B ) and then rotating the drive shaft, forcing the semicircular needle 30 and the sharpened cap 38 with its suture thread 36 to pass through the tissue in an arc and exit again with the suture cap 38 still on the tip of the needle 30 . A minimally invasive forceps (not shown), passing through an off-center working port of the robot 10 will be used to grasp the thread 36 , lift the thread 36 and its cap 38 from the tip of the needle 30 , and retract the cap 38 and distal end of the thread 36 all the way back through the cannula to the outside of the body. Here, the surgeon will knot the suture with his own hands, tying a single throw (or half of a square knot) in the thread. Once the single throw has been tied, the surgeon will place a wire with a slightly forked tip against the knot, with the knot resting in the notch of the fork, and will use the wire to push the knot all the way back against the epicardium. He will then tie a second throw and use the wire to push it forward until it meets the first throw, completing the knot. Given an ample supply of sutures fitted with sharpened caps, this technique can be repeated as many times as necessary, by placing each sharpened cap on the tip of the needle using the same forceps that is used to retrieve it from the needle.
[0034] The robot 10 will have a separate electrode channel that will allow passage of the electrode and its wire lead from outside the body into the pericardium to be sutured to the heart. The needle 30 , forceps, wire “fork”, suture with sharpened cap, and all supporting instrumentation needed for the suturing technique may be designed for sterilizability. Actuation from outside the body is the most feasible option for the forceps, because the forceps must be fully retractable to bring the tip of the suture thread back to the hand of the surgeon. Actuation of the needle for suturing may be performed locally by motors inside the robot, or from outside the body using a wire running through the cannula. Visual feedback for suturing may be provided by the same device used during locomotion.
[0035] Another end effector (tool) is illustrated in FIGS. 7A and 7B . Like components carry the same reference numbers as used in the previous figures. In the device of FIGS. 7A and 7B , the washer-like structure 31 and spacer springs have been eliminated for purposes of clarity. The reader will understand that a plurality of washer-like structures 31 and spacer springs may be used in the embodiment of FIGS. 7A and 7B . An experiment using this end effector, needle 70 , was performed on a pig. Through a 15 mm pericardial opening at the junction between the pericardium and the diaphragm at the midline, the device 10 was manually introduced inside the intact pericardium. Suction was applied to both suction pads. Stable contact with the epicardium of the beating anterior wall of the right ventricle was visually confirmed for a period of 30 seconds. The device 10 was then advanced across the left anterior descending coronary artery over the anterior wall of the beating left ventricle. Consistent stable contract with the epicardium of the beating left ventricle was observed. The device 10 was then further advanced over the left atrial appendage and stable fixation to the surface of the beating left atrium was confirmed.
[0036] Successful locomotion of the device 10 inside the intact pericardium was confirmed on the following areas: anterior wall of the beating right ventricle, anterolateral wall of the beating left ventricle, and anterior wall of the left atrial appendage. No gross epicardial or pericardial damage was observed. Because the present prototype has no outer shell between the bodies 12 , 14 , nothing prevented the pericardium from hanging down one or two millimeters between the bodies, and the leading edge of the proximal body 12 , which was not tapered, then tended to snag somewhat on the pericardium. The pericardial sac also showed a tendency to adhere to all surfaces of the device 10 that it contacted, no matter how smooth. This seemed to be largely caused by drying of the sac due to exposure to air. Occasional infusions of normal saline solution were used for lubrication, which succeeded in alleviating the problem.
[0037] Two myocardial injections of tissue-marking dye were performed during the experiment. In each case, the device 10 walked to the desired site, locked down both bodies using suction, and then the surgeon performed the injection manually by advancing the 27G custom needle 70 through a working port. For the first injection, the device 10 was positioned over the bifurcation of the left anterior descending coronary artery and the takeoff of the diagonal branch; the needle 70 was advanced into the left ventricular myocardium for 2-3 mm and 0.5 cc of dye was injected. The maximum force applied during injection was 0.72 N. The device 10 was then moved over the diagonal coronary artery and another injection of 0.5 cc of dye was made over the anterolateral wall of the left ventricle. The maximum force applied to the needle during the second injection was 1.15 N. No bleeding was observed after the needle 70 was withdrawn. Confirmation of successful injection was made at postoperative examination.
[0038] Because the device is tethered, pulling the tether provided a feasible method in the preliminary experiments to apply a tangential force to dislodge the device, without requiring the development of additional hardware that could be inserted somehow into the pericardial sac for testing. The force necessary to dislodge the device from the epicardium by pulling on the tether was measured with a force gauge while the device held onto the heart. A small clamp was applied to the part of the tether consisting of the three drive wires and their sheaths, and this clamp was attached to a handheld digital force gauge. The surgeon then pulled on the force gauge until the device was dislodged, and the gauge recorded the maximum force encountered during each trial. This test was performed three times with suction applied only to the distal body, three times with suction applied only to the proximal body, and three times with suction applied to both bodies. The results are presented in Table 1. No damage to the device resulted from these tests.
TABLE 1 Body with Number of Standard suction applied trials Mean (N) deviation (N) distal 3 1.62 0.37 proximal 3 3.23 0.70 both 3 4.48 0.43
[0039] During this experiment we demonstrated a technique for reattachment that can be used if the device is accidentally detached from the epicardium. This test was performed while the device was inside the intact pericardium. In this test, all suction was turned off, and, by manually twisting the tether, the device was intentionally rotated and was left lying on its right side on the epicardium. The suction in both pads 20 , 22 was then turned on. By manually twisting the tether with a counterclockwise motion, the device was righted so that once again it correctly grasped the epicardial surface using the suction, and remained attached as before. The first time this test was performed, a video device was used to view the device 10 , and by its presence lifted the pericardium somewhat, so that it did not lie as low on and around the device 10 as it normally would. Therefore, to avoid this effect, the video device was removed from the pericardium, and the test was repeated, this time with only the external video recorder monitoring the trial. Righting and reattaching of the device was performed successfully in both trials with no tissue damage and no damage to the device.
[0040] The ease with which the device can be retrieved from the pericardium was tested by measuring the maximum force encountered during extraction. The device was positioned normally inside the pericardium, standing upright on its feet with the distal body of the device near the left atrium, roughly 10 cm from the entry incision. All suction was turned off. The device was then retracted completely from the pericardium by pulling on the tether. This test was repeated three times, and the peak force measured during retrieval was recorded during each trial. The mean peak force measured was 2.49±0.51 N.
[0041] FIG. 8 illustrates a self-contained design of the device 10 , with the proximal body 14 shown at the upper left of the figure and the distal body 12 at the lower right. This design involves two motors for locomotion. One motor would be located in the vertical cylindrical body of the proximal body 14 and the other motor located in the horizontal cylinder 74 visible in the arm connecting the proximal 14 and distal 12 bodies. For clarity, a streamline housing, discussed below, is not shown in FIG. 8 . The motors could receive power and instructions through a tether (not shown) or from an onboard battery and an onboard computer (not shown).
[0042] FIGS. 9A and 9B illustrate a device 10 with a capsular or pill-like design for streamline interaction with the pericardial sac. The device 10 has a two piece hard covering, one piece of which slides inside the other like a gelatin capsule of the sort often used for pills. FIG. 9A illustrates the device 10 in an extended phase of a step, i.e. maximum distance between the distal body 12 and proximal body 14 , while FIG. 9B illustrates the contracted phase of the step, i.e. minimal distance between the proximal body 14 and distal body 12 .
[0043] FIGS. 10A and 10B illustrate another design of the device 10 with a one-piece outer shell designed for streamline interaction with the pericardial sac. This design may be used in place of the design of FIGS. 9A and 9B should that design be found to cause pinching of the pericardium during locomotion. FIG. 10A illustrates the extended phase of a step while FIG. 10B illustrates the contracted phase of the step.
[0044] FIGS. 11A and 11B illustrate a design in which deployable outrigger-like struts 80 , 82 are used if stronger safeguards against tipping become necessary. The outrigger-like struts 80 , 82 would be foldable from the horizontal positions shown to vertical positions adjacent distal body 12 on both sides of the device 10 . Once the device 10 is deployed within the pericardium, the struts 80 , 82 may be moved from the horizontal to the vertical position shown in the figures to guard against tipping. If the struts 80 , 82 evidence any tendency to snag the pericardium, a stretchable membrane 84 may be employed to cover both the device 10 and the struts 80 , 82 as shown in the figures. FIG. 11A illustrates the extended phase of a step while FIG. 111B illustrates the contracted phase of the step.
[0045] Turning to FIG. 12 , in operation according to one aspect of the present invention, the device 10 will enter the pericardium and be placed on the epicardial surface of the heart using a rigid or flexible endoscope with a working port. The endoscope will be introduced into the pericardial sac through a port or limited incision beneath the xiphoid process of the sternum.
[0046] Once positioned appropriately with the endoscope under direct visual confirmation, the device 10 will grasp the epicardium using suction. The suction forces are applied through the two independent suction pads 20 , 22 (see FIG. 5 ) that may be attached directly to bodies 12 , 14 or through compliant or flexible feet 56 , 58 , respectively. The vacuum pressure is supplied to the suction pads 20 , 22 by the vacuum source 52 through the operation of valves 50 and suction lines 16 , 18 respectively. The vacuum source provides a vacuum pressure of −0.08 N/mm 2 , which was found to be effective and safe for use in FDA approved cardiac stabilizers. The suction forces generated by this pressure have proven effective for our application, and did not damage the epicardial tissue. During locomotion, the vacuum pressure is monitored by the external pressure sensors 48 and regulated by computer-controlled solenoid valves 50 , both located within the control system 46 . Based on this pressure, the normal and tangential forces calculated to dislodge one of the bodies 12 , 14 are 1.76 N and 0.87 N, respectively. Bench testing using a force gauge to dislodge the device from a poultry model verified normal and tangential forces of 2.01 N and 0.86 N. The tangential force that can be resisted by the device will be increased significantly by reducing the profile.
[0047] The device 10 will provide visual feedback to the surgeon during locomotion and administration of therapy. That can be accomplished using fiberoptics to relay the image from the distal end 12 of the device 10 to the camera 42 located in the control system 46 . Alternatively, a CCD video camera can be mounted directly to the distal end 12 of the device 10 . It may be possible to provide all of the necessary vision with a single visual sensor on a fixed mount. More likely, however, either the viewing head will be actuated for motion, or two imaging devices will be incorporated: one tangential to the surface of the organ (looking forward) for providing information for navigation, and the other normal to the surface (looking down) for providing a view of the area to receive attention. “Attention” is intended to be a broad term that includes all types of interventions in addition to all forms of testing, viewing or inspecting a site, etc., or any other activity that results in consideration being devoted to an organ or a portion of an organ.
[0048] The device 10 differs from prior art robotic surgical systems in several fundamental ways: (1) it operates within the reference frame of the heart rather than that of an operating table, (2) it will be introduced using a sub-xiphoid rather than an intercostal approach, obviating general endotracheal anesthesia (GETA), (3) it has locomotive capabilities, and (4) it will be relatively inexpensive and possibly disposable. For surgical procedures that can be performed completely within the pericardium, the device 10 will eliminate many of the limitations of these surgical systems.
[0049] Therapies administered from the device 10 will not require stabilization of the heart because the device 10 will be located in the same reference frame as the surface of the heart, rather than that of a fixed operating table. This eliminates the need for either endoscopic stabilizers, which require additional incisions, or cardiopulmonary bypass, which increases the complexity and risk of the procedure.
[0050] The teleoperative surgical systems in use today utilize laparoscopic manipulators and cameras and are introduced to the pericardial sac through several intercostal (between rib) incisions. These instruments must then pass through the pleural space before reaching the heart, which requires the collapsing of a lung. The delivery of the device 10 onto the heart will not require collapsing a lung because it will be introduced to the thoracic cavity through an incision made directly below the xiphoid process. The endoscope will then be pushed through the tissue and fascia beneath the sternum until the bare area of the pericardium is reached, never entering the pleural space. The scope will also be used to breach the pericardium, thus delivering the device 10 directly to the epicardium. Because the device 10 will not require the collapsing of a lung, it will also not require differential ventilation of the patient, and it is therefore possible that local or regional anesthesia could be used instead of general endotracheal anesthesia (GETA). As a result, a potential benefit is that the device 10 may enable certain cardiovascular interventions to be performed on an ambulatory outpatient basis, something that has never been done before.
[0051] The locomotive capabilities of the device 10 will enable it to reach virtually any position and orientation on the epicardium. This is not the case with rigid laparoscopes, which are limited to a relatively small workspace near the entry incision. In addition, these systems require the removal and re-insertion of the tools to change the operative field within a single procedure. The device 10 , on the other hand, can easily change its workspace by simply moving to another region of the heart.
[0052] The da Vinci surgical system is very expensive and consists of a surgeon's computerized console and a patient-side cart with multiple large robotic arms. For procedures that can be performed within the pericardium, the device 10 will provide a small, extremely low-cost alternative to this system.
[0053] With proper development of end-effectors, the TEM will be able to perform epicardial cardiac procedures such as: cell transplantation, gene therapy, atrial ablation, and electrode placement for resynchronization myocardial revascularization. Devices such as an ultrasound transducer, diagnostic aid or other sensor, drug delivery system, therapeutic device, optical fiber, camera or surgical tool(s) may be carried by the device 10 .
[0054] Procedures for organs other than the heart can be developed while remaining within the teachings of the present disclosure. Additionally, procedures on living bodies other than humans, e.g. pets, farm animals, race horses, etc. can be developed while remaining within the teachings of the present disclosure. Thus, while the present invention has been described in connection with preferred embodiments thereof, those of ordinary skill in the art will recognize that many modifications and variations are possible. The present invention is intended to be limited only by the following claims and not by the foregoing description which is intended to set forth the presently preferred embodiment. | Rather than trying to immobilize a living, moving organ to place the organ in the fixed frame of reference of a table-mounted robotic device, the present disclosure teaches mounting a robot in the moving frame of reference of the organ. That task can be accomplished with a wide variety of robots including a miniature crawling robotic device designed to be introduced, in the case of the heart, into the pericardium through a port, attach itself to the epicardial surface, and then, under the direct control of the surgeon, travel to the desired location for treatment. The problem of beating-heart motion is largely avoided by attaching the device directly to the epicardium. The problem of access is resolved by incorporating the capability for locomotion. The device and technique can be used on other organs and on other living bodies such as pets, farm animals, etc. Because of the rules governing abstracts, this abstract should not be used in construing the claims. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to dihydropyridine (DHP) calcium antagonist compounds, and more particularly to DHP calcium antagonist compounds, preparation methods, and medical applications for the treatment of cardiovascular diseases.
[0003] 2. Description of the Related Art
[0004] Calcium antagonist, also known as calcium channel blocker, can be used for suppressing calcium influx across membranes and calcium release in cells, reducing the calcium ion concentration in the cells and the utility rate of calcium ions, suppressing the activity of adenosine triphosphatase (ATPase) activity, reducing cardiomuscular contraction force, relaxing smooth muscle cells dilating blood vessels, and lowering the resistance of peripheral blood vessels. Clinically, calcium antagonist is mainly used for the treatment of hypertension, angina, arrhythmia, dilated cardiomyopathy and ischemic heart disease, etc., and extensively used as a cardiovascular medicine. As increasingly more new medicines are introduced to the market, the DHP particularly catches our attention, since the DHP not only provides an excellent medical effect for lowering blood pressures, but also has little side effects, and a low price. The DHP has become a first-tier clinical medicine.
[0005] As the first DHP calcium antagonist nifedipine (1) launched to the market, its side-chain ester structure is electrically neutral, and thus having poor water solubility and absorption; and an amino side chain with a good water solubility is introduced to the nicardipine (2) ester group to give a better absorption effect, but it does not provide a long-lasting calcium antagonistic effect due to the first pass effect of the liver or the quick metabolism of the body. When we are looking for a new DHP medicine, a piperazine group using an aromatic branched chain is provided to substitute an amino structure of a side chain of an ester group in the structure of a substituted nicardipine medicine. With the fat solubility of the aromatic branched chain and the space hindrance of large substituent groups, the combination of medicines and receptors is affected to change the chemical properties of medicines and delay metabolism. According to this hypothesis, a series of DHP compounds with piperazine esters are synthesized.
[0000]
SUMMARY OF THE INVENTION
[0006] In view of the drawbacks of the prior art, the present invention intends to overcome the following technical issues: finding a way of how to apply the fundamental theory of medicine design and integrating the computer-aided drug design to synthesize a series of new DHP compounds having a better activity of calcium antagonisis and screen the activity of resistant hypertension, in hope of obtaining new resistant hypertension drugs having a resistant hypertension activity better than those of the existing medicines for treating hypertension diseases.
[0007] Another objective of the present invention is to provide a preparation method of the aforementioned compounds.
[0008] A further objective of the present invention is to apply these compounds for treating cardiovascular diseases.
[0009] To achieve the aforementioned objectives, the present invention provides the following technical solutions:
[0010] Compounds or their pharmaceutical salts of general formula (I):
[0000]
[0011] where, R 1 represents a substituted or unsubstituted heterocyclic, aromatic ring or aralkyl group, and the substituent can be a C 1 -C 4 alkyl group, a C 1 -C 4 alkoxyl group, a halogen, a cyano group, a trifluoromethyl group, a trifluoromethoxyl group, a methylthio group, a nitro group, an amino group or a hydroxyl group.
[0012] R 2 represents a C 1 -C 8 alkyl group, and the alkyl group selectively has a hydroxyl group or a C 1 -C 6 alkoxyl substituent.
[0013] R 3 and R 4 can be the same or different, and each represents hydrogen, a halogen, a cyano-group, a trifluoromethyl group, a trifluoromethoxyl group, a methylthio group, a nitro group, amino group or a C 1 -C 4 alkyl group, a C 1 -C 4 alkoxyl group, a C 1 -C 4 alkenyl group, or a C 1 -C 4 alkinyl group.
[0014] R 5 and R 6 can be same or different, and each represents a C 1 -C 4 alkyl group, and the alkyl group selectively has a hydroxyl group or a C 1 -C 4 alkoxyl substituent.
[0015] X represents O, S or a single bond.
[0016] m=0-6, n=1-6, and m and n are the same or different.
[0017] Compounds or their pharmaceutical salts of general formula (II):
[0000]
[0018] where, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , X, and n are defined the same as above.
[0019] In the present invention, R 1 is preferably 2-methooxyphenyl, 2,3-dichlorophenyl group, p-nitrophenyl group, p-methylphenyl group, methyl diphenyl group; R 2 is preferably methyl group and ethyl group; R 3 is preferably hydrogen; R 4 is preferably 3-nitro group; R 5 and R 6 are preferably a methyl group, X is preferably O or a single bond; m is preferably equal to 0, 1, 2, 3; and n is preferably equal to 2, 3, 4.
[0020] In the present invention, the pharmaceutical salts include salts of compounds of general formulas (I) and (II) and salts formed by the following acids: sulfuric acid, nitric acid, hydrochloric acid, hydrobromic acid, phosphoric acid, formic acid, acetic acid, maleic acid, citric acid, tartaric acid, lactic acid, benzenesulfonic acid, p-methylbenzenesulfonic acid, pyruvic acid, or furamic acid. The preferred pharmaceutical salts are monohydrochloride salts or dihydrochloride salts of compounds of general formulas (I) and (II).
[0021] Preferred compounds of general formulas (I) and (II) or their pharmaceutical salts include:
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)ethyl ester (I 1 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)propyl ester (I 2 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester-4-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)butyl ester (I 3 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)propyl ester hydrochloride (I 4 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester-4-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)butyl ester hydrochloride (I 5 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(diphenylmethoxy ethyl)piperazinyl)ethyl ester hydrochloride (I6); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(diphenylmethoxy ethyl)piperazinyl)propyl ester hydrochloride (I 7 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(4-nitrobenzl)piperazinyl)ethyl ester hydrochloride (I 8 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(4-nitrobenzl)piperazinyl)propyl ester hydrochloride (I 9 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(4-methylbenzl)piperazinyl)propyl ester hydrochloride (I 10 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(2,3-dichlorophenyl)piperazinyl)ethyl ester (I 11 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(2,3-dichlorophenyl)piperazinyl)propyl ester hydrochloride (I 12 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester-4-(N-4-(2,3-dichlorophenyl)piperazinyl)butyl ester hydrochloride (I 13 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)ethyl ester hydrochloride (I 14 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester 2-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)ethyl ester (I 15 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester3-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)propyl ester (I 16 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester 2-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)ethyl ester (I 17 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester 3-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)propyl ester (I 18 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(3-(2-methoxyphenoxy)-2-hydroxpropyl)piperazinyl)ethyl ester hydrochloride (II 1 ); 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(3-(2-methoxyphenoxy)-2-hydroxpropyl)piperazinyl)propyl ester hydrochloride (II 2 ), 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester4-(N-4-(3-(2-methoxyphenoxy)-2-hydroxpropyl)piperazinyl) butyl ester hydrochloride (II 3 )
[0043] A preparation method of compounds of general formula (I) comprises the steps of having a substitution reaction between compounds of general formulas Ib and Ic or between the compounds of general formulas Ia and Id.
[0044] More specifically, a compound of general formula Ib has a substitution reaction with a compound of general formula Ic under the catalysis of NaOH; or a compound of general formula Ib has a substitution reaction with a compound of general formula Ic under the catalysis of triethylamine; or a compound of general formula Ib has a substitution reaction with a compound of general formula Ic directly.
[0000]
[0045] A compound of general formula Ia has a substitution reaction with a compound of general formula Id under the catalysis of NaOH; or a compound of general formula Ia has a substitution reaction with a compound of general formula Id under the catalysis of triethylamine; or a compound of general formula Ia has a substitution reaction with a compound of general formula Id directly.
[0000]
[0046] where, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , X, and m are defined the same as above, and Y is a halogen atom.
[0047] A preparation method of compounds of general formula (II) comprises the steps of having an addition reaction between compounds of general formulas Ib and IIa with under the catalysis of triethylamine.
[0000]
[0048] where, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , X, and n are defined the same as above.
[0049] A preparation method of compounds of general formula Ib comprises the step of having a substitution reaction between a compound of general formula Ia and piperazine.
[0050] The structures of some of the compounds related to the present invention are listed below:
[0000]
[0051] To obtain their pharmaceutical salts, a compound of general formula (I) or a compound of general formula (II) have an acid reaction to form an addition salt.
[0052] The present invention further provides a composite of cardiovascular drugs containing a compound of general formula (I) or a compound of general formula (II) or their pharmaceutical salt as an active ingredient. The pharmaceutical medicine composite contains an active ingredient and a carrier acceptable by the medicine, wherein the active ingredient constitutes 0.01-99.99% (by weight) of the composite, and the carrier acceptable by the medicine constitutes 0.01-99.99% (by weight) of the composite.
[0053] The composite can be in a form applicable for the pharmaceutical preparations, and the pharmaceutical medicine can be in a pharmaceutical form of tablets, capsules, oral liquids, mixtures, oral tablets, granules, infusions, pills, powders, plasters, circular pills, augmentins, solutions, injections, powder needle medicines, freeze-dried powder injections, suppositories, ointments, hard pastes, creams, sprays, aerosols, drops, patches, and etc.
[0054] In the pharmaceutical preparation composite of the present invention, the pharmaceutical form used for preparing a unit dosage contains an active medical ingredient of 0.1 mg-1000 mg, and each pharmaceutical preparation refers to a pharmaceutical preparation unit such as a tablet and a capsule, and it also refers to the dosage taken for each time. For example, a dosage of 100 mg is taken for each time.
[0055] If the pharmaceutical medicine composite of the present invention is prepared in a solid or semi-solid pharmaceutical form of powders, tablets, capsules, suppositories, and creams, a solid carrier can be used, wherein the solid carrier is composed of one or more substances selected from the collection of a diluent agent, a disintegrating agent, a flavoring agent, a solubilizer, a lubricant, a suspending agent, a binder, and an expander, or a packaging substance. Appropriate solid carriers include magnesium carbonate, magnesium stearate, talc, sucrose, lactose, pectin, dextrin, starch, gelatin, methyl cellulose, sodium carboxymethyl cellulose, low boiling wax, coco butter, etc. and easily provided for medications, and tablets, powders, and capsules are best oral solid pharmaceutical preparation.
[0056] The liquid pharmaceutical preparations of the present invention include solutions, suspensions and emulsions. For example, an injection of a nongastrointestinal medication can be in form of a water solution or a water-propylene glycol solution, whose permeability and pH value are adjusted to fit the physiological conditions of living organisms. The liquid pharmaceutical preparation can be made in a solution form in polyethylene glycols or water solution. The active ingredient can be dissolved in water, and then an appropriate quantity of coloring agent, flavoring agent, stabilizer and thickener can be added to prepare an oral water solution. The granular active ingredient can be spread into an adhesive substance such as natural or synthetic glue, methyl cellulose, sodium carboxymethyl cellulose and other known suspending agents for preparing an oral water suspension.
[0057] To uniformize the medication and dosage, the aforementioned pharmaceutical preparation is preferably made in the form of a dosage unit. The dosage unit of the pharmaceutical preparation refers to a physical separate unit of a single dosage, and each unit contains a predetermined quantity of active ingredients calculated for achieving an expected curing effect. The form of such dosage unit can be in a packaged form such as a tablet, a capsule, powders contained in a small tube or a small bottle, or creams, gels or paste contained in a tube or a bottle.
[0058] Although the quantity of active ingredients contained in the dosage unit form can be varied, the quantity is generally adjusted within a range of 1˜800 mg according to the effect of the selected active ingredients.
[0059] The medication dosage of the present invention can be changed according to the requirements of a patient, the level of seriousness of a desired treatment, a selected compound, etc.
[0060] For the persons skilled in the art can confirm a preferred dosage for a certain particular situation according to common rules and methods. In general, the quantity used at the beginning of a treatment is less than the best dosage of an active ingredient, and then the medication dosage is increased gradually until the best treatment effect is achieved. For convenience, the total daily dosage can be divided into several parts or several times of medications, such as 1˜4 times a day and 1˜10 doses are taken each time.
[0061] The following experiment data show the advantages of the present invention:
[0062] The effect of compounds of the present invention to the contraction of an isolated rat's thoracic aorta ring caused by KCl is described as follows:
[0063] The present invention synthesizes 21 new DHP compounds, and some of the compounds are selected for performing pharmacological tests. With reference to Comparison of vasodilatation effect between quercetin and rutin in the isolated rat thoracic aorta authored by ZHOU Xin-mei, YAO Hui, XIA Man-li, et al, and published in Journal of Zhejiang University: Medical Sciences, 2006, 35(1), 29-33 for an embodiment.
1. Experimental Materials
1.1 Medicine and Test Sample
[0064] Control Articles: Levamlodipine Besylate, and Compounds I 4 , I 5 , I 6 , I 14 and II 2 are provided by School of Pharmacy of China Pharmaceutical University.
[0065] Norepinephrine (Shanghai Harvest Pharmaceutical Co., Ltd) and acetylcholine (Shanghai Experiment Reagent, Plant 2), and other test samples are analyzed to be pure.
[0000] 1.2 Main Instrument The Experiment System of Bio-function (BL-410) and the Constant Temperature Smooth Muscle Trough (HW-400S) are produced by Chengdu Tme Technology Co, Ltd.
1.3 Laboratory Animal
[0066] A male SD rat, 240-260 g, supplied by Institute of Laboratory Animal Breeding and Reproduction, Qing Long Shan of Jiang Ning. Certificate of Quality No.: SCXK (So) 2002-0018.
2. Experiment Method
2.1 Preparation of Krebs Henseleit (K-H) Nutrient Solution
[0067] NaCl:118.3 mmol/L, KCl:4.7 mmol/L, CaCl 2 : 2.5 mmol/L, MgSO 4 .7H 2 O:1.2 mmol/L, KH 2 PO 4 :1.2 mmol/L, NaHCO 3 :25 mmol/L, and glucose:11.1 mmol/L.
2.2 Preparation of Thoracic Aorta Ring and Measure of Tensions
[0068] Hit a male rat at its head until it faints. Quickly remove the thoracic aorta, and put it into a K-H solution passed with a mixed gas having 95% O 2 +5% CO 2 . Carefully remove connective tissues around the thoracic aorta and cut the blood vessel into a vascular ring of 3 mm wide. Avoid any excessive pulling to prevent damages to the endodermis. Hang the vascular ring into a bathing trough containing 30 ml of K-H liquid, and keep passing the mixed gas of 95% O 2 +5% CO 2 , and maintain the temperature at 37±0.5□. Adjust the rest tension to 2.0 g. Keep it in equilibrium for 2 hrs, and change the liquid once every 15 min.
[0069] Inspection of the activity of the endodermis of the blood vessel: After the thoracic aorta ring is stable, change the liquid once, and add 1 μmol/L of NA into the bathing trough. After the contraction has reached the peak value for 15 min., add 1 μmol/L of Ach. If the expected contraction of the vascular relaxation is greater than 60% after Ach is added, then the endodermis is considered to be complete, or else the endodermis will be damaged.
[0070] A thoracic aorta ring with a complete endodermis is selected for conducting the experiment. After the changed liquid is stable, Add 80 mmol/L KCl to induce the maximum contraction amplitude, sequentially accumulate the medications, such that the medicine concentrations are 0.05 μmol/L, 0.1 μmol/L, 0.5 μmol/L, 1 μmol/L, 2 μmol/L, 4 μmol/L, and 10 μmol/L respectively. Record the change of tensions. The vascular relaxation level is indicated by the inhibition rate. In other words, KCl induces a difference of values between the maximum tension of the contraction and the vascular tension after medicines with different concentrations are added. The ratio of differences of the values to the maximum contraction amplitude induced by KCl reflects the level of vascular relaxation. The sample size of the arota rings for each medicine group is 6. In other words, the experiment is performed repeatedly for 6 times.
3. Experiment Results
[0071] In Table 1, compounds I 4 , I 5 , I 6 , I 14 , II 2 has an inhibition effect to the contraction of a vascular ring with complete endodermis caused by KCl, and Ic 50 values are equal to 2.0, 0.5, 1.9, 0.2, 0.8 μmol/L respectively, which are smaller than the Ic 50 value (4.1 μmol/L) of the control article (Levamlodipine Besylate). Obviously, the activities of I 4 , I 5 , I 6 , I 14 , and II 2 are greater than that of the control article (Levamlodipine Besylate), wherein I 5 and I 14 have the strongest activities. Table 1. Effects of compounds to the contraction of an isolated rat's thoracic aorta ring caused by KCl ( x ±S, n=6)
[0000]
Inhibition Rate (%)
Group
0.05 μmol/L
0.1 μmol/L
0.5 μmol/L
1 μmol/L
2 μmol/L
4 μmol/L
10 μmol/L
Control
4.5 ± 0.6
18.4 ± 2.6
37.7 ± 3.6
46.8 ± 4.1
69.0 ± 5.9
84.6 ± 6.1
I 4
13.2 ± 1.3
20.5 ± 2.2
33.8 ± 2.8
59.4 ± 4.0
62.4 ± 4.8
72.0 ± 4.7
I 5
24.5 ± 3.2
47.9 ± 3.9
66.0 ± 4.0
75.0 ± 3.5
91.6 ± 3.2
100.1 ± 3.0
I 6
9.3 ± 1.0
20.5 ± 2.5
33.7 ± 2.4
49.7 ± 3.5
66.9 ± 3.6
79.0 ± 4.5
I 14
27.4 ± 3.4
35.7 ± 3.0
62.9 ± 6.8
81.7 ± 3.3
96.2 ± 4.5
101.1 ± 3.4
II 2
11.0 ± 1.5
32.2 ± 3.0
50.7 ± 5.7
65.2 ± 4.2
93.4 ± 3.1
101.2 ± 3.2
[0072] Other compounds have the same or similar biological activity, and they are not listed one by one here.
[0073] The compounds or their pharmaceutical salts in accordance with the present invention show an excellent receptor combining capability in the treatment of cardiovascular diseases, so as to achieve the effects of extending the metabolism, improving the bio-availability, reducing the side effects, and providing the value of extensive applications.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] The technical characteristics of the present invention will become apparent with the detailed description of preferred embodiments and the illustration of related drawings as follows.
[0075] The following embodiments are provided for illustrating the present invention, but not intended for limiting the scope of the present invention.
Preferred Embodiment 1
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 2-(N-1-piperazinyl)ethyl ester (Ib 1 )
[0076] 1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 2-chloroethyl ester (Ia 1 ): 11.84 g (30 mmol), piperazine (anhydrous) 7.76 g (90 mmol), acetonitrile 60 ml are blended, and then refluxed for 3 hrs, and a pressure reduction contraction is performed, and dichloromethane (40 ml) is added, blended, and rinsed by water, dried by sodium sulfate (anhydrous), blended, rinsed by water, filtered, and a pressure reduction and a concentration process are performed to the filtered liquid, and a remnant silicone tubing chromatography (ethylacetate: acetone, 3:1) is used for separating and obtaining a light yellow solid (8.66 g) with a yield rate of 65%, mp 166˜169□.
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-1-piperazinyl) propyl ester (Ib 2 ),
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 4-(N-1-piperazinyl) butyl ester (Ib 3 )
[0077] Refer to the Ib 1 synthesis method for the synthesis.
Preferred Embodiment 2
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 2-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)ethyl ester (I 1 )
[0078] Compounds Ib 1 1.33 g (0.003 mol), Ic 2 0.602 g (0.003 mol), sodium hydroxide 0.12 g (0.003 mol), and toulene 10 ml are blended, and then refluxed for 2 hrs, and a pressure reduction and a concentration process are performed, and dichloromethane (10 ml) is added, blended, and rinsed by water, and the organic layer is dried by sodium sulfate (anhydrous) and filtered, and the pressure reduction and concentration process are performed to the filtered liquid, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 7:1) is used for separating and obtaining a yellow oil 1.30 g with a yield rate of 71%.
[0079] ESI-MS (m/z):609.3 [M+H] +
[0080] IR (cm −1 ):3550, 3340, 3085, 2961, 2924, 2852, 2816, 1700, 1528, 1503, 1457, 1348, 1260, 1212, 1095, 1020, 802, 704, 702, 678
[0081] 1 H-NMR (CDCl 3 ): δ1.99 (2H, m, —NCH 2 CH 2 CH 2 O), 2.34 (6H, s, C 2-6 —CH 3 ), 2.46-2.58 (12H, m, —COOCH 2 CH 2 N, piperazidine-H, —NCH 2 CH 2 CH 2 O), 3.61 (3H, s, —COOCH 3 ), 3.82 (3H, s, —OCH 3 ), 4.02-4.16 (4H, m, —COOCH 2 , —CH 2 O), 5.07 (1H, s, C 4 —H), 5.75 (1H, brs, —NH), 6.87 (4H, m, methoxyphenyl-H), 7.33 (1H, t,Nitrophenyl 5-H), 7.6 (1H, d,Nitrophenyl 6-H), 7.98 (1H, d,Nitrophenyl 4-H), 8.06 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 3
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)propyl ester (I 2 )
[0082] With reference to the I 1 synthesis method, the aforementioned compound is prepared by Ib 2 and Ic 2 , with a yield of 65.5%.
[0083] ESI-MS (m/z):623.3 [M+H] +
[0084] IR (cm −1 ):3344, 2963, 2815, 1700, 1528, 1504, 1348, 1261, 1069, 1020, 800, 742, 703
[0085] 1 H-NMR (CDCl 3 ): δ1.79 (2H, m, —COOCH 2 CH 2 CH 2 N), 2.04 (2H, m, —NCH 2 CH 2 CH 2 O), 2.27 (2H, t, —COOCH 2 CH 2 CH 2 N), 2.32 (6H, s, C 2-6 —CH 3 ), 2.46-2.58 (10H, m, piperazidine-H, —NCH 2 CH 2 CH 2 O), 3.64 (3H, s, —COOCH 3 ), 3.85 (3H, s, —OCH 3 ), 4.02-4.16 (4H, m, —COOCH 2 , —CH 2 O), 5.07 (1H, s, C 4 —H), 5.86 (1H, brs, —NH), 6.89 (4H, m, methoxyphenyl-H), 7.33 (1H, t,Nitrophenyl 5-H), 7.6 (1H, d,Nitrophenyl 6-H), 7.98 (1H, d,Nitrophenyl 4-H), 8.09 (1H, m,Nitrophenyl 2-H).
Preferred Embodiment 4
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 4-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl) butyl ester (I 3 )
[0086] With reference to the I 1 synthesis method, the aforementioned compound is prepared by Ib 3 and Ic 2 with a yield of 69.7%.
[0087] ESI-MS (m/z):637.3 [M+H] +
[0088] IR (cm −1 ):3344, 3080, 2963, 2814, 1701, 1530, 1506, 1350, 1262, 1213, 1020, 805, 741, 703
[0089] 1 H-NMR (CDCl 3 ): δ1.48 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 1.61 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 2.02 (2H, m, —NCH 2 CH 2 CH 2 O), 2.29 (2H, t, —COOCH 2 CH 2 CH 2 CH 2 N), 2.36 (6H, s, C 2-6 —CH 3 ), 2.50-2.60 (10H, m, piperazidine-H, —NCH 2 CH 2 CH 2 O), 3.64 (3H, s, —COOCH 3 ), 3.85 (3H, s, —OCH 3 ), 4.02-4.16 (4H, m, —COOCH 2 , —CH 2 O), 5.08 (1H, s, C 4 —H), 5.86 (1H, brs, —NH), 6.90 (4H, m, methoxyphenyl-H), 7.37 (1H, t,Nitrophenyl 5-H), 7.6 (1H, d,Nitrophenyl 6-H), 7.98 (1H, d,Nitrophenyl-4-H), 8.09 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 5
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 3-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)propyl ester hydrochloride (I 4 )
[0090] Compounds Ib 2 1.37 g (0.003 mol), Ic 1 0.693 g (0.003 mol), sodium hydroxide 0.12 g (0.003 mol), and toulene 10 ml are blended, and then reacted at 60□ for 1 hr, and the pressure reduction and concentration process are performed, and dichloromethane (10 ml) is added, blended, and rinsed by water, and the organic layer is dried by sodium sulfate (anhydrous) and filtered, and the pressure reduction and concentration process are performed to the filtered liquid, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 8:1) is used for separating and obtaining a yellow oil, soluble in ethyl ether (anhydrous) 5 ml, and dry HCl at room temperature is passed into the solution until the pH value of the solution is 2, and then filtered, and dried to obtain a light yellow powder 1.53 g with a yield rate of 75%, and amp of 173˜175□.
[0091] ESI-MS (m/z):609.3 [M+H] +
[0092] IR (cm −1 ):3424, 2950, 2837, 1693, 1527, 1503, 1349, 1254, 1213, 1120, 1095, 1018, 745, 705
[0093] 1 H-NMR (CDCl 3 ): δ1.81 (2H, m, —COOCH 2 CH 2 CH 2 N), 2.31 (2H, t, —COOCH 2 CH 2 CH 2 N), 2.37 (6H, s, C2,6-CH 3 ), 2.44 (4H, brs, —CH 2 NCH 2 ), 2.61 (4H, brs, —CH 2 NCH 2 ), 2.84 (2H, t, —NCH 2 CH 2 O), 3.64 (3H, s, —COOCH 3 ), 3.85 (3H, s, —OCH 3 ), 4.12 (4H, m, —COOCH 2 , —CH 2 O), 5.08 (1H, s, C 4 —H), 5.73 (1H, brs, —NH), 6.90 (4H, m, methoxyphenyl-H), 7.37 (1H, t,Nitrophenyl 5-H), 7.62 (1H, d,Nitrophenyl 6-H), 7.98 (1H, d,Nitrophenyl 4-H), 8.09 (1H, m,Nitrophenyl 2-H).
Preferred Embodiment 6
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester-4-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)butyl ester hydrochloride(I 5 )
[0094] With reference to the I 4 synthesis method, it is prepared by Ib 3 and Ic 1 , with a yield of 73%, and amp of 163˜166□.
[0095] ESI-MS (m/z):623.3 [M+H] +
[0096] IR (cm −1 ):3426, 2949, 1692, 1502, 1348, 1254, 1215, 1122, 1020, 746
[0097] 1 H-NMR (CDCl 3 ): δ1.45 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 1.61 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 2.31 (2H, t, —COOCH 2 CH 2 CH 2 CH 2 N), 2.36 (6H, s, C 2-6 —CH 3 ), 2.45 (4H, brs, —CH 2 NCH 2 ), 2.61 (4H, brs, —CH 2 NCH 2 ), 2.85 (2H, t, —NCH 2 CH 2 O), 3.64 (3H, s, —COOCH 3 ), 3.85 (3H, s, —OCH 3 ), 4.05 (2H, m, —COOCH 2 ), 4.15 (2H, t, —CH 2 O), 5.08 (1H, s, C 4 —H), 5.74 (1H, brs, —NH), 6.90 (4H, m, methoxyphenyl-H), 7.36 (1H, t,Nitrophenyl 5-H), 7.61 (1H, d,Nitrophenyl 6-H), 7.98 (1H, d,Nitrophenyl 4-H), 8.09 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 7
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(diphenylmethoxy ethyl)piperazinyl)ethyl ester hydrochloride(I 6 )
[0098] Compounds Ib 1 1.33 g (0.003 mol), Ic 3 0.738 g (0.003 mol), and toulene (10 ml) are blended, and 6N NaOH solution (0.5 ml) is added and reacted at 80□ for 2 hrs, and the pressure reduction and concentration process are performed, and dichloromethane (10 ml) is added, blended, and rinsed by water, and the organic layer is dried by sodium sulfate (anhydrous) and filtered, and the pressure reduction and concentration process are performed to the filtered liquid, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 8:1) is used for separating and obtaining a yellow oil soluble in ethyl ether (anhydrous) 5 ml, and dry HCl gas at room temperature is passed into the solution until pH=2, and filtered and dried to obtain a light yellow powder (0.63 g) with a yield rate of 31.9%, and amp of 170˜173□.
[0099] ESI-MS (m/z): 655.3 [M+H] +
[0100] IR (cm −1 ):3402, 3198, 2949, 2422, 1694, 1526, 1490, 1348, 1213, 1019, 744, 703
[0101] 1 H-NMR (CDCl 3 ): δ2.30-2.70 (18H, m, —COOCH 2 CH 2 N, C 2-6 —CH 3,2 x-NCH 2 C H 2 N, —NCH 2 CH 2 O), 3.58 (2H, t, —CH 2 O), 3.63 (3H, s, —COOCH 3 ), 4.13 (2H, m, —COOCH 2 CH 2 N), 5.09 (1H, s, C 4 —H), 5.37 (1H, s, —CHO), 5.70 (1H, brs, —NH), 7.20-7.40 (11H, t, m-Nitrophenyl 5-H, Diphenylmethyl-H), 7.65 (1H, d, m-Nitrophenyl 6-H), 7.98 (1H, d, m-Nitrophenyl 4-H), 8.09 (1H, s, m-Nitrophenyl 2-H)
Preferred Embodiment 8
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 3-(N-4-(diphenylmethoxy ethyl)piperazinyl)propyl ester hydrochloride (I 7 )
[0102] With reference to the I 6 synthesis method, the aforementioned compound is prepared by Ib 2 and Ic 3 with a yield of 32.2%, and a mp of 159˜162□.
[0103] ESI-MS (m/z):669.3 [M+H] +
[0104] IR (cm −1 ):3408, 3201, 3064, 2949, 2837, 2442, 1692, 1526, 1491, 1348, 1214, 1118, 1019, 745, 704
[0105] 1 H-NMR (CDCl 3 ): δ1.79 (2H, m, —COOCH 2 CH 2 CH 2 ), 2.30-2.64 (16H, m, —COOCH 2 CH 2 CH 2 , C 2-6 —CH 3,2 x-NCH 2 CH 2 N), 2.71 (2H, t, —NCH 2 CH 2 O), 3.59 (2H, t, —CH 2 O), 3.64 (3H, s, —COOCH 3 ), 4.07 (2H, m, —COOCH 2 CH 2 CH 2 ), 5.08 (1H, s, C 4 —H), 5.37 (1H, s, —CHO), 5.82 (1H, br, —NH), 7.20-7.40 (11H, m, m-Nitrophenyl 5-H, Diphenylmethyl-H), 7.61 (1H, d, m-Nitrophenyl 6-H), 7.99 (1H, d, m-Nitrophenyl 4-H), 8.09 (1H, s, m-Nitrophenyl 2-H)
Preferred Embodiment 9
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 2-(N-4-(4-nitrobenzl)piperazinyl)ethyl ester hydrochloride(I 8 )
[0106] compound Ib 1 2.22 g (0.005 mol), Ic 4 1.08 g (0.005 mol), sodium hydroxide 0.2 g (0.005 mol), and dichloromethane (10 ml) are blended and then refluxed for 1 hr, and the reacting liquid is rinsed by water, and dried by sodium sulfate (anhydrous), filtered, and the pressure reduction and concentration process are performed to the filtered liquid, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 8:1) is used for separating and obtaining a yellow oil soluble in ethyl ether (anhydrous) 5 ml, and dry HCl gas at room temperature is passed into the solution until pH=2, and filtered, and dried to obtain a light yellow powder (1.70 g) with a yield rate of 52.3%, and a mp of 182˜185□.
[0107] ESI-MS (m/z):580.3 [M+H] +
[0108] IR (cm −1 ):3373, 2956, 2874, 2815, 2773, 1698, 1528, 1513, 1340, 1210, 1094, 1010, 742, 709
[0109] 1 H-NMR (CDCl 3 ): δ2.36-2.60 (16H, m, —COOCH 2 CH 2 N, C 2-6 —CH 3 , piperazid ine-H), 3.57 (2H, s, —CH 2 -p-Nitrophenyl), 3.65 (3H, s, —COOCH 3 ), 4.12-4.19 (2H, m, —COOCH 2 CH 2 N), 5.10 (1H, s, C 4 —H), 5.72 (1H, brs, —NH), 7.36 (1H, t, m-Nitrophenyl 5-H, Diphenylmethyl-H), 7.49 (2H, d, p-Nitrophenyl 2-H, 6-H), 7.64 (1H, d, m-Nitrophenyl 6-H), 7.98 (1H, d, m-Nitrophenyl 4-H), 8.01 (1H, s, m-Nitrophenyl 2-H), 8.17 (2H, d, p-Nitrophenyl 3-H, 5-H)
Preferred Embodiment 10
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 3-(N-4-(4-nitrobenzl)piperazinyl) propyl ester hydrochloride(I 9 )
[0110] With reference to the I 8 synthesis method, the aforementioned compound is prepared by Ib 2 and Ic 4 with a yield rate of 42.3%, and a mp of 170˜171□.
[0111] ESI-MS (m/z): 616.2 [M+Na] +
[0112] IR (cm −1 ):3424, 2954, 1690, 1525, 1487, 1349, 1215, 807, 742
[0113] 1 H-NMR (CDCl 3 ): δ1.78 (2H, q, —COOCH 2 CH 2 CH 2 N), 2.31-2.60 (16H, m, —COOCH 2 CH 2 CH 2 N, C2,6-CH 3,2 x-NCH 2 CH 2 N), 3.58 (2H, s, —CH 2 -p-Nitrophenyl), 3.65 (3H, s, —COOCH 3 ), 4.09 (2H, m, —COOCH 2 CH 2 CH 2 N), 5.08 (1H, s, C 4 —H), 5.85 (1H, brs, —NH), 7.37 (1H, t, m-Nitrophenyl 5-H), 7.49 (2H, d, p-Nitrophenyl 2-H, 6-H), 7.62 (1H, d, m-Nitrophenyl 6-H), 7.98 (1H, d, m-Nitrophenyl 4-H), 8.10 (1H, s, m-Nitrophenyl 2-H), 8.16 (2H, d, p-Nitrophenyl 3-H, 5-H)
Preferred Embodiment 11
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 3-(N-4-(4-methylbenzl)piperazinyl) propyl ester hydrochloride (I 10 )
[0114] With reference to the I 8 synthesis method, the aforementioned compound is prepared by Ib 2 and Ic 5 , with a yield of 32.7%, and a mp of 163˜165 □.
[0115] ESI-MS (m/z):563.3[M+H] +
[0116] IR (cm −1 ):3424, 2954, 1690, 1525, 1487, 1349, 1215, 807, 742
[0117] 1 H-NMR (CDCl 3 ): δ1.56 (3H, s, —CH 3 ), 1.77 (2H, q, —COOCH 2 CH 2 CH 2 N), 2.30-2.60 (16H, m, —COOCH 2 CH 2 CH 2 N, C 2-6 —CH 3,2 x-NCH 2 CH 2 N), 3.45 (2H, s, —CH 2 -p-Methylphenyl), 3.65 (3H, s, —COOCH 3 ), 4.10 (2H, m, —COOCH 2 CH 2 CH 2 N), 5.09 (1H, s, C4-H), 5.68 (1H, brs, —NH), 7.15 (4H, m, p-Methylphenyl 2-H, 3-H, 5-H, 6-H), 7.43 (1H, s, m-Nitrophenyl 5-H), 7.62 (1H, d, m-Nitrophenyl 6-H), 8.00 (1H, d, m-Nitrophenyl 4-H), 8.09 (1H, s, m-Nitrophenyl 2-H)
Preferred Embodiment 12
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(2,3-dichlorophenyl)piperazinyl)ethyl ester (I 11 )
[0118] Compounds Ia 1 1.97 g (0.005 mol), Id 1 hydrochloride 1.52 g (0.005 mol), triethylamine (0.2 ml) are refluxed in toulene for 2 hrs, and the pressure reduction and concentration process are performed, and dichloromethane (20 ml) and 1N NaOH solution (10 ml) are added and blended, and the organic layer is rinsed by water to neutral, and dried by sodium sulfate (anhydrous), and filtered, and the pressure reduction and concentration process are performed to the filtered liquid, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 6:1) is used for separating and obtaining a yellow solid (1.80 g) with a yield rate of 61.0%, and amp of 115˜120□.
[0119] ESI-MS (m/z):589.2 [M+H] +
[0120] IR (cm −1 ):3441, 3258, 3221, 3100, 2953, 1704, 1681, 1529, 906, 710
[0121] 1 H-NMR (CDCl 3 ): δ2.39 (6H, d, C 2-6 —CH 3 ), 2.67 (6H, m, —COOCH 2 CH 2 N, —CH 2 NCH 2 ), 3.01 (4H, s, —CH 2 NCH 2 ), 3.65 (3H, s, —COOCH 3 ), 4.20 (2H, m, —COOCH 2 ), 5.12 (1H, s, C 4 —H), 5.71 (1H, brs, —NH), 6.93 (1H, m, Dichlorophenyl 5-H), 7.14 (2H, m, Dichlorophenyl 4-H, 6-H), 7.38 (1H, t, m-Nitrophenyl 5-H), 7.66 (1H, d, m-Nitrophenyl 6-H), 7.99 (1H, d, m-Nitrophenyl 4-H), 8.11 (1H, m, m-Nitrophenyl 2-H)
Preferred Embodiment 13
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 3-(N-4-(2,3-dichlorophenyl)piperazinyl)propyl ester hydrochloride(I 12 )
[0122] Compounds Ia 2 2.04 g (0.005 mol), Id 1 hydrochloride 1.52 g (0.005 mol), triethylamine (0.2 ml) are refluxed in toulene (20 ml) for 2 hrs, and the pressure reduction and concentration process are performed, and dichloromethane (20 ml) and 1N NaOH solution (10 ml) are added and blended, and the organic layer is rinsed by water to neutral, and dried by sodium sulfate (anhydrous) and filtered, and the pressure reduction and concentration process are performed, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 6:1) is used for separating and obtaining a yellow solid soluble in ethyl ether (anhydrous) 10 ml, and dry HCl gas at room temperature is passed into the solution until pH=2, and filtered and dried to obtain a light yellow powder (1.79 g) with a yield rate of 53.1%, and a mp of 178-1800.
[0123] ESI-MS (m/z):603.2[M+H] +
[0124] IR (cm −1 ):3416, 2950, 1693, 1526, 1348, 1213, 956, 699
[0125] 1 H-NMR (CDCl 3 ): δ2.36 (6H, d, C 2-6 —CH 3 ), 2.45 (2H, m, —COOCH 2 CH 2 CH 2 N), 2.65 (4H, s, —CH 2 NCH 2 CH 2 ), 3.09 (4H, s, —CH 2 NCH 2 ), 3.65 (3H, s, —COOCH 3 ), 4.12 (2H, m, —COOCH 2 ), 5.10 (1H, s, C 4 —H), 5.85 (1H, brs, —NH), 6.93 (1H, m, 2,3-Dichlorophenyl 5-H), 7.14 (2H, m, 2,3-Dichlorophenyl 4-H&6-H), 7.38 (1H, t, m-Nitrophenyl 5-H), 7.63 (1H, d, m-Nitrophenyl 6-H), 7.99 (1H, d, m-Nitrophenyl 4-H), 8.11 (1H, m, m-Nitrophenyl 2-H)
Preferred Embodiment 14
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester 4-(N-4-(2,3-dichlorophenyl)piperazinyl)butyl ester hydrochloride (I 13 )
[0126] With reference to the I 12 synthesis method, it is prepared by Ia 3 and Id 1 , with a yield of 66.0%, and a mp of 170-173□.
[0127] ESI-MS (m/z):617.3 [M+H] +
[0128] IR (cm −1 ):3363, 2954, 2827, 1702, 1652, 1527, 1348, 1215, 949, 781, 709
[0129] 1 H-NMR (CDCl 3 ): δ1.49 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 1.65 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 2.38 (8H, m, C 2-6 —CH 3 , —COOCH 2 CH 2 CH 2 CH 2 N), 2.58 (4H, s, —CH 2 NCH 2 ), 3.05 (4H, brs, —CH 2 NCH 2 ), 3.65 (3H, s, —COOCH 3 ), 4.06 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 5.10 (1H, s, C 4 —H), 5.72 (1H, brs, —NH), 6.95 (1H, m, Dichlorophenyl 5-H), 7.14 (2H, m, Dichlorophenyl 4,6-H), 7.37 (1H, t, m-Nitrophenyl 5-H), 7.64 (1H, d, m-Nitrophenyl 6-H), 7.99 (1H, d, m-Nitrophenyl 4-H), 8.11 (1H, m, m-Nitrophenyl 2-H)
Preferred Embodiment 15
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)ethyl ester hydrochloride(I 14 )
[0130] Compounds Ia 1 1.97 g (0.005 mol), Id 2 1.19 g (0.005 mol), sodium hydroxide 0.2 g (0.005 mol), and acetonitrile (15 ml) are blended and reacted at 60□ for 1 hr, and the pressure reduction and concentration process are performed, and dichloromethane (15 ml) and water (15 ml) are added and blended, and the organic layer is dried by sodium sulfate (anhydrous) and filtered, and the pressure reduction and concentration process are performed to the filtered liquid, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 8:1) is used for separating and obtaining a yellow oil soluble in ethyl ether (anhydrous) 5 ml, and dry HCl gas at room temperature is passed into the solution until pH=2, and filtered and dried to obtain a light yellow powder (1.25 g) with a yield rate of 37.6%, and amp of 112-115 □.
[0131] ESI-MS (m/z):595.3 [M+H] +
[0132] IR (cm −1 ):3409, 3197, 2951, 1696, 1503, 1215, 1123, 748
[0133] 1 H-NMR (CDCl 3 ): δ1.99 (2H, m, —COOCH 2 CH 2 N), 2.37 (6H, s, C 2-6 —CH 3 ), 2.59 (8H, m, 2x-NCH 2 CH 2 N), 2.83 (2H, t, —NCH 2 CH 2 O), 3.64 (3H, s, —COOCH 3 ), 3.85 (3H, s, —OCH 3 ), 4.14 (4H, m, —COOCH 2 , —CH 2 O), 5.10 (1H, s, C4-H), 5.86 (1H, brs, —NH), 6.91 (4H, m, methoxyphenyl-H), 7.36 (1H, t,Nitrophenyl 5-H), 7.64 (1H, d,Nitrophenyl 6-H), 7.97 (1H, d,Nitrophenyl 4-H), 8.09 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 16
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester 2-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl)ethyl ester (I 15 )
[0134] Compounds Ia 4 2.29 g (0.005 mol), Id 2 1.19 g (0.005 mol), sodium hydroxide 0.2 g (0.005 mol), and toulene (10 ml) are blended and then refluxed for 2 h, and the pressure reduction and concentration process are performed, and dichloromethane (15 ml) and water (15 ml) are added and blended, and the organic layer is dried by sodium sulfate (anhydrous) and filtered, and the pressure reduction and concentration process are performed, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 8:1) is used for separating and obtaining a yellow oil (1.17 g) with a yield rate of 37.6%.
[0135] ESI-MS (m/z):609.3 [M+H] +
[0136] IR (cm −1 ):3344, 3068, 2939, 1697, 1528, 1504, 1455, 1348, 1252, 1212, 1022, 960, 742, 706
[0137] 1 H-NMR (CDCl 3 ): δ1.23 (3H, t, —COOCH 2 CH 3 ), 2.35 (6H, s, C 2-6 —CH 3 ), 2.50-2.65 (10H, m, —COOCH 2 CH 2 N, piperazidine-H), 2.85 (2H, t, —NCH 2 CH 2 O), 3.84 (3H, s, —OCH 3 ), 4.08 (2H, q, —COOCH 2 CH 3 ), 4.02-4.16 (4H, m, —COOCH 2 , —CH 2 O), 5.07 (1H, s, C 4 —H), 5.81 (1H, brs, —NH), 6.90 (4H, m, methoxyphenyl-H), 7.36 (1H, t,Nitrophenyl 5-H), 7.64 (1H, d,Nitrophenyl 6-H), 7.98 (1H, d,Nitrophenyl 4-H), 8.10 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 17
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester 3-(N-4-(2-(2-methoxyphenoxy)ethyl)piperazinyl) propyl ester (I 16 )
[0138] With reference to the I 15 synthesis method, the aforementioned compound is prepared by Ia 5 and Id 2 with a yield of 32.1%.
[0139] ESI-MS (m/z): 623.3 [M+H] +
[0140] IR (cm −1 ):3343, 3082, 2945, 2818, 1697, 1528, 1504, 1348, 1307, 1253, 1211, 1121, 1096, 1021, 804, 742, 705, 679
[0141] 1 H-NMR (CDCl 3 ): δ1.22 (3H, t, —COOCH 2 CH 3 ), 1.77 (2H, m, —COOCH 2 CH 2 CH 2 N), 2.27 (2H, m, —COOCH 2 CH 2 CH 2 N), 2.36 (6H, s, C2,6-CH 3 ), 2.44 (4H, brs, —CH 2 NCH 2 ), 2.61 (4H, br, —CH 2 NCH 2 ), 2.86 (2H, t, —NCH 2 CH 2 O), 3.84 (3H, s, —OCH 3 ), 4.06-4.16 (6H, m, —COOCH 2 CH 3 , —COOCH 2 , —CH 2 O), 5.08 (1H, s, C 4 —H), 5.92 (1H, brs, —NH), 6.90 (4H, m, methoxyphenyl-H), 7.36 (1H, t,Nitrophenyl 5-H), 7.62 (1H, d,Nitrophenyl 6-H), 8.00 (1H, d,Nitrophenyl 4-H), 8.11 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 18
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester 2-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)ethyl ester (I 17 )
[0142] With reference to the I 15 synthesis method, the aforementioned compound is prepared by Ia 4 and Id 3 with a yield of 38.2%.
[0143] ESI-MS (m/z):623.4[M+H] +
[0144] IR (cm −1 ):2963, 2927, 1689, 1528, 1504, 1348, 1261, 1209, 1020, 801, 706
[0145] 1 H-NMR (CDCl 3 ): δ1.23 (3H, t, —COOCH 2 CH 3 ), 2.04 (2H, m, —NCH 2 CH 2 CH 2 O), 2.28 (2H, t, —COOCH 2 CH 2 N), 2.35 (6H, s, C 2-6 —CH 3 ), 2.50-2.65 (10H, m, —NCH 2 CH 2 O, piperazidine-H), 3.85 (3H, s, —OCH 3 ), 4.05-4.18 (4H, m, —COOCH 2 CH 3 , —COOCH 2 , —CH 2 O), 5.10 (1H, s, C 4 —H), 5.73 (1H, brs, —NH), 6.89 (4H, m, methoxyphenyl-H), 7.39 (1H, t,Nitrophenyl 5-H), 7.67 (1H, d,Nitrophenyl 6-H), 8.00 (1H, d,Nitrophenyl 4-H), 8.11 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 19
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridine carboxylic acid ethyl ester 3-(N-4-(3-(2-methoxyphenoxy)propyl)piperazinyl)propyl ester (I 18 )
[0146] With reference to the I 15 synthesis method, the aforementioned compound is prepared by Ia 5 and Id 3 , with a yield of 32.7%.
[0147] ESI-MS (m/z): 637.4 [M+H] +
[0148] IR (cm −1 ):3342, 3069, 2963, 2814, 1698, 1528, 1504, 1348, 1261, 1094, 1020, 800, 742, 703
[0149] 1 H-NMR (CDCl 3 ): δ1.19 (3H, t, —COOCH 2 CH 3 ), 1.75 (2H, m, —COOCH 2 CH 2 CH 2 N), 1.99 (2H, m, —NCH 2 CH 2 CH 2 O), 2.27 (2H, t, —COOCH 2 CH 2 CH 2 N), 2.32 (6H, s, C 2-6 —CH 3 ), 2.40-2.50 (10H, m, —NCH 2 CH 2 CH 2 O, piperazidine-H), 3.82 (3H, s, —OCH 3 ), 4.05 (6H, m, —COOCH 2 CH 3 , —COOCH 2 , —CH 2 O), 5.03 (1H, s, C 4 —H), 5.74 (1H, brs, —NH), 6.89 (4H, m, methoxyphenyl-H), 7.34 (1H, t,Nitrophenyl 5-H), 7.59 (1H, d,Nitrophenyl 6-H), 7.95 (1H, d,Nitrophenyl 4-H), 8.08 (1H, m,Nitrophenyl 2-H)
Preferred Embodiment 20
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester2-(N-4-(3-(2-methoxyphenoxy)-2-hydroxpropyl)piperazinyl)ethyl ester hydrochloride (II 1 )
[0150] Compounds Ib 1 1.34 g (0.003 mol), IIa 0.54 g (0.003 mol), triethylamine (0.5 ml) and acetonitrile (10 ml) are blended, and reacted at 60□ for 1 hr, and the pressure reduction and concentration process are performed, and dichloromethane (10 ml) is added, blended, and rinsed by water, and the organic layer is dried by sodium sulfate (anhydrous), filtered, and the pressure reduction and concentration process are performed to the filtered liquid, and the remnant silicone tubing chromatography (petroleum ether:ethylacetate, 6:1) is used for separating and obtaining a yellow oil, soluble in ethyl ether (anhydrous) 5 ml, and dry HCl gas at room temperature is passed into the solution until pH=2, and filtered, and dried to obtain a light yellow powder (1.20 g) with a yield rate of 56.3%, and amp of 175-177 □.
[0151] ESI-MS (m/z):625.3 [M+H] +
[0152] IR (cm −1 ):3349, 3074, 2950, 2837, 2440, 1692, 1527, 1503, 1349, 1254, 1214, 1121, 1099, 1021, 747, 706
[0153] 1 H-NMR (CDCl 3 ): δ2.36 (6H, s, C 2-6 —CH 3 ), 2.45-2.65 (13H, m, 2x-NCH 2 CH 2 N, —COOCH 2 CH 2 N, —NCH 2 CH(OH)), 3.65 (3H, s, —COOCH 3 ), 3.85 (3H, s, —OCH 3 ), 4.03 (2H, d, —CH 2 O), 4.15 (3H, m, —COOCH 2 CH 2 N, —OH), 5.10 (1H, s, C 4 —H), 5.75 (1H, brs, —NH,), 6.88-6.96 (4H, m, methoxypheny-H), 7.37 (1H, t, m-Nitrophenyl 5-H), 7.64 (1H, d, m-Nitrophenyl 6-H), 8.00 (1H, d, m-Nitrophenyl 4-H), 8.09 (1H, s, m-Nitrophenyl 2-H)
Preferred Embodiment 21
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester3-(N-4-(3-(2-methoxyphenoxy)-2-hydroxpropyl)piperazinyl)propyl ester hydrochloride (II 2 )
[0154] With reference to the I 11 synthesis method, the aforementioned compound is prepared by Ib 2 and IIa, with a yield of 52.1%, and a mp of 168˜171□.
[0155] ESI-MS (m/z):639.2[M+H] +
[0156] IR (cm −1 ):3389, 3078, 2950, 2839, 2642, 2439, 1689, 1527, 1503, 1349, 1253, 1216, 1122, 1097, 1019, 957, 747, 706
[0157] 1 H-NMR (CDCl 3 ): δ2.29 (2H, t, —COOCH 2 CH 2 CH 2 N), 2.36 (6H, s, C 2-6 —CH 3 ), 2.58 (12H, m, 2x-NCH 2 CH 2 N, —COOCH 2 CH 2 CH 2 N, —NCH 2 CH(OH)), 3.65 (3H, s, —COOCH 3 ), 3.85 (3H, s, —OCH 3 ), 4.03 (2H, d, —CH 2 O), 4.10 (3H, m, —COOCH 2 , —CHOH), 5.08 (1H, s, C 4 —H), 5.71 (1H, brs, —NH), 6.92 (4H, m, methoxyphenyl-H), 7.37 (1H, t,Nitrophenyl 5-H), 7.64 (1H, d,Nitrophenyl 6-H), 7.99 (1H, d,Nitrophenyl 4-H), 8.10 (1H, s,Nitrophenyl 2-H)
Preferred Embodiment 22
1,4-dihydro-2,6-dimethyl-4-(3-nitrophenyl)-3,5-pyridinecarboxylic acid methyl ester4-(N-4-(3-(2-methoxyphenoxy)-2-hydroxpropyl)piperazinyl)butyl ester hydrochloride (II 3 )
[0158] With reference to the I 11 synthesis method, the aforementioned compound is prepared by Ib 3 and IIa with a yield of 48.7%, and a mp of 142˜145□.
[0159] ESI-MS (m/z):653.4 [M+H] +
[0160] IR (cm −1 ):3341, 3073, 2949, 2836, 2580, 1692, 1527, 1503, 1348, 1253, 1215, 1122, 1097, 1020, 746, 705
[0161] 1 H-NMR (CDCl 3 ): δ1.37 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 1.55 (2H, m, —COOCH 2 CH 2 CH 2 CH 2 N), 2.10-2.60 (19H, m, —COOCH 2 CH 2 CH 2 CH 2 N, C 2-6 —CH 3,2 x-NCH 2 CH 2 N, —NCH 2CH(OH)), 3.57 (3H, s, —COOCH 3 ), 3.77 (3H, s, —OCH 3 ), 3.95-4.05 (2H, d, —CH 2 O), 4.05 (3H, m, —COOCH 2 , —CHOH), 5.02 (1H, s, C 4 —H), 5.89 (1H, brs, —NH), 6.80-6.90 (4H, m, methoxypheny-H), 7.29 (1H, t, m-Nitrophenyl 5-H), 7.56 (1H, d, m-Nitrophenyl 6-H), 7.93 (1H, d, m-Nitrophenyl 4-H), 8.02 (1H, s, m-Nitrophenyl 2-H)
[0162] While the invention has been described by device of specific embodiments, numerous modifications and variations could be made thereto by those generally skilled in the art without departing from the scope and spirit of the invention set forth in the claims. | A dihydropyridine (DHP) calcium antagonist compound and its preparation method and medical use are related to preparation methods of compounds of general formulas (I) and (II) as shown below and their pharmaceutical salts and applications for treating cardiovascular diseases, and R 1 represents a substituted or unsubstituted heterocyclic, aromatic ring or aralkyl group, and the substituent may be C 1 -C 4 alkyl, C 1 -C 4 alkoxyl, halogen, cyano, trifluoromethyl, trifluoromethoxyl, methylthio, nitro, amino or hydroxyl group; R 2 represents a C 1 -C 8 alkyl group; R 3 and R 4 are the same or different, and each represents a hydrogen, halogen, cyano, trifluoromethyl, trifluoromethoxyl, methylthio, nitro or amino group or a C 1 -C 4 alkyl, C 1 -C 4 alkoxyl, C 1 -C 4 alkenyl, or C 1 -C 4 alkinyl group; R 5 and R 6 are the same or different, and each represents a C 1 -C 4 alkyl group; X represents O, S or a single bond; m=0-6, n=1-6, and m and n are the same or different. | 2 |
This application claims priority to provisional application Ser. No. 60/059,389 filed Sep. 19, 1997, which is hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates generally to electrical power systems and more particularly to a programmable logic controller for capacitor switching to adjust reactive compensation and harmonic distortion.
BACKGROUND OF THE INVENTION
It is well known to electrical utilities and their industrial customers that alternating current (AC) electrical systems commonly have a reactive load, i.e. a load having an inductive or capacitive component. Most commonly the reactive load is inductive. Due to the effects of these loads and the elements of the electrical system, there is a difference between the real power available to the load and the apparent power supplied by the source. This difference is referred to as reactive power, measured in volt-amperes reactive or VAR. The power factor (PF) is the ratio of real power (W) over reactive power (VAR). It is preferable to maintain the power factor as close to one as possible. An inductive load causes a lagging reactive current since the voltage leads the current, and a capacitive load causes a leading current since the current leads the voltage.
Leading PF loads are caused by elements such as fluorescent lightbulbs; however, most industrial installations use significant numbers of motors or equipment, such as air conditioners, which cause inductive loads. This has a significant effect on the power factor for industrial users where it is known to have inefficient power factors as low as 0.6. This is undesirable from the utility or source's standpoint because the utility must supply the apparent power while only being able to charge for the real power percentage. Additionally, the excess, unused reactive power on the line causes excess losses and heat requiring larger equipment or more generation. Other effects may include poor voltage regulation at transformers or false signals to overvoltage regulation devices.
To encourage industries to maintain a power factor approaching one (unity), utilities often charge industries a premium for power supplied when the power factor falls below a set level such as 0.9. As such, it is also in the industries' best interest to maintain a power factor near unity. A near unity power factor also allows more constant and efficient transmission of power over smaller lines or allows more power to be distributed over the lines. Although possible for residential installations, normally residential users do not carry sufficient inductive loads to justify power factor compensation.
Capacitors installed at the industrial user's location are an efficient way to compensate for lagging current but traditionally have been subject to certain disadvantages. In particular, the compensation of a capacitor cannot be varied over time, while the inductive load may vary. Accordingly, the capacitor may be insufficient for a varied demand, or may provide excess correction leading to an overvoltage situation. Utility company or power engineers in the past have calculated the correction for an industrial user and installed single or multiple capacitors, but have not had the ability to adjust the capacitance in response to drastic changes in power factors or operation outside of the designed range.
Recently, the ability to dynamically add and subtract capacitors or capacitor banks has been envisioned using a microprocessor type of controller. For example, U.S. Pat. No. 5,670,864 to Marx describes a controller which measures the phase angle variation and adaptively connects or disconnects capacitor banks. U.S. Pat. No. 5,469,045 to Dove illustrates a high speed microprocessor which senses current and voltage and corrects the power factor by connecting and disconnecting capacitor banks.
Although these designs address some of the problems in correcting power factor, they do not solve all of the problems. In particular, a resonance problem can arise in a power system when a controller switches a capacitor into or out of a system. When a capacitor is switched, normally there is a ringing transient. This ringing transient should attenuate in a few cycles unless the frequency is the same as a harmonic generated by the customer thereby producing resonance which results in a high harmonic level. The percentage of harmonic energy or distortion is called the Total Harmonic Distortion (THD). If the THD is too high and remains that way, there can be damage to the system such as overload of the capacitor banks or insulation damage to the customers' equipment. Electrical customers are required to ensure that the THD does not exceed five percent (5%) due to their load. Utilities may charge customers a premium or, in a worst case, disconnect a customer if the THD is too high.
Normally a study is carried out to size the capacitor banks to the installation in order to minimize the probability of resonance. Unfortunately this model may be inaccurate, or changes may be made to the system which result in errors in the model and the potential for damage. Additionally the model becomes more complex when capacitor banks are dynamically switched into or out of the system. Accordingly, there is a need for an apparatus which can be used in combination with a capacitor bank switching controller, which minimizes or prevents electrical harmonic resonance thereby preventing high levels of THD due to resonance in an electrical system after a capacitor bank is switched.
SUMMARY OF THE INVENTION
A system for minimizing resonance in an AC power supply line after a capacitor bank is switched, including a detector for detecting the harmonic distortion in a supply line and a plurality of capacitor banks in parallel to the supply line. A plurality of switches is provided wherein at least one switch is in series with each of said capacitor banks to selectively connect or disconnect each of the capacitor banks to the supply line. A controller is operatively coupled to the switches and receives input from the detector. The controller adds or removes capacitor banks from the circuit if an overvoltage or undervoltage situation occurs in order to provide a more nearly constant AC voltage. Once a capacitor bank is switched, the controller compares the total harmonic distortion to an action threshold and closes one of said switches to connect a capacitor bank if the total harmonic distortion exceeds the action threshold for a predetermined period of time. The controller sequentially opens each of the plurality of switches to remove capacitor banks if the detected total harmonic distortion continues to exceed the first reference value for a predetermined time period after the one switch is closed or after each of the switches is opened. The comparison and opening repeats as long as the THD exceeds the action threshold and capacitor banks remain connected to the circuit.
Accordingly, it is one object of this invention to provide a system that maintains a more nearly constant AC voltage.
It is a further object of this invention to provide a system which prevents resonance from causing damage to a power supply system.
It is another object of the present invention to provide a system which adds or subtracts capacitor banks from a circuit in order to minimize resonance.
Further objects, features and advantages of the present invention shall become apparent from the detailed drawings and description provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a power supply circuit with switched capacitor banks.
FIGS. 2A-E are a flow diagram of the control logic for switching capacitor banks to optimize the power factor in a power supply system.
FIGS. 3A-D are a flow diagram of the control logic for switching capacitor banks to minimize total harmonic distortion in a power supply system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations, modifications, and further applications of the principles of the invention being contemplated as would normally occur to one skilled in the art to which the invention relates.
The present invention relates to an apparatus for minimizing resonance in an AC power supply system after a capacitor bank is switched into or out of the system to more nearly supply a constant voltage with a unity power factor. When a capacitor bank is switched in a system, a ringing transient is created which attenuates in a few cycles unless the frequency is the same as a natural harmonic frequency created by the electrical customer. The present invention measures the harmonic distortion of such a system and switches capacitor banks to avoid damage caused by excess Total Harmonic Distortion (THD).
Illustrated in FIG. 1 is a schematic diagram of capacitor switching circuit 10 having a plurality of capacitor banks 50, 52, 54, 55, 57 and 59. Switching circuit 10 is situated between power supply transformers 16 and 18, and metering current transformers 12 and 14 on first bus 13 and second bus 15. Power supply transformers 16 and 18 are connected to main circuit breakers 20 and 24 with tie circuit breaker 22 between them to allow transformers 16 and 18 to work in parallel or independently. The capacitor banks are similar and each capacitor bank, such as bank 50, has capacitor 60, fuse 61, vacuum switch 62, inductor 64, disconnect 68 and ground 66. For convenience, a capacitor bank is considered with one capacitor, but it will be understood that multiple capacitors could be used. By way of example, each capacitor bank is preferably rated at 2400K VAR and mounted in a capacitor can rated at 12 kV (not shown). In a preferred embodiment, circuit breakers 20 and 24 are rated at 2000 amps and tie circuit breaker 22 is rated at 3000 amps.
Fuses 32, 34, 36 and 38 and switches such as disconnect 68 allow the capacitor banks to be selectively connected or disconnected from circuit 10, in particular situations. Tie switch 30 is located between capacitor bank 50 and capacitor bank 55. Tie switch 30 can be open such that bank 50 is connected to metering current transformer 12 and bank 55 is connected to metering current transformer 14, or tie switch 30 may be closed so that banks 50 and 55 are in parallel and can be connected in tandem to either metering current transformer 12 or 14. In a preferred embodiment, circuit 10 allows capacitance to be varied from 0 to 9600 KVAR in increments of 2400 KVAR for metering current transformer 12 or 14. This allows a greater range of operation and finer voltage control. It also allows individual capacitor banks or groups of capacitor banks to be isolated from the circuit for maintenance such as replacement or service while the remaining banks remain in service. The physical layout of circuit 10 allows the addition of capacitor banks in the future without structural changes.
In a preferred embodiment, it is possible to utilize a standard distribution class capacitor switch 68, which is rated at 200 amps continuous, 12 kA peak transient closing current and 9000 kA asymmetrical making current. The load interrupting current is less than 200 amps and the maximum voltage rating is 15 kV. These switches are readily available from several sources, for example, Cooper type VCS-1 switches. In a preferred embodiment, the 2400 kVAR capacitor banks would draw 112 amps at 12.47 kV voltage. However, the switch should be rated with at least a 35% safety factor. This means that the switch must be rated at a 150 amp minimum (112×1.35=150).
Capacitor banks 50, 52, 54, 55, 57 and 59 are mounted on the same structure and thus are physically mounted close together. Accordingly, the back to back switching currents must be limited to below a peak current. This is addressed by adding inductor or reactor 64 in each phase of each capacitor bank; in a preferred embodiment a 40 μh inductor rated at 140 amps continuous is used. Capacitor banks 50, 52, 54, 55, 57 and 59 are preferably grounded such as with ground 66 to allow ease of rack construction and faster fuse operation. The capacitor banks could alternatively be ungrounded with expulsion fuses.
Capacitor switching circuit 10 is preferably controlled by a controller such as a programmable logic controller (PLC) with control logic 100 as illustrated in FIGS. 2A-E. In a preferred embodiment, control logic 100 is implemented using two Modicon model no. 612-00 PLCs and a man-machine interface or operator-input device manufactured by KEP, commonly called Zoid.
In FIG. 2A, section A, from starting status 102, the controller operates to measure 105 and 107 voltages of bus potential transformers 16 and 18. For example, a voltage transducer such as Action Instruments Model G468-0000 may be used. Measured voltages 105 and 107 are filtered through a 60 Hz low pass filter and applied to the controller inputs.
In FIG. 2B, section B, resulting voltage 105 is compared 110 to a predetermined gross high voltage setting. If voltage 105 exceeds the gross high voltage setting, an alarm is reported 112 and the capacitor banks connected to bus potential transformer 16 are tripped 114 or removed from the circuit. Voltage 105 is next compared 116 to a predetermined gross low voltage setting. If voltage 105 is below the predetermined gross low voltage setting, an alarm is reported 118 and the controller blocks operation of the capacitor bank switches. If voltage 105 rises 120 above the gross low voltage setting, a message will be reported 122 and the capacitor switches will be unblocked.
Similarly, resulting voltage 107 is compared 125 to a predetermined gross high voltage setting. If voltage 107 exceeds the gross high voltage setting, an alarm is reported 127 and the capacitor banks connected to bus potential transformer 18 are tripped 129 or removed from the circuit. Voltage 107 is next compared 131 to a predetermined gross low voltage setting. If voltage 107 is below the gross low voltage setting, an alarm is reported 133 and the controller blocks operation of the capacitor bank switches. If voltage 107 rises 135 above the gross low voltage setting, message 137 will be reported and the capacitor switches will be unblocked.
In FIG. 2C, section C, the controller checks 140 and 143 the closed or tripped condition of buses 13 and 15 and breakers 20, 22 and 24. If either breaker 20 or 24 are open, the controller immediately trips or removes 141 or 144 the capacitor banks associated with that bus. This prevents an overvoltage condition when the buses are reenergized. If breaker 22 is open, breakers 20 and 24 will operate independently 148. If breaker 22 is closed, breakers 20 and 24 work with operate with parallel voltage check 150 and the trips and closes will be sequenced in a particular order between the two buses.
In section D, the controller considers the conditions on whether a plurality of capacitor bank should be tripped or closed by comparison 155 of the bus voltages with preset high and low setpoints previously entered. The high and low setpoints define a range within the range defined by the gross high voltage and gross low voltage settings. If voltage 105 or 107 exceeds the high setpoint for that bus, and does so for a preset period of time, the next scheduled capacitor bank switch will be tripped. The voltage is then repeatedly checked on successive passes through the logic, and, if the voltage continues to exceed the high setpoint, additional available capacitor bank switches will be opened. The controller is able to control a plurality of capacitor banks available to the circuit, which exact number may be altered or varied as determined by additional capacitor banks, the tie breakers and the fuses.
Likewise, if bus voltage 105 or 107 falls below the low volts setpoint, and does so for a preset period of time, a close command will be issued and the capacitor bank switch next scheduled to close will do so. The voltage is rechecked, and if it is still abnormal, the next bank in the sequence will close. This process will continue as long as the voltage is abnormal and there are still banks left to operate. A time delay, such as five minutes, is preferably included to allow the capacitors in a bank to discharge before the bank is reenergized. This reduces the stress imposed on the cans due to the switching transient.
The capacitor bank switches can only be operated under certain conditions depending on the current state of the circuit and external factors. In particular, a capacitor trip command can be executed under the following conditions:
A1--The capacitor bank must be presently closed.
A2--The capacitor bank must not have been locked out as a consequence of a previous trip or close malfunction.
A3--The associated bank breaker has tripped. In this case, all of the banks on this bus will be immediately tripped.
A4--A gross overvoltage condition exists on the bus. This condition will also result in all of the banks on the associated bus being tripped.
A5--If a high voltage condition has been detected, a capacitor bank will be tripped if it is the next bank in the trip sequence.
A6--If the "man/auto" switch is in manual and the manual control switch for a capacitor bank is switched to the trip position.
A close command can be executed under the following conditions:
B1--The bank is presently tripped.
B2--More than 5 minutes has elapsed since the bank was tripped. This is to allow the bank to fully discharge before it is switched back into the system. This condition also applies for manual operation.
B3--The associated bank breaker is closed. This condition applies only in automatic operation.
B4--If a low voltage condition has been detected, a capacitor bank will be closed if it is the next bank in the close sequence.
B5--A capacitor bank may be closed in manual mode if the "auto/man" switch is in the "man" position and the manual control switch associated with that bank is switched to the "close" position. The other criteria for this mode of operation has already been mentioned.
Capacitor banks 50 and 55 deviate from the other banks in that they may both be switched to either bus, or one on each bus as is normal. This is accomplished by manually switching the bank over to the desired bus in the yard using tie-switch 30, then changing the position of the capacitor bank bus selector switch on the panel. The capacitor bank controller automatically changes its switching sequence to accommodate the desired mode of operation.
Once the capacitor banks have been switched, the controller checks the neutral current of the capacitor banks in section E in case a fuse blows or a phase is not switched in correctly as a consequence of a switch malfunction. A current transducer is used in series with each capacitor bank's neutral lead. In a preferred embodiment a Honeywell Micro-Switch (Cat CSLESJG) is used to act as a current transducer. If a current imbalance is detected 160 in capacitor bank 50, and remains high for a preset period of time 162, an alarm message will be sent 164. This is repeated for each capacitor bank 52, 54, 55, 57 and 59.
In a preferred embodiment, a programmable logic controller is used to implement the control logic. Although a microprocessor could be used, a PLC is more preferred for simplicity and speed. In particular, a PLC provides flexibility for a specific design yet allows future changes with simple software updates. A PLC can be configured to provide diagnostic information or sequence of event recording as well as alphanumeric or hardcopy outputs. There has not previously been a commercially available PLC incorporating all of these advantages. In a preferred embodiment the Zoid controller has a number of LED indicators which may be tested 196 in FIG. 2E, section F by pressing the "Lamp Test" button on the Zoid. The lights will flash for four seconds if operational. The bus potential indicators and the PLC indicator are not tested since these indicators are normally on. In a preferred embodiment, manual switches are used to operate the capacitor bank switches in case the PLC fails.
Another feature of the Zoid, in section G, is that the alarm light is latched on 198 if the Zoid malfunctions and an alarm condition occurs. This light will remain on until cancelled by the "alarm acknowledge" button or the "alarm reset" button. Once the cycle of control logic 100 is complete 199, the system will revert to start status 102 and repeat the cycle.
For purposes of illustration, the following settings were used with control logic 100. It will be understood that these are examples only and will be varied for specific situations as understood by those of skill in the art.
Trip high setpoint voltage--122V
Close low setpoint voltage--119V
Time delay--60 seconds
Gross high voltage trip--126 V with a 0.5 second delay
Gross low voltage--107 V with a 0.5 second delay
Switch failure set for 10 seconds
Unbalance alarm delay 10 seconds
Unbalance set point 40 primary amps
Additionally, it is preferred to have a printer or other output device connected to the controller for reporting alarms or messages and associated information such as time, date and circuit conditions. The output device can provide information onsite or could communicate with a remote location. It is also preferred that the controller have a port to which a computer or other device could connect for testing, analysis or reprogramming.
The controller follows the control logic in FIGS. 2A-E to trip or connect capacitor banks in order to more nearly maintain a constant AC supply voltage. The controller incorporates the additional control logic 200 in FIGS. 3A-D to prevent damage to the capacitor banks in the event of excessive total harmonic distortion after a capacitor bank is switched.
From the initial starting status in FIG. 3A, a meter is used to measure 109 the harmonic distortion or THD in the system. In a preferred embodiment a Bitronics Meter with a ModBus protocol output that measures the THD as well as volts, power factor, watts, individual harmonics, etc. is used. Control logic 200 then compares the measured voltage against a gross high voltage and a gross low voltage as described in Section B of control logic 100. The preferred Bitronics Meter displays the THD, but it will be understood that THD can be measured in multiple ways such as by calculating the total based on a specific measured harmonic or by measuring the distortion after discounting the fundamental. Measuring the THD is intended to encompass these and other methods of measuring the harmonic distortion in a system. The invention is equally applicable if only individual harmonics are measured or the THD is calculated based on other measurements.
Section H compares 232 the measured THD to an alarm threshold such as five percent (5%). If the THD exceeds the alarm threshold, an alarm is reported 234. The electrical customer may then take appropriate action to correct the problem, or in a worst case the customer may be tripped off of the system.
The controller then proceeds to Section I in FIG. 3B where the controller takes protective action if the THD exceeds an action threshold such as six percent (6%). The controller compares 240 if the THD exceeds the action threshold for a predetermined period of time. If the THD falls, no action is taken. If the THD exceeds the action threshold for a predetermined period of time, the controller checks 242 if the last switching action was a close. If check 242 shows that the last action was a close, the controller checks 244 if another capacitor bank is available. When check 244 shows that a capacitor bank is available, the controller closes 246 the available bank and initiates a timer 248, preferably a five second timer. The added capacitor bank should eliminate the possibility of the capacitor bank being near the natural resonance frequency of the system. If the last switching action was not a close, the controller will not close any additional capacitor banks, but will trip 252 the next capacitor bank and initiate the timer 248.
After the timer expires, the controller compares 250 the THD to the action threshold. If the THD continues to exceed the action threshold, the next connected capacitor bank is tripped 252 and the timer is again initiated 248. Comparison 250 of the THD to the action threshold and tripping 252 of available banks continues until the THD falls below the action threshold or all capacitor banks are removed from the system. Control logic 200 then continues through sections D, E, F and G in FIGS. 3C and D as previously described in control logic 100.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A system for regulating the voltage by switching capacitor banks and for preventing damage due to harmonic resonance in an AC power supply line after a capacitor bank is switched. The system includes a detector for detecting the harmonic distortion in the supply line, and multiple capacitor banks connected in parallel to the supply line. At least one switch is in series with each capacitor bank to connect or disconnect the capacitor bank to the supply line. A controller operates the switches and receives input from the detector. After a capacitor bank is switched to improve conditions in the supply line, the controller compares the total harmonic distortion to an action threshold and switches capacitor banks as programmed when the total harmonic distortion exceeds the action threshold for a predetermined period of time in order to avoid a resonant condition that could cause damage to equipment. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of waste disposal. More specifically, the invention comprises an incinerator capable of incinerating biomass materials such as animal carcasses and the like.
[0003] 2. Description of the Related Art
[0004] Incinerators in general, and organic waste incinerators in particular, have been in widespread use for decades. A typical example is shown in U.S. Pat. No. 3,861,335 to Przewalski (1975). The Przewalski device uses a rotary type incinerator in which waste is fed through a chute into a rotating combustion chamber. The reader will observe that the waste material tends to burn in a linear fashion (from the burner end of the combustion chamber to the end of the combustion chamber opposite the burner).
[0005] While the rotation of the chamber helps move the waste material around during the combustion process, most of the waste material is gradually “pushed” away from the burner to collect on the end of the combustion chamber opposite the burner. This often results in the incomplete combustion of the waste material since waste products are moved away from the burner. It also can make it difficult to remove the combusted remains from the combustion chamber.
[0006] It would therefore be desirable to provide an incinerator which is more suitable for the complete combustion of a biomass waste material. It would also be desirable to provide an incinerator providing for easier removal of the products of the combustion process.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention comprises an incinerator for burning waste products such as animal carcasses. The incinerator features a rotating combustion chamber with sloping side walls. The sloping side walls cause the waste product to concentrate in the center of the combustion chamber where the product is subjected to the flame of a burner. A hatch is provided in the center of the combustion chamber to allow for easy cleaning of the combustion chamber.
DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1A is a perspective view, illustrating the main combustion chamber.
[0009] FIG. 1B is a perspective view, illustrating the afterburner assembly.
[0010] FIG. 2 is a section view, showing the rotary joint between the main burner and the main combustion chamber.
[0011] FIG. 3 is a perspective view with a cutaway, showing the position of the restrictor plate within the main combustion chamber.
[0012] FIG. 4 is a section elevation view, showing how the angles side walls concentrate the solid waste in the middle of the combustion chamber.
[0013] FIG. 5 is a section elevation view, showing how the hatch cover may be positioned for removing the contents of the combustion chamber.
[0014] FIG. 6 is an elevation view, showing an alternate embodiment of the present invention.
REFERENCE NUMERALS IN THE DRAWINGS
[0015] 10 incinerator
[0016] 12 combustion chamber
[0017] 14 frame
[0018] 16 rollers
[0019] 18 motor
[0020] 20 chain
[0021] 22 rib
[0022] 24 rib
[0023] 26 hatch cover
[0024] 28 burner receiver
[0025] 30 burner
[0026] 32 stop plate
[0027] 34 spring
[0028] 36 spring
[0029] 38 fuel supply line
[0030] 40 exhaust
[0031] 42 exhaust receiver
[0032] 44 flange
[0033] 46 flange
[0034] 48 spring
[0035] 50 secondary combustion chamber
[0036] 52 spring
[0037] 54 chimney
[0038] 56 burner mount plate
[0039] 58 burner
[0040] 60 fuel supply line
[0041] 62 burner mount plate
[0042] 64 nozzle
[0043] 66 insulator
[0044] 68 opening
[0045] 70 restrictor plate
[0046] 72 vents
[0047] 74 rotary joint
[0048] 76 flame
[0049] 78 rotary joint
[0050] 80 solid waste
DETAILED DESCRIPTION OF THE INVENTION
[0051] The present invention, incinerator 10 , is illustrated in FIGS. 1A and 1B . Incinerator 10 includes combustion chamber 12 which is supported by rollers 16 on frame 14 . Ribs 22 and 24 engage a groove on each roller and serve to keep combustion chamber 12 from shifting horizontally during operation. Motor 18 drives chain 20 which causes combustion chamber 12 to rotate on rollers 16 . Teeth are provided on the exterior surface of combustion chamber 12 for engagement with chain 20 . Combustion chamber 12 is generally positioned on frame 14 such that combustion chamber 12 has an axis of rotation along its central, horizontal axis.
[0052] Combustion chamber 12 has a sloping interior wall which slopes away from the axis of rotation from both ends of combustion chamber 12 to the middle. Thus, the interior has a varying cross-sectional area that is greatest at the middle of combustion chamber 12 . This forces the waste product toward the middle during the combustion process. This allows the heat of burner 30 to be applied directly to the waste product as it is tumbled in combustion chamber, thereby rapidly burning the waste product.
[0053] Forcing the combusted remains of the waste product to the center of combustion chamber 12 also makes it easier to clean combustion chamber 12 . To clean combustion chamber 12 , hatch cover 26 is removed to uncover the hatch opening, and combustion chamber 12 is rotated so that the hatch opening faces the ground and the contents of the chamber spill out. The contents may be captured in a container and transported to another location for disposal.
[0054] Burner 30 is attached to one end of combustion chamber 12 within burner receiver 28 . Burner 30 is typically of the gas (commonly propane or methane) or fuel oil type. It features an integral blower which pulls in ambient air through an intake. Fuel is provided to burner 30 through fuel supply line 38 . Burner 30 is angled downward with respect to the axis of rotation of combustion chamber 12 such that the flame projected by burner 30 is projected at an off-axis orientation toward the bottom of combustion chamber 12 . Because the waste material concentrates in the middle portion of combustion chamber 12 (due to the sloping side walls), burner 30 targets the flame on the waste product. This dramatically reduces the amount of time it takes to burn the product to completion compared to conventional rotating combustion chambers. As the product is tumbled, the waste product is exposed to the flame from various angles.
[0055] Burner 30 is mounted to stop plate 32 which is attached to frame 14 by several springs including springs 34 and 36 . As such, combustion chamber 12 rotates independently of burner 30 . Springs 34 and 36 absorb vibrations transmitted to stop plate 32 when combustion chamber 12 rotates.
[0056] Exhaust 40 is provided on the end of combustion chamber 12 opposite of burner 30 . Exhaust 40 is nested in and rotates within exhaust receiver 42 . Exhaust receiver 42 mates with rotary joint 78 on combustion chamber 12 and allows combustion chamber 12 to rotate along its center axis while exhaust receiver 42 remains stationary. Flange 44 of exhaust receiver 42 is attached to flange 46 of secondary combustion chamber 50 . Secondary combustion chamber 50 is suspended from frame 14 by springs 48 and 52 . Like springs 34 and 36 , springs 48 and 52 absorb vibrations transmitted when combustion chamber 12 rotates. Secondary combustion chamber 50 has burner 58 mounted on one end by burner mount plate 56 . Burner 58 receives fuel through fuel supply line 60 . Burner 56 projects a flame into secondary combustion chamber 50 to further combust material escaping through exhaust 40 . Chimney 54 vents combustion chamber 50 to the atmosphere.
[0057] FIG. 2 shows a detailed view of the interface between burner 30 and burner receiver 28 . Rotary joint 74 is provided on stop plate 32 and engages burner receiver 28 such that combustion chamber 12 can rotate along its central, horizontal axis, while stop plate 32 remains stationary. Nozzle 64 of burner 30 extends through burner mount plate 62 , stop plate 32 and insulator 66 , so that the end of burner 30 faces opening 68 of combustion chamber 12 . Nozzle 64 is angled downward with respect to the axis of rotation of combustion chamber 12 . Because combustion chamber 12 rotates independently of burner 30 , nozzle 64 remains at the same orientation while combustion chamber 12 rotates. This configuration results in the flame being directed at the bottom of combustion chamber 12 where the waste products tend to accumulate. As shown in FIG. 2 , flame 76 follows the angled side wall along the bottom of combustion chamber 12 .
[0058] FIG. 3 shows the end of combustion chamber 12 near the exhaust. Restrictor plate 70 is attached to combustion chamber 12 and prevents an undesirable amount of waste product from passing through exhaust 40 into secondary combustion chamber 50 . Vents 72 are provided in restrictor plate 70 and allow exhaust gases and small particulates from the combustion of the waste product to pass into secondary combustion chamber 50 .
[0059] FIG. 4 , shows how the shape of combustion chamber 12 causes solid waste 80 to accumulate in the middle portion of the combustion chamber. The reader will recall that flame 76 produced by the main burner is directed towards this region of the combustion chamber. As combustion chamber 12 rotates, solid waste 80 tumbles but remains concentrated in the middle of combustion chamber 12 . As such, solid waste 80 is maintained in the optimal burning location. Because solid waste 80 tumbles when combustion chamber 12 rotates, the waste is exposed to the flame from many different angles. This allows the material to be combusted to completion in the shortest period of time.
[0060] FIG. 6 illustrates how the concentration of solid waste 80 in the middle of combustion chamber 12 further facilitates the removal of the solid waste when burning operations are completed. To empty combustion chamber 12 , hatch cover 26 is simply moved to the open position and solid waste 80 pours out of the hatch opening. As mentioned previously, a container may be placed under the hatch opening for catching the contents of combustion chamber 12 as they spill out. The waste product may then be transported to an alternate location for disposal.
[0061] An alternate embodiment of the present invention is shown in FIG. 6 . This embodiment is much the same as the embodiment shown in FIGS. 1A and 1B , except that secondary combustion chamber 50 has been placed on top of the frame supporting combustion chamber 12 . Like the previous embodiment, combustion chamber 12 rotated about its central, horizontal axis. Fine waste particulates pass through a restrictor plate and are combusted in secondary combustion chamber 50 , which remains stationary. In this configuration, the waste incinerator takes up less floor space.
[0062] Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiment of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given. | An incinerator for burning waste products such as animal carcasses. The incinerator features a rotating combustion chamber with sloping side walls. The sloping side walls cause the waste product to concentrate in the center of the combustion chamber where the product is subjected to the flame of a burner. A hatch is provided in the center of the combustion chamber to allow for easy cleaning of the combustion chamber. | 5 |
TECHNICAL FIELD
[0001] The present invention relates generally to communications between computer systems and, more particularly, the present invention is directed to supporting a method and apparatus to send messages between multiple partitions within each computer system when a channel is shareable by plural operating systems in a computer electronic complex (CEC) supporting both shared and unshared I/O channels.
BACKGROUND
[0002] Presently, messages sent between a computer system and a coupling facility require Input/Output channels as generally described in U.S. Pat. US5452455: Asynchronous command support for shared channels for a computer complex having multiple operating systems, assigned to International Business Machines Corporation (IBM). Within prior IBM mainframes, as exemplified by the S/390 systems and recent z Series mainframes (s/390 and z Series are trademarks of IBM), while these channels can be shared by multiple operating system images within the computer system, the channel can only be allocated to a single coupling facility. These IBM mainframes are considered the closest prior art and described below in some drawings. This needed invention departs from the prior art practice and provides a mechanism needed to allow a single physical message I/O channel to be shared by multiple host images, both operating systems and coupling facilities, within a computer system having multiple CECs.
SUMMARY OF THE INVENTION
[0003] The present method supports sharing of coupling channels among multiple coupling facility images for primary messages sent from an operating system allowing the operating system to send messages between multiple partitions within each computer system when a channel is shareable by plural operating systems in one or more computer electronic complexes (CEC) having a hypervisor memory and supporting both shared and unshared I/O channels. The method uses the hypervisor's memory and provides for the computer electronic complex (CEC) with the computer system coupling Input/Output channels performing the steps of receiving a message request in the hypervisor's memory and interrupting said hypervisor; having the hypervisor examine fields within the message request to identify the target Coupling Facility; moving this message request to the targeted Coupling Facilities memory; and then setting an indicator in the targeted Coupling Facility to alert it to the arrival of the message request.
[0004] Using the method and hardware provided, now it will be possible to use said coupling Input/Output channels to pass messages directly between instances of the operating system without CF involvement.
[0005] These changes allow sharing of receiver resources among multiple Coupling Facility (CF) logical partitions (LPARs), and direct CEC to CEC message passing, as well as CF interrupts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0007] [0007]FIG. 1 depicts a diagram of two CECs, each containing three OS and two CF partitions where each CF partition requires its own I/O channel;
[0008] [0008]FIG. 2 depicts a diagram of the sequences of frames used in primary and secondary messages;
[0009] [0009]FIG. 3 depicts a diagram where the primary message MCBs and MRBs are sent directly to and from a single CF partition's memory;
[0010] [0010]FIG. 4 depicts a diagram where the data portion of the primary message is sent directly to and from a single CF partition's memory;
[0011] [0011]FIG. 5 depicts a diagram of two CECs, each containing three OS and two CF partitions where the two CF partitions share a single I/O channel in accordance with a preferred embodiment of the present invention;
[0012] [0012]FIG. 6 depicts a diagram where the primary message MCBs of the present invention are sent to a common area before they are routed to one of the two CFs, and the primary message MRBs are sent directly from one of the two CFs' memories in accordance with a preferred embodiment of the present invention;
[0013] [0013]FIG. 7 depicts a diagram where a single I/O channel is shared by two CFs to send the data portion of the primary message directly to an from the CFs' memories in accordance with a preferred embodiment of the present invention;
[0014] [0014]FIG. 8 depicts a diagram where the secondary message MCBs and MRBs are sent directly from and to a single CF partition's memory; and
[0015] [0015]FIG. 9 depicts a diagram where the secondary message MCBs of the present invention are collected in a common area before they are sent to the OSs, and the secondary message MRBs are sent directly one of the two CFs' memories in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The IBM design of the coupling Input/Output channels, called InterSystem Channels (ISCs), used by the recently introduced successor to the IBM S/390 system call the IBM's zSeries mainframe computers allows ownership by only a single Coupling Facility (CF), and when multiple CFs are in a CEC, each needs its own ISCs. In addition, the only way that a CF detects that requests, data, and responses have been transferred is by polling. The Coupling Facility Control Code (CFCC) uses the Locate Channel Buffer (LCB) instruction to poll for the arrival of new messages and it spins on indicator bits in the Channel Buffer Operation Block (CBOB) to determine when data has been transferred and responses from secondary commands have been received.
[0017] Using the method and hardware provided, now it will be possible to use ISCs to pass messages directly between instances of the operating system without CF involvement. With the hardware in ISC the system can now generate hardware interrupts to the hypervisor as the message transfer progresses and extends the present transfer commands sent from the processors to the hardware and processor microcode to accept the interrupts and drive the new commands.
[0018] [0018]FIG. 1 shows the prior art where System 1 102 is connected to System 2 104 with two coupling channels, called InterSystem Channels, or ISCs. Channel A 106 in System 1 connects to Channel A 110 in System 2 104 over link 114 . To support multiple Coupling Facilities (CFs), a second channel, Channel B 108 in System 1 102 is connected to Channel B 112 in System 2 104 over link 116 . In System 1 102 , Operating System 0 (OS 0 ) 118 , OS 1 120 , and OS 2 122 can all share both Channel A 106 and Channel B 108 , but Coupling Facility 0 (CF 0 ) 124 and CF 1 126 cannot share Channel A 106 or Channel B 108 . Instead, a separate channel is dedicated to each CF. In this example, CF 0 124 uses Channel A 106 and CF 1 126 uses Channel B 108 . A similar situation exists in System 2 104 . In System 2 104 , OS 0 128 , OS 1 130 , and OS 2 132 can all share both Channel A 110 and Channel B 112 ; and CF 0 134 uses Channel A 110 and CF 1 136 uses Channel B 112 .
[0019] Within each channel there are facilities used to send and receive coupling messages. Originator Primary (OP) facilities 140 , 150 , 160 , 170 send primary messages from an OS to a CF; Recipient Primary (RP) facilities 144 , 154 , 164 , 174 receive primary messages by a CF from an OS; Originator Secondary (OS) facilities 146 , 156 , 166 , 176 send secondary messages for a CF to an OS; and Recipient Secondary (RS) facilities 142 , 152 , 162 , 172 receive secondary messages from a CF to an OS. It should be understood that multiple OP, RP, OS, and RS facilities may be present in each channel to allow multiple simultaneous messages. In the present embodiment, seven facilities of each type are in each channel.
[0020] [0020]FIG. 2 shows the sequences of frames used in primary and secondary messages. FIG. 2 a is the no data case where a Message Command Block (MCB) 202 is sent from the originator to the recipient; primary messages may have optional data and secondary messages never have data. The recipient responds by sending the Message Response Block (MRB) 204 back to the originator. FIG. 2 b is the write case. The Message Command Block (MCB) 212 is sent from the originator to the recipient followed by Data 214 . After the recipient receives the Data 214 , it sends the Message Response Block (MRB) 216 back to the originator. FIG. 2 c is the read case. The Message Command Block (MCB) 222 is sent from the originator to the recipient. When the recipient processes the MCB 222 , it sends Data 224 back to the originator. The recipient then sends the Message Response Block (MRB) 226 back to the originator.
[0021] [0021]FIG. 3 shows how the prior art sends a primary message with no optional data from an OS in System 1 302 to a CF in System 2 304 . Primary messages in the form of Message Command Blocks (MCBs) 306 are sent directly to an area of main memory owned by the CF called the Channel Buffer Operation Block (CBOB) 310 . Within CBOB 310 the MCB is stored in the MCB area 312 . Likewise, the Message Response Block (MRB) 308 is sent from an area 314 in the same CBOB 310 . The sequence is as follows:
[0022] 1) The MCB 306 is stored directly in the CF's memory in the CBOB 310 .
[0023] 2) The channel sets the Command Active indicator 316 in the CBOB to alert the CF.
[0024] 3) The CF executes the Locate Channel Buffer (LCB) instruction that scans Command Active indicators in the CBOBs owned by the CF looking for work.
[0025] 4) If a Command Active indicator is set, the CF examines the MCB 312 in CBOB 310 and executes the command.
[0026] 5) The CF generates the response, the MRB, and places it into the CBOB 314 .
[0027] 6) The CF executes an instruction that causes the channel to transmit the MRB 308 back to the OS.
[0028] While this arrangement allows the MCB to be stored directly into the CF's memory, it does not allow multiple CFs to share a channel.
[0029] [0029]FIG. 4 shows how the prior art moves the optional data between an OS in System 1 402 to a CF in System 2 404 . The data is sent directly to and from the CFs main memory and comprises the following steps:
[0030] 1) The CF in System 2 404 decodes the MCB (as described in FIG. 3) and determines that there is data to be transferred.
[0031] 2) The CF 404 builds an address list of the data to be moved and loads the Data Transfer List Facilities 406 .
[0032] 3) The CF 404 executes a special instruction to move the DATA 408 .
[0033] 4) The channel moves the DATA, and when the DATA 408 has been moved, the channel sets the Data Complete indicator 318 in the CBOB 310 (see FIG. 3).
[0034] 5) When the CF 404 detects the indicator (by polling), it sends the MRB back to the OS as described in FIG. 3.
[0035] [0035]FIG. 5 shows the present embodiment where multiple CFs share a channel resulting in saving the hardware associated with the additional channel (Channels B) shown in FIG. 1. The figure is very similar to FIG. 1, but System 1 502 has only Channel A 506 , and System 2 504 has only Channel A 510 . Also, CF 0 524 and CF 1 526 in System 1 502 both share Recipient Primary (RP) 544 and Originator Secondary (OS) 546 facilities, and CF 0 534 and CF 1 536 in System 2 504 both share Recipient Primary (RP) 564 and Originator Secondary (OS) 566 facilities. It should be understood that Channels A 506 , 510 may be shared by more than just two Cfs.
[0036] [0036]FIG. 6 shows the flow of message frames within System 2 604 where two CFs share a recipient primary facility. Instead of sending the MCB 614 from System 1 602 directly to the main memory of the CF in System 2 604 , the MCB 614 is received by System 2 604 in a special shared CBOB 606 located in the System 2 hypervisor's memory, called Hardware System Area (HSA). This is shown as Step 1 650 . After the MCB is stored in an area 620 of the CBOB 606 , System 2 's 604 channel generates a hardware interrupt to its hypervisor. The hypervisor then examines a new field in the MCB in CBOB area 620 to determine to which CF the MCB should be sent. In step 2 652 , the MCB is sent to either the CBOB 608 in CF 0 's main memory or to the CBOB 610 in CF 1 's main memory. After the hypervisor moves the MCB to either area 630 or area 640 , it sets the Command Active indictor 634 , 644 in either CBOB 608 , 610 to alert either CF 0 or CF 1 , respectively. At this point, the CF 0 and CF 1 operate in the same manner as in FIG. 3. Namely, both CFs execute the Locate Channel Buffer (LCB) instruction that scans the CBOBs owned by the CF looking for work. In this case, only one of the CFs finds the Command Active indicator set, and that CF examines the MCB 630 , 640 in CBOB 608 , 610 and executes the command. The CF then generates the response, the MRB 632 , 642 , and places it into the CBOB 608 , 610 . The CF then executes an instruction telling the channel to transmit the MRB 612 , 616 back to the OS as shown in steps 3 654 , 656 . The channel knows which MRB 632 , 642 to transmit since it knows which CF is executing the instruction.
[0037] [0037]FIG. 7 shows the details of data transfer for primary messages. As in the prior art shown in FIG. 4, the optional data is sent between an OS in System 1 702 and either CF 0 or CF 1 in System 2 704 . The data is sent directly to and from the CFs main memory and comprises the following steps:
[0038] 1) The CF 0 or CF 1 in System 2 704 decodes the MCB and determines that there is data to be transferred (as described in FIG. 6).
[0039] 2) One of the CFs builds an address list of the data to be moved and loads its Data Transfer List Facilities 708 , 710 .
[0040] 3) One of the CFs executes a special instruction to move the DATA 706 .
[0041] 4) The channel knows which Data Transfer List Facility 708 , 710 to process since it knows which CF is executing the instruction. After the DATA 706 has been moved, System 2 's 704 channel generates another hardware interrupt to its hypervisor. The hypervisor determines which CF finished sending data, and sets the Data Complete indicator 636 , 646 in the CBOB 608 , 610 (see FIG. 6) to alert either CF 0 or CF 1 , respectively.
[0042] 5) When the CF 404 detects the Data Complete indicator (by polling), it sends the MRB back to the OS as described in FIG. 6.
[0043] [0043]FIG. 8 shows how the prior art sends a secondary message from a CF in System 2 804 to an OS in System 1 802 . The following steps are used.
[0044] 1) The CF in System 2 804 generates an MCB 814 in its CBOB 810 located in the CF's main memory.
[0045] 2) The CF executes an instruction to send the MCB.
[0046] 3) The channel in System 2 804 sends the MCB 806 to System 1 802 .
[0047] 4) System 1 802 executes the MCB and sends the MRB 808 back to System 2 804 .
[0048] [0048] 5 ) System 2 's 804 channel stores the MRB directly into the CF's CBOB 810 in area 812 .
[0049] 6) System 2 's 804 channel sets the Command Complete indicator 816 in the CBOB 810 signaling the arrival of the MRB.
[0050] 7) The CF detects the Arrival of the MRB by polling the Command Complete indicator in the CBOB and completes the message exchange.
[0051] [0051]FIG. 9 shows the flow of secondary message frames within System 2 904 where two CFs share an originator secondary facility. Instead of sending the MCB 908 directly from either CF 0 's CBOB 914 in its main memory or CF 1 's CBOB 916 in its main memory to System 1 902 , the instruction that the CFs use to send the MCB interrupts System 2 's 904 hypervisor. The hypervisor then moves the MCB from either MCB area 922 or MCB area 926 to the hypervisor's CBOB 912 in Hardware System Area (HSA), shown in step 1 930 . The hypervisor then instructs the channel to send the MCB 918 to System 1 902 in step 2 932 . At the same time, the hypervisor prepares the channel in System 2 904 to steer the subsequent MRB 906 , 910 to the correct CFs' CBOB 914 , 916 . When System 1 902 responds with the MRB, it is stored directly into the CFs' CBOB in area 924 , 928 . After System 2 's 904 channel completes storing the MRB, shown in step 3 934 , 936 , it sets the Command Complete indicator 950 , 952 in either CBOB 914 , 916 signaling the arrival of the MRB. One of the CFs detects the arrival of the MRB by polling the Command Complete indicator in its CBOB 914 , 916 and completes the message exchange.
[0052] The method and system of sharing recipient primary facilities is also used as a basis for replacing the CF's polling the Command Active indicators for active MCBs by an interrupt. In situations where the CF work load is low, polling consumes too many cycles. The CF would like to be blocked and then be restarted by an interrupt. In this case, the target system's hypervisor receives the MCB in its CBOB in its memory (HSA) and examines a field to determine to which CF or OS the message is to be routed. Once routed there, the hypervisor sets an interrupt to the CF or OS in addition to setting the Command Active indicator in the CBOB. This same interrupt can also be presented to the CF when data transfer completes and when a secondary command completes.
[0053] The method and system of sharing recipient primary and originator secondary facilities is also extended from CFs to OSs. OSs can send primary messages to not only multiple CFs within a target system, but they can also send primary messages to multiple OSs within the target system.
[0054] The OS sending the message creates an MCB targeted to either another OS or a CF. In the case of messages sent to another OS, the MCB describes the message buffer in the target to use. When the MCB is received at the other end of the link, the channel places it in a CBOB in HSA, and interrupts the hypervisor. If the hypervisor determines that the message is for a CF, it copies the MCB to the appropriate CBOB in the CF's memory, and sets the Command Active indicator. If the hypervisor determines that the command is for an OS, it has to move the data and creates an MRB since it cannot rely on the OS to be responsive in detecting and executing the MCB. A unresponsive OS will tie up the originator and recipient facilities. Assuming that the message is for an OS, the hypervisor examines the MCB to determine where to move the data, if any. The MCB itself can be moved into a pool of MCB buffers visible to the the OS, and the data can also be moved through a pool of buffers. Instead of a pool of buffers, the MCB may specify a particular buffer in the OS's memory. To move the data, the hypervisor instructs the channel in the same way that a CF does. After data movement is complete, a second hardware interrupt is generated, and the hypervisor generates an MRB depending on the outcome of the data transfer. The hypervisor instructs the channel to send the MRB. If the MRB can be generated before the data is moved to or from memory, the channel can be primed to automatically send the MRB from the CBOB pair after successful data transfer. When the originating OS receives the MRB, the message finishes as usual.
[0055] At this point, the originator and recipient facilities can be reused for the next message. It is up to a higher level protocol to establish and control the data buffers. The OS responses to the messages are accomplished through higher level protocols that cause a message to be sent in the opposite direction.
[0056] By having the hypervisor execute the messages (interpreting the commands (MCBs), transferring the optional data, and generating the responses (MRBs)), the originator and recipient facility utilization can be kept low and the link utilization can be kept high.
[0057] The Virtual Interface Architecture (VIA) can also be implemented with the OS to OS message passing described above. One of the most important characteristics of VIA is to be able to efficiently send messages from one system to another without calls to the operating system kernel. To do this, programs at each end of a link register portions of memory that can be accessed (read, write, or both) directly by the other end of the link. When data is received from the far end of the link, the address (or process ID) is used as an index into a translation table to determine the target of the data. Validation, or protection keys (32 bits) are provided to better isolate threads within the process owning the particular area of memory.
[0058] In VIA, the registration of the memory is performed by the kernel, and the hypervisor is informed of the mappings. Once the memory is registered, messages can be sent.
[0059] The message header is transmitted as an MCB, and if the message is short enough (less than about 1000 bytes) it could also be included in the MCB. After an MCB is received, the hypervisor examines the MCB to determine the address. It translates the address, and for short messages uses this address to move the message from the MCB buffer in HSA to the OS's memory. For longer messages, the hypervisor moves the optional data. After the message has been successfully transferred (with or without a large data area), the response is sent in the form of an MRB.
[0060] The VIA doorbell is implemented as an interrupt set by the hypervisor.
[0061] While the preferred embodiment to the invention has 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 method for use in a computer system for extending coupling channels through the addition of specific hardware interrupts and controls to allow 1) sharing of receiver resources among multiple Coupling Facility (CF) logical partitions (LPARs), 2) direct CEC to CEC message passing, and 3) CF interrupts. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to microwave receiver/transmitter earth stations of the type having a reflector dish and, in particular, to low cost structures for such.
2. Prior Art
Microwave receiver/transmitters of the so-called reflector dish type have long been known in the communications industry. To date, most have been of industrial quality, namely--large, exceptionally ruggedly constructed units suitable for long-lived use in remote locations. Examples of such units are the relay stations installed by telephone companies. Units of this type cost one or more thousands of dollars. With the advent of communications satellites sited in geosynchronous or "parking" orbits some 22,300 miles above the earth's equator (in the so-called "Clarke Belt"), broadcasting of television and other signals from end to end of a continent or even from one continent to another with just one relay station (the satellite) has been made possible, but a high cost of the receivers--if it persists--would be a barrier to establishment of a market among the members of the general population. Further, the prior dishes have generally been heavy, ungainly and unsightly--particulary when formed of open framework--and (where non-uniformly exposed to the full strength of the sun's rays) have a tendency to warp, with resultant decrease in stability of the response characteristic to the input signals. This last has usually been taken care of by introduction of compensating electronic circuits with corresponding increase in actual cost of the item.
Use of plastic foams has long been known in conjunction with antennas in general and also with respect to those of the reflector dish type--e.g., patents such as U.S. Pat. Nos. 2,689,304; 3,169,311; 3,374,482; 3,381,371 and 3,745,158. The teachings in these patents relate to methods of making lightweight reflectors, embedment of a tilted reflector as a means of reducing dynamic unbalance of rotating radar scanners, combination of this last with a gyro rotor, and lastly, embedment of a double halo marine frequency antenna after separating the halos a predetermined distance by use of a number of spacers. Clearly, these patents do not address and solve the problems of supporting microwave receptor elements without deleterious effects of tripodal support arms on signal power and similarly undesirable effects of warping attendant upon non-uniform solar heating of the reflector dish. Moreover, none of these patents show embedment of electronic circuits along with the antenna elements because, as known, high heat dissipation of a-c/d-c power converters when combined with low thermal conductivity of plastic foam adversely affects active elements of these circuits, resulting in high probability of an early failure (thermal runaway).
Thus, there is need for a low cost, relatively light weight, compact, and yet thermally stable microwave earth station suitable for use in the mass market.
SUMMARY OF THE INVENTION
The invention resides generally in an improved microwave receiving/transmitting earth station of the type having a reflector dish in a shape concentrating intercepted rays of a microwave signal beam at a focal point on the axis of the dish, a feed horn being located thereat to interact with the focussed beam, and the dish being alternatively adapted to emit a beam of microwave signals generated by a microwave source, the signals being supplied to the feed horn for beam emission; together with a signalconducting member connecting the feed horn to a utilization device/the source of microwaves. In particular, the improved earth station comprises (a) a layer of thin, microwave reflective material forming the reflector dish, the dish having a front and a back; (b) a first mass of material transparent to the microwave beam and having a discrete surface portion in a shape matching the front of the dish, the first mass projecting beyond the focal point by an amount sufficient to encompass the feed horn and thereby provide the sole support therefor as well as the spacing thereof from the dish; (c) a second mass of the transparent material, the second mass having a particular surface portion in a shape matching the back of the dish; and (d) means integrating the layer of thin, microwave reflective material the first mass of transparent material, and the second mass of transparent material into a composite unit having the layer reinforcedly supported between the first and second masses.
As a feature of the invention, thermal instability due to solar irradiation is avoided by use of low thermal conductivity, low density, rigid plastic foam for fabricating the composite unit.
Another feature of the invention, is that for the receiveonly version, at least a low-noise amplifier and optionally a downconverter and satellite receiver channels may also be supported in the composite unit, the problem of readily dissipating internally generated heat from any of these embedded elements being resolved by retaining only d-c powered portions of elements in the composite unit.
As yet another feature of the invention, application of the technique to larger units is made possible by a modularization of the composite unit.
Other features of the invention as well as advantages of same will be found in the following detailed description of the preferred embodiments with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a microwave earth station according to a first embodiment of the invention.
FIG. 2 shows an exploded cross-sectional view of the microwave earth station of FIG. 1.
FIG. 3 shows an enlarged view of the elements for sensing a microwave beam impinging on the reflector in the microwave earth station of FIG. 1 and for converting the beam into a signal of lower frequency, these elements being supported on the reflector axis at the focal point of the reflector without benefit of the usual "buttonhooks" or tripodal support arms or other form of separate spacers.
FIG. 4 shows a modification of the enlarged view of FIG. 3 in which a microwave-transparent rod attached to the microwave-sensing element traverses the earth station near the axis of the reflector from the focal point to a back cavity and is available for a slight manual re-positioning of the sensing-element, if necessary, to develop the optimum signal output.
FIG. 5 shows a modular construction for a microwave earth station according to a second embodiment of the invention.
FIG. 6 is a perspective view of a microwave earth station according to a modification of the embodiment of FIG. 1 wherein the axis of the reflector dish passes through the middle of opposing edges of the cube.
FIG. 7 is a perspective view of a microwave earth station according to a third embodiment in which the reflector dish is spanned along the diameter of a right-circular cylinder.
FIG. 8 shows a microwave earth station according to yet another embodiment of the invention in which a platform attached to the back of the unit of FIG. 1 is adjustable to provide support for the unit in any desired position, thus affording portable utility (to the beach, to the mountains, etc.)
FIG. 9 shows the arrangement of FIG. 1 (or FIG. 8) adapted to support a microwave earth station on top of a recreational vehicle, the earth station normally resting behind a wind screen and being rotatable and inclinable into a position for optimum interception of a particular satellite's beam.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of an earth station 10 according to the invention is shown in FIG. 1, where a first layer 14 made of a material readily penetrable by microwave radiation, a second, thin parabolic reflector layer 12; and a third layer 16 of the same (or similar) microwave-penetrable material form a composite unit in the shape of a cube 10 (or other parallelepiped) about four feet on each side, say, or larger if needed. Layer 14 and layer 16 preferably are made of rigid, low density plastic, formed--for example--by molding polystyrene beads using longknown techniques. Alternatively, they could be foamed-in-place in a likewise known fashion--e.g., by use of a two-part epoxy foam system such as that available from Tap Plastics Inc. of Dublin, Calif. They could also be carved from blocks of styrofoam, as is also known.
As best seen in the exploded cross-sectional view of FIG. 2, layer 14 is preferably molded such that it has a planar front surface 18 and planar sides 36-b1, 36-d1 (respectively, the upper and lower sides when facing the front surface 18 in FIG. 1), together with a convex parabolic back surface 17 having a focal point 21 on a central axis 13 of reflector 12. Similarly, layer 16 is molded such that it has a concave parabolic front surface 19 matching the back surface 17 of layer 14, of course, together with a planar back surface 38 and planar sides 36-b2, 36-d2 (again, respectively, the upper and lower sides when facing the front surface 18 in FIG. 1). To form cube 10, the parabolic back surface 17 of layer 14 is first coated in known fashion (brushing, say) with a layer 33 of adhesive (e.g. "Elmer's Latex Wood Glue" manufactured by Borden Inc. of Columbus, Ohio) then preferably covered with a layer 12a of thin metal foil (such as 0.010" thick aluminum).
Front surface 25 of foil layer 12a is next conformed manually, say, to the contours of back surface 17 to form the microwave reflector layer 12 or "reflector" 12 (as earth station 10 will be termed hereinafter for convenience). Thereafter, a further coating 33a of the same adhesive is applied to convex back surface 37 of foil 12a and layer 16 is then joined to layer 14 with reflector 12 intervening between the two so as to form the basic cube 10. Although reflector dish 12 has been described above as being formed of a thin aluminum foil layer 12a, it will be evident that it could equally well be formed of known aluminum fibers or known reflective paints of the type containing fine metallic particles. As used hereinafter, the term "foil" will include such equivalents.
To prevent impingement of stray microwave radiation 39 on reflector 12--often referred to in the art as terrestrial interference or "TI"--the four sides of layer 14 only sides 36-b1 and 36-d1 being shown in FIG. 2) are preferably covered with a shield or skirt layer 31 of thin aluminum foil similar to 12a. Lastly, for protection of cube 10 from vandals or weather (if not concealed in the usual shelter--a simulated tool-shed, cabana or the like), an external fiberglass-resin layer 35 may be applied by known techniques. Layer 16 could be omitted, if desired, and layer 35 applied directly to back surface 37 of foil 12a.
While cube 10 may be realized using the structure disclosed above and incorporating known transmitting/receiving elements (such as equipment utilized in the microwave antennas available from Andrew Corporation of Orland Park, Illinois), for brevity, just the receive-only version of the earth station according to the invention will be described in detail. Cube 10 is normally oriented such that axis 13 of reflector 12 is parallel to the rays of microwave beam 20 and thus these last are focused by reflector 12 onto a point 21 at an inner end 22 of a cavity 24 in layer 14. Outer end 18a (FIG. 3) of cavity 24 is defined by the planar front surface 18 of layer 14, sufficient depth and width being provided to permit cavity 24 to accept within it a microwavesensing assemblage 26 responsive to beam 20 (which has a frequency in the range of several gigaherz--e.g., 3.8 to 4.2 gHz and may be even higher, if necessary). Assemblage 26 serves to extract, in known fashion, desired video or other information signals from beam 20 with output at a lower frequency compatible with common TV equipment. Assemblage 26 may be temporarily supported on axis 13 in known fashion (clamped to the mold, say) in operative position relative to dish 12 and then foamed in place to hold it in that position. On the other hand, cavity 24 may first be formed by use of an appropriately-shaped, removable insert, as is also known, to provide a friction fit for assemblage 26 and this last then forced down into cavity 24 until it contacts inner end 22. Alternatively, the cavity 24 may be dimensioned to provide a sliding fit for assemblage 26 and this last slipped into cavity 24, brought into contact with end 22 (just as above), where it may next be cemented, again using adhesive 33, say. In all cases, outer end 18a is covered with an access panel 23 preferably provided with vents 23a for reasons discussed subsequently.
Microwave-sensing assemblage 26 may comprise a known feed horn 28 and a low-noise amplifier 28a (respectively, Uniden's Unirotor Model UST 460 made by Satellite Technology, Inc. of Indianapolis, Ind. and Drake Model 2576 LNA (75°-85°) made by R.L. Drake Company of Miamisburg, Ohio) together with an equally well-known frequency downconverter 30 (preferably compatible with choice of the TV channel device or transponder, described subsequently). Amplifier 28a and downconverter 30 are serially connected to this last by a short length of standard RG 213 ultrahigh frequency, flexible coaxial cable 32. A rigid, N-type connector may be used in place of cable 32 if a close-coupled, in-line arrangement is desired. (All these items are available, ordinarily, from a microwave equipment supply house such as Echosphere West Company of Sacramento, Calif.) Downconverter 30 and connecting cable 32 may be relocated, if desired, in some applications. Also, though FIG. 3 shows the elements 28a and 30 as being axially aligned with feed horn 28, they may be located behind it in a more compact arrangement (not shown, but known), though at possible cost of slight loss in signal power, if there is increased blockage of beam 20.
It may be remarked at this point that, for best results, provision should be made for minor adjustment in the rotational and axial position of feed horn 28 to achieve a final setting. The need for these adjustments stems from tolerance accumulations in manufacturing cube 10 and in the 180° polarization of satellite signals having the same frequency, the satellite then having a doubled channel capacity. The adjustments may be made by visual inspection of the picture received, or by use of a known signal strength meter. Rotational and axial adjustment may be somewhat difficult to perform through panel 23 after cube 10 has been mounted on post 72 of FIG. 1 and directed to align it with beam 20 from a particular satellite. FIG. 4 accordingly shows a further improvement in which a microwave-transparent (e.g. nylon) rod 90 is connected eccentrically and rigidly (as by a screw-threaded, shouldered end 93 and matching nut, say) to horn 28. Rod 90 extends rearwardly via a passageway 92 into the cavity 40a, where about an inch or two of rod 90 protrudes to form a grip portion 94. Passageway 92 is made sufficiently large to allow slight arcuate movement (+/-10°) of rod 90 by lateral displacement of portion 94, causing horn 28 to rotate likewise and attain a rotational position yielding a first improvement in the signal. Then, by pulling or pushing axially on rod 90, horn 28 can be moved inward or outward by the small fraction of an inch possibly needed to develop the true peak signal. The order of the "peaking" adjustments just given could be inverted and the same result obtained, of course.
It will be noted (see the exploded view of FIG. 2 and an enlarged view in FIG. 3 showing cavity 24 and its contents in block form) that by locating assemblage 26 in cavity 24, all support for assemblage 26 is derived from layer 14 without requiring any of the previously-used support arms (so-called "buttonhooks" or tripods) with their known interference with and resultant reduction of the strength of beam 20. Furthermore, optimum spacing from reflector 12 is set by the above-described "peaking" adjustments and layer 14 then retains that spacing by engagement with feed horn 28 (frictionally or by introduction of adhesive or additional foam).
Output from microwave assemblage 26--an information modulated carrier wave operating at 70 mHz, say--preferably is to a flexible coaxial cable 34 of standard type--e.g., a 75-ohm shielded unit. Cable 34 is preferably run rearwardly in the shadow 29 of feed horn 28 and then through a suitable aperture 15 in reflector 12 toward back surface 38 of cube 10 (cable 34 may also be run along a longer route over or just below front surface 18 and one of the lateral surfaces 36a, 36b to the back surface 38, although as between increased shadow of the former and increased conductor length of the latter, the trade-off seemingly favors the former). Cable 34 is connected to a full set of known TV channels (called "transponders" in the art), shown generally as a box 40 near back surface 38 in FIG. 1. These channels or transponders are referred to as "TVRO" in the communications industry when microwave transmission capabilities are not included, earth station 10 then being intended to operate in a receiving mode only, as in this exemplary description. Representative units are, say, the Model 7600A receiver and associated downconverter in the Model 5800 Test Equipment of Gillespie & Associates, now Geo Tech Communications Co. at Milpitas, California. Because of ready interfacing with the satellite tracking device identified subsequently, the Drake Model ESR 240A receiver made by R. L. Drake Co. (previously-mentioned) is believed more preferable. Choice of a transponder must be accompanied, for best results, by use of a known matching downconverter--normally that supplied with the particular make and model of transponder, though equivalents may be used where desirable.
Box 40 (together with its contents) is preferably foamed in place while forming layer 16, or may be lodged in a matching cavity 40a formed--as mentioned above--by use of an appropriatelyshaped insert during that same procedure. Location of box 40 is not critical at all, except for considerations of minimizing the length of cable 34. In a multiple-user version (e.g. trailer parks), box (channels) 40 may include for each channel a known low-power transmitter unit of very short range (i.e., range being limited by use of individual, known stub antennas, not shown in FIG. 1). For single user (home) applications, box 40 may alternatively include known high frequency or infra-red responsive channel selection circuits 42. Cavity 40a is again preferably covered with a vented access panel 43 which may be similar to panel 23 except that it need not be transparent to microwave radiation. The reason for venting cavities 24 and 40a will next be discussed.
In view of the very low thermal conductivity of most plastic foams (polystyrene, polyurethane, etc.), layers 14,16 reduce the inward flow of heat resulting from exposure of cube 10 to solar irradiation, but note that they likewise reduce the outward flow of heat corresponding to energy dissipated within the circuits of assemblage 26 and box 40, (comprising the lownoise amplifier 28, downconverter 30, and channel selection circuits 42). Hence it is desirable first to limit such dissipation and second to augment cooling of the electronic circuits. Accordingly, cavities 24 and 40a are convectively cooled by use of vented cover panels 23, 43. Moreover, all power supply components (the primary source of much heat) are preferably remotely located with respect to cube 10. Only d-c power is supplied to cube 10. This may be done (see FIG. 1) via a two-wire lead 44 from cube 10 to the remote source of d-c power +V. As shown in that figure, lead 44 is separate from a further coaxial cable 46--which may be identical in type to cable 34--ordinarily only supplying display information to the TV (or other utilization device). More preferably, this is done by dual use of cable 46. By biasing central lead 47 of cable 46 to +V relative to a ground shield 49 (as depicted in FIG. 2), d-c power may readily be supplied to electronic circuits 28,30 and 42. Cable 46 is then advantageously the sole lead from cube 10.
Before discussing some further embodiments, it should be mentioned that cube 10 is normally intended for fixed installation, being attachable to a biaxial mounting (e.g., on "gimbals") as shown in semi-schematic form in FIG. 1, where cube 10 is pivotally supported on a bracket 69 rigidly fastened to a shaft 70 rotatable within a cylindrical post 72 anchored in the usual concrete pad 74. Shaft 70 may be rotated bidirectionally (indicated by a double-headed arc 76) under control of a known d-c powered worm-gear drive 78. Similarly, pivoting of cube 10 about bracket 69 to change the angle of inclination (double-headed arrow 80) is depicted by the dash-dot line 81 between cube 10 and another d-c powered worm-gear drive 82. Dash-dot line 81 represents any one of many well-known gear-driven linear actuators. Drives 78,82 may be remotely-controlled to "home-in" on a desired satellite by the user's operation of a well-known high-frequency wireless channel selector. The discrete signal emitted by the selector may, for instance, cause a program in the circuits of a tracking device (not shown, but known - e.g., a Houston "Tracker IV" made by Houston Satellite Systems of Houston, Texas) to control azimuth positioning by drive 78, and a similar tracking device programmed to control elevation of cube 10 by drive 82.
As is known, signals from satellites vary in strength at the earth's surface beneath them, the "footprints" (so-called because of their shape) being so much weaker in fringe areas that a four-fold increase in size of reflector 12 is necessary in order to achieve the same image quality as in the central, strongest signal area (e.g., Denver, Colo. for continental U.S.) with the same power to microwave assemblage 26. A modular construction according to a second embodiment of the invention is therefore shown in FIG. 5. There, cube 10 of FIG. 1 has been subdivided into four identical parts or "modules" 110 (only one being shown) readily transportable to a desired site for easy assembly into a complete receiver/transmitter having the sensing elements of assemblage 26 (not shown in FIG. 5) lodged in a cavity equivalent to cavity 24, but formed by four quarter-cylinders 124 in the example chosen for purposes of this description. Alignment to bring the four sections 112 of parabolic reflector 12 together properly is provided, say, by the interaction of a key 148 on each given module 110 and a corresponding notch 150 in the module 110 counterclockwise from it. Modules 110 are preferably cemented together (using a suitable adhesive such as that previously-mentioned) during assembly into a complete cube 10. Though each quarter cavity 124 of FIG. 5 is shown with a smooth surface 125, its shape could be made complementary to that of assemblage 26. If the surface of that assemblage possesses assymetric features, then modules 110 may need differential characteristics to prevent improper assembly--for example, keys 148 and notches 150 may be formed in mutually exclusive sets. While the arrangement of FIG. 4 has been described in terms of subdivision into just four parts, it will be recognized that a greater number of parts is possible, though maintaining accuracy of reintegration of reflector 12 when assembling modules 110 becomes more difficult as that number increases.
While the first embodiment shows microwave earth station 10 as being cubical in shape and having the reflector axis 13 passing through the center of opposed faces 18 and 38, it will be appreciated that many other shapes and orientations may have discrete advantages and thus be desirably adoptable in practicing the invention. As one example (see FIG. 6), axis 13 of a parabolic reflector 212 may be oriented so as to pass through the middle of each of the edges 270, 272 of a parallelepiped 210 having a square cross-section as in FIG. 1, but reflector 212 here being spanned substantially along a diagonal between edges 274,276 thus yielding a considerable gain in surface area for reflector 212. As currently envisioned, the arrangement of FIG. 6 is more preferred, requiring little adjustment in the angle of inclination of parallelepiped 210 for optimum interception, while maintaining a lower profile. An example of a different shape is shown in FIG. 7, where a parabolic reflector 321 is spanned substantially along a diameter of a cylindrical section 310 suitably dimensioned in accordance with the interception area needed. As before, a cavity 324 in a forward portion 314 of section 310 is aligned with axis 13 of reflector 312, the inner end 322 of cavity 324 being located in the plane of focal point 321 of reflector 312. Though not shown, a cavity similar to 40 in FIG. 1 could also be provided in portion 316, if desired. Should the size of section 310 be such that focal point 321 falls outside forward portion 314, an additional projection (not shown in FIG. 7) in the form of a truncated pyramid or a parallepiped, could be included to provide the requisite volume for supporting assemblage 26.
Because of the compactness and self-contained nature of the cube 10, it lends itself very well to portability. To this end, as shown in a third embodiment (FIG. 8), cube 10 may be pivotally fastened to a support platform 52 at the bottom rear edge 54 of cube 10, and provided with one (or more) adjustable rod-and-tube linkages 56 connecting cube 10 and platform 52 for purposes of positioning cube 10 at any desired inclination relative to platform 52. Linkage 56 includes, of course, a clamp 58 (e.g., a known screw-tightened split ring) for retaining cube 10 in that position. In operation, platform 52 may be oriented to the necessary azimuthal position for alignment with the location of a particular satellite, cube 10 inclined to give optimum reception for signals from that satellite, and clamp 58 tightened. Platform 52 may then be given some minor azimuthal adjustment for even better reception and finally anchored to the ground 59 in known fashion by use of one or more stakes 60, for example.
As shown in FIG. 9, cube 10 can also be mounted on roof 64 of a recreational vehicle 66 atop a rotatable platform 52a having a wind deflector 68 affixed to it with cube 10 normally located behind deflector 68 when in a lowered, "travel" condition (indicated by dashed lines). In the embodiment of FIG. 9, cube 10 is pivotally connected to wind deflector 68 by a suitable hinge 62 at top front edge 63 of cube 10. In operation, platform 52a may be rotated to proper azimuthal position in the manner described above with respect to FIG. 8, and locked in that position in known fashion. Cube 10 is then again inclined (shown by solid lines) to align axis 13 with beam 20 from a desired satelite and retained at that angle by use of a linkage 56a similar to that of FIG. 8, say.
It may be remarked that though description of embodiments of FIGS. 8 and 9 implies manual orientation of cube 10 to align axis 13 with beam 20, it is contemplated that such could utilize the previously-mentioned power actuators and automated controls. Furthermore, while FIG. 1 shows cube 10 tiltably supported on bracket 69 (appropriate bearing inserts not being shown, but being well-known) and FIGS. 8 and 9 show cube 10 as being tiltably supported directly on platform 52 or windscreen 68, it will be clear that--if desired--cube 10 could as well be cradled in an open metal framework with the necessary bearings affixed to this last, rather than affixed to cube 10.
Although the foregoing description has been given in terms of specific details of construction, those skilled in the art will readily envision further modifications without departing from the spirit of the invention. Accordingly, it is intended that such modifications fall within the scope of the invention, which is to be limited only by the appended claims. | A low-cost, essentially self-contained microwave earth station having a reflector dish together with the microwave sensing/emitting elements embedded in a rigid, low density and low thermal conductivity plastic foam. At least the sides and back of the unit may be encased in a fiberglass-resin shell. Shielding for terrestrial interference also may be present. For a receive-only station, a low noise amplifier together with frequency conversion and channel selection (or all-channel transmission) to circuits may also be embedded in the foam. The only connections to such a receive-only unit are a line from a d-c source of power for supplying the required operating voltages to the electronics, and a coaxial cable supplying the selected one of the received information signals to the TV display or other device utilizing those signals. Preferably, a single coaxial line with the dual function of information output and d-c power input is employed. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method of heating process streams fed to a boiler in which the process streams include a boiler feed water stream and an oxygen-containing stream and the boiler utilizes an oxygen transport membrane device to separate oxygen from the oxygen-containing stream to support combustion of the fuel stream to in turn generate heat to produce steam by heating the boiler feed water stream with a retentate stream and a flue gas stream. More particularly, the present invention relates to such method in which heat is recovered and the process streams are heated by separately heating portions of the oxygen-containing stream and the boiler feed water stream with the retentate stream and the flue gas stream.
BACKGROUND OF THE INVENTION
[0002] A variety of boilers and like devices have been proposed in the prior art that make use of oxygen transport membranes to separate oxygen from a heated oxygen-containing feed to support combustion of a fuel. The heat produced by such combustion can be indirectly transferred to boiler feed water flowing within steam tubes to raise steam. A central advantage of such boilers and devices is that carbon dioxide produced by the combustion can be sequestered for environmental purposes and for use in other processes.
[0003] Oxygen transport membranes are known devices that incorporate a ceramic material that is capable of oxygen ion transport at elevated temperatures. When an oxygen-containing gas is exposed to one side of the membrane, conventionally known as a cathode side, the oxygen is ionized and oxygen ions are transported through the membrane to the opposite side known as the anode side. The oxygen ions react with a fuel species that consumes the oxygen ions. This consumption of oxygen ions creates a partial pressure difference of oxygen between the cathode side and the anode side of the membrane that provides a driving force for the oxygen ion transport. The partial pressure difference can also be created by compressing a feed stream containing the oxygen and/or reducing the pressure on the anode side.
[0004] Electrons are made available for oxygen ionization at the cathode side by electrons being lost from the oxygen ions at the anode side. Certain ceramic materials, formed from perovskites, exhibit both oxygen ion and electron conductivity and thus are known as mixed conductors. In such materials, the electrons flow through the material from the anode to the cathode side. Other ceramic materials are ionic conductors and are capable of only ionic transport. Such materials are thus used in combination with an electrically conductive phase for the electron transport or with an external circuit for electrical circuit. A typical example of such an ionic conductor is yttrium stabilized zirconia.
[0005] As indicated above, the heat generated by the combustion of the fuel introduced to the anode side of the membrane can be used to generate steam. Membranes utilized in such boilers can be driven under a positive oxygen partial pressure that is produced by combusting a fuel at the anode side of the membrane. For example, in U.S. Pat. No. 6,394,043 a boiler is disclosed in which steam tubes and ceramic membrane elements are interspersed. Fuel is introduced into the device that reacts with oxygen ions that have been transported through the membrane to generate heat to raise steam in boiler feed water flowing within the steam tubes. This type of boiler has been optimized in a paper entitled, “Cost and Feasibility Study on the Praxair Advanced Boiler for the CO 2 Capture Project Refinery Scenario”, Switzer et al., Elsevier (2005). In this paper a boiler is illustrated having rows of oxygen transport membrane tubes located within a housing and alternating with steam tubes to superheat saturated steam by combustion of a fuel supported by oxygen separation. The resulting heated and oxygen depleted retentate is used to heat heated boiler feed water and thereby to generate the saturated steam. Such heating takes place within the housing upstream of the oxygen transport membrane tubes. Part of the flue gas is recirculated, mixed with the fuel and also introduced into the housing.
[0006] As can be appreciated, it is desirable to recover heat energy from both the heated flue gas stream and the retentate stream for use in preheating the air feed to the oxygen transport membrane device and for heating boiler feed water. In Switzer, the incoming air is heated against flue gas after having passed through a heat exchanger being used to preheat the boiler feed water. Preheated air is passed through a heat exchanger in which the air is further heated by the retentate stream after having been used to generate the saturated steam. Thereafter, the retentate stream flows into another heat exchanger to further heat the boiler feed water.
[0007] The boiler, described above and like systems, operates at high temperatures and therefore require that the air be preheated to a temperature of generally about 900° C. Such high temperature operation requires expensive, high temperature heat exchangers that are necessary to recover heat and thereby capture a sufficient thermal efficiency to make the use of such boilers and systems practical. As will be discussed, the present invention provides an inherently efficient process for recovering heat energy and thereby heating the oxygen-containing stream, the boiler feed water stream and the fuel stream that optimizes the use of the heat exchangers to decrease the costs involved in fabricating such boilers.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method of heating process streams fed to boiler utilizing an oxygen transport membrane unit. In accordance with the method, the process streams that are fed to the boiler include a heated boiler feed water stream and a heated oxygen-containing stream.
[0009] The heated boiler feed water stream is heated within the boiler through indirect heat exchange with a retentate stream and a flue gas stream to generate steam. The flue gas stream is produced by combustion of a fuel supported by oxygen separated from the heated oxygen-containing stream by the oxygen transport membrane device. The separation of the oxygen thereby also produces the retentate stream with a higher mass flow rate than the flue gas stream.
[0010] Heat is indirectly transferred from the retentate stream to a first subsidiary oxygen-containing stream and thereafter, to a first subsidiary boiler feed water stream. The heat exchange produces a heated first subsidiary oxygen-containing stream and a first heated boiler feed water stream. The flue gas stream indirectly exchanges further heat to a second subsidiary oxygen-containing stream and thereafter, to a second subsidiary boiler feed water stream, thereby to produce a second heated oxygen-containing stream and a second heated boiler feed water stream.
[0011] The heated first subsidiary oxygen-containing stream and the heated second subsidiary oxygen-containing stream are combined to form the heated oxygen-containing stream and the heated first boiler feed water stream and the heated second boiler feed water stream are combined to form the heated boiler feed water stream.
[0012] The heat exchange area required for the indirect heat exchange between the retentate stream and the flue gas stream to the oxygen-containing stream and the boiler feed water stream is minimized by providing the first oxygen-containing stream with a greater mass flow rate than that of the second oxygen-containing stream. This minimization of the required heat transfer area for the heat recovery allows fabrication costs to be reduced.
[0013] In an embodiment of the present invention, the water condenses during the indirect heat exchange of the flue gas stream and the second boiler feed water stream. This increases overall thermal efficiency of the heat recovery process.
[0014] The indirect heat exchange between the retentate stream and the first subsidiary oxygen-containing stream and the flue gas stream and the second subsidiary oxygen-containing stream are each conducted within two heat exchangers operating at higher and lower temperatures and upstream of the indirect heat exchange with the first boiler feed water stream and the second boiler feed water stream. The use of higher and lower operational temperatures for such heat exchangers allows fabrication costs to be further reduced by the reduction of the requirement for the use of expensive high temperature materials.
[0015] In an alternative embodiment, the indirect heat exchange between the retentate stream and the first subsidiary oxygen-containing stream and the flue gas stream and the second subsidiary oxygen-containing stream are each conducted within two heat exchangers operating at higher and lower temperatures. The indirect heat exchange of the retentate stream and the first boiler feed water stream and the indirect heat exchange of the flue gas stream and the second boiler feed water stream occurring between the two heat exchangers. In such embodiment, water may condense during the indirect heat exchange of the flue gas stream with the second subsidiary oxygen-containing stream and within the other of the two heat exchangers. This embodiment is applicable for situations in which the boiler feed water is available at high temperature. Again, such embodiment minimizes the use of expensive high temperature materials required for heat exchange at high temperatures.
[0016] The heated oxygen-containing stream can be further heated by introducing the oxygen-containing stream into a duct burner and combusting a fuel within the duct burner. In any embodiment, the oxygen-containing stream can be air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] While the specification concludes with claims distinctly pointing out the subject matter that applicants regard as their invention, it is believed that the invention will be better understood when taken in connection with the accompanying drawings in which:
[0018] FIG. 1 is a schematic, sectional view of a boiler used in connection with the present invention;
[0019] FIG. 2 is a schematic, fragmentary process flow diagram of a heat recovery system of the present invention;
[0020] FIG. 3 is a graphical representation of a required total product of the heat transfer coefficient and heat transfer area against the part of the air that exchanges heat solely with the flue gas stream;
[0021] FIG. 4 is a schematic, fragmentary process flow diagram of an alternative embodiment of a heat recovery system in accordance with the present invention;
[0022] FIG. 5 is a graphical representation of a product of the overall heat transfer coefficient and the heat transfer area versus the fraction of the air that exchanges heat solely with the flue gas; and
[0023] FIG. 6 is a schematic, fragmentary process flow diagram of an alternative embodiment of a heat recovery system in accordance with the present invention.
[0024] The same reference numbers having been used in the Figures for elements having the same description to avoid needless repetition in the description of such elements.
DETAILED DESCRIPTION
[0025] With reference to FIG. 1 , a boiler 1 is illustrated that is to be used in connection with a method in accordance with the present invention. It is understood, however, that boiler 1 is discussed herein for exemplary purposes and is not intended to limit the application of the present invention as the present invention has application to similar devices in which, as will be discussed, water is heated to steam by heat generated through combustion supported by oxygen ion transport.
[0026] Boiler 1 is provided with a housing 10 that contains an oxygen transport membrane device formed by tubular oxygen transport membrane tubes 12 . In boiler 1 , oxygen transport membrane tubes 12 are formed from a dual phase conductor, that is, a mixture of ionic and electronically conducting phases. However, it is understood that the present invention would have equal applicability to a boiler incorporating oxygen transport materials formed by mixed conductors or ionic conductors used in a manner described above and also, possibly for combined cycles in which the oxygen ion transport occurred within a fuel cell type of device incorporating an ionic conducting membrane.
[0027] A heated oxygen-containing stream 14 is introduced into the interior of oxygen transport membrane tubes 12 through inlets 16 . At the same time, a heated fuel stream 17 is introduced into housing 10 to combust at the outer surface of oxygen transport membrane tubes 12 by combination with oxygen ions permeating through oxygen transport membrane tubes 12 . The consumption of oxygen ions establishes a partial pressure differential to drive oxygen ion transport through oxygen transport membrane tubes 12 and electronic transport to ionize the oxygen contained within heated oxygen-containing stream 14 to accomplish the oxygen separation. As a result of this separation operation, a flue gas stream 18 is created that is discharged from the housing 10 of boiler 1 and a retentate stream 20 that by way of conduit 22 is introduced into a heat recovery steam generator 24 and discharged from outlets 25 thereof.
[0028] A heated boiler feed water stream 26 is introduced into steam tubes 28 of heat recovery steam generator 24 and is indirectly heated by retentate contained in retentate stream 20 to form a saturated steam stream that by way of conduit 30 is collected in steam drum 32 . The saturated steam is thereafter introduced into a heat recovery steam generator 33 having steam tubes 34 intermingled with oxygen transport membrane tubes 12 to superheat the steam through indirect heat exchange with the flue gas that is evolved from the combustion occurring at the outer surfaces of oxygen transport membrane tubes 12 and that is discharged as flue gas stream 18 . The superheating thereby forms a product steam stream 36 that is discharged from boiler 1 for use in downstream processes.
[0029] As illustrated, fuel stream 17 can be combined with a recirculated subsidiary flue gas stream 37 with the use of a recirculation blower 38 . A steam stream 39 can then be combined to adjust the steam to carbon ratio in the fuel to be combusted to control carbon formation on oxygen transport membrane tubes 12 . The combined stream is then preheated in a preheater 40 and passed through heat recovery steam generator 24 and to the oxygen transport membranes 12 as indicated by the arrowheads “A”.
[0030] With reference to FIG. 2 , heat from retentate stream 20 and flue gas stream 18 is recovered by a heat recovery network 41 that is designed to carry out a method in accordance with the present invention for heating oxygen-containing stream 42 and a boiler feed water stream 44 to form heated oxygen-containing stream 14 and heated boiler feed water stream 26 that constitute the process streams being fed to boiler 1 .
[0031] Oxygen-containing stream 42 , for example, air, is introduced into a heat recovery flow network 41 and eventually boiler 1 by way of a blower 46 . No compression is required given that the combustion of the fuel drives the transport. It is to be noted, however, that the present invention has applicability to a system in which oxygen ion transport is driven by a positive total pressure and as such, the oxygen-containing stream 42 could be compressed for such purposes. A first subsidiary oxygen-containing stream 48 derived from oxygen-containing stream 42 is introduced into a heat exchanger 50 to effect indirect heat exchange with retentate stream 20 and thereby to produce a heated first subsidiary oxygen-containing stream 52 . At the same time a second subsidiary oxygen-containing stream 54 derived from oxygen-containing stream 42 is introduced to a heat exchanger 56 to effect indirect heat exchange with flue gas stream 18 and thereby form a heated second subsidiary oxygen-containing stream 58 . First heated subsidiary oxygen-containing stream 52 and second heated subsidiary oxygen-containing stream 58 are then combined to form heated oxygen-containing stream 14 . Optionally, a fuel stream 60 can be also combined with heated oxygen-containing stream 14 within a duct burner 61 by means of a blower 62 for partial combustion and further heating of the heated oxygen-containing stream 14 .
[0032] Retentate stream 20 after passage through heat exchanger 50 and flue gas stream 18 after passage through heat exchanger 56 are then introduced into heat exchangers 64 and 66 that are located downstream of heat exchangers 50 and 56 used in heating oxygen-containing stream 42 . Boiler feed water stream 44 is pumped by a pump 68 and thereby pressurized to a desired operational pressure of product steam stream 36 . A first subsidiary boiler feed water stream 70 made up of boiler feed water stream 44 is heated by retentate stream 20 within heat exchanger 64 to produce first heated subsidiary boiler feed water stream 72 . A second subsidiary boiler feed water stream 74 , also made up of boiler feed water stream 44 , is heated by flue gas stream 18 within heat exchanger 66 to form second heated subsidiary boiler feed water stream 76 . First heated subsidiary boiler feed water stream 72 is then combined with second heated subsidiary boiler feed water stream 76 to form heated boiler feed water stream 26 .
[0033] It is to be noted that all of the heat exchangers 50 , 56 , 64 and 66 can be of shell and tube design. In order to increase the thermal efficiency of the heat exchange process, water contained in flue gas stream 18 can be condensed within heat exchanger 66 as the dew point for such water is at a high temperature and the heat of condensation is therefore significant and can be recovered within second subsidiary boiler feed water stream 74 . However, since flue gas stream 18 also contains carbon dioxide, the resulting acid can be corrosive and require special materials in the fabrication of heat exchanger 66 that can increase the fabrication costs.
[0034] As described above, a process of the present invention is conducted with the aim of reducing the costs involved in fabricating the heat exchangers, described above, in the heat recovery network 41 . As indicated above, the mass flow rate of retentate stream 20 is greater than that of flue gas stream 18 by virtue of the fact that air contains about 80 percent nitrogen. By diverting the flow within oxygen-containing stream 42 into first subsidiary oxygen-containing stream 48 that is subjected to indirect heat exchange with the retentate stream 20 having the higher mass flow rate than flue gas stream 18 , temperature differences at the inlet and outlet of heat exchanger 50 between the streams can be minimized to also increase the amount of heat able to be transferred. As a result, a product of the heat transfer coefficient and area is reduced in heat exchanger 50 . Since there is a closer flow rate match in heat exchanger 56 and less heat will be transferred the size of heat exchanger 56 can be optimized. The resulting closer correspondence of outlet temperatures of the retentate stream 20 and the flue gas stream 18 upon their discharge from heat exchangers 50 and 56 allows for a closer approach in temperatures at the downstream heat exchangers 64 and 66 used in heating boiler feed water stream 44 to also result in an area savings for the total required heat exchange.
[0035] A calculated example in tabular form is set forth below for the operation of the heat recovery network 41 illustrated in FIG. 2 .
[0000]
TABLE
Mass
Vapor
Pressure
Flow
Composition
Stream #
Fraction
Temperature C.
[psia]
[lb/hr]
Methane
Ethane
Nitrogen
Oxygen
CO2
H2O
42
1.00
25
14.7
121500
0
0
0.79
0.21
0
0
42 after
1.00
55
19
121500
0
0
0.79
0.21
0
0
blower 46
14
1.00
550
18
121500
0
0
0.79
0.21
0
0
60
1.00
25
14.7
1028
0.95
0.03
0.02
0
0.01
0
60 after
1.00
44
18
1028
0.95
0.03
0.02
0
0.01
0
blower 62
14 after
1.00
882
18
122500
0
0
0.78
0.18
0.01
0.03
firing within
duct burner
61
20
1.00
600
16.5
105600
0
0
0.89
0.06
0.02
0.03
20 after
1.00
150
15.5
105600
0
0
0.89
0.06
0.02
0.03
passage
through heat
exchanger 50
20 after
1.00
70
14.8
105600
0
0
0.89
0.06
0.02
0.03
passage
through heat
exchanger 64
44
0.00
25
14.7
100000
0
0
0
0
0
1
44 after
0.00
25
140.5
100000
0
0
0
0
0
1
having been
pressurized
by pump 44
26
0.00
97
140
100000
0
0
0
0
0
1
18
1.00
600
16.5
21330
0
0
0
0.01
0.33
0.65
18 after
1.00
257
15.5
21330
0
0
0
0.01
0.33
0.65
passage
through heat
exchanger 56
18 after
0.50
70
14.8
21330
0
0
0
0.01
0.33
0.65
passage
through heat
exchanger 66
[0036] FIG. 3 , set forth a further calculation based on the data developed in the above table in a graphical form. As is apparent from the graph, a minimum UA is obtained where the flow rate of second subsidiary oxygen-containing stream 54 is roughly 18 percent of the flow rate of oxygen-containing stream 42 and therefore the remainder of the flow is concentrated in first subsidiary oxygen-containing stream 48 . For a constant heat transfer coefficient, this also represents the minimum heat transfer area required to conduct the process of the above example and therefore, the minimum costs to fabricate the heat exchangers.
[0037] With reference to FIG. 4 , costs can further be reduced by splitting the heat exchange duty of heat exchangers 50 and 56 into two heat exchangers 50 a and 50 b and 56 a and 56 b . Heat exchangers 50 a and 56 a operate at higher temperatures than heat exchangers 50 b and 56 b . As such, the use of expensive, high temperature materials can be concentrated within the higher temperature heat exchangers 50 a and 56 a to also reduce fabrication costs.
[0038] With reference to FIG. 5 , again using the data of the above table, the calculated split of oxygen-containing stream 42 involves second subsidiary oxygen-containing stream 54 being roughly 26 percent of the total flow within oxygen-containing stream 42 and with the remainder of the flow within first subsidiary oxygen-containing stream 48 .
[0039] With reference to FIG. 6 , another economizing method can be taken when boiler feed water stream 44 is available at high temperature. In such embodiment, the heat exchange duty for oxygen-containing stream 40 can be split between two sets of heat exchangers 50 a ′; 50 b ′ and 56 a ′; 56 b ′, each set operating at higher and lower temperatures. In such embodiment, heat exchangers 50 b ′ and 56 b ′ are located downstream of heat exchangers 64 and 66 with condensation of water within flue gas stream 18 occurring in heat exchanger 56 b ′. The use of expensive, high temperature materials are therefore confined to heat exchangers 50 a ′ and 56 a ′ to also produce a cost savings.
[0040] While the present invention has been described with reference to a preferred embodiment, as will occur to those skilled in the art, numerous changes, additions and omissions can be made without departing from the spirit and scope of the present invention as set fort in the appended claims. | A method of heating process streams fed to a boiler incorporating an oxygen transport membrane device that includes an oxygen-containing stream and a boiler feed water stream. The membrane device separates oxygen to support combustion of a fuel and generate heat to raise the steam. Heat is recovered and process streams are heated by separately heating portions of the oxygen-containing stream and the boiler feed water stream with a retentate stream produced from the oxygen separation and a flue gas stream generated from the combustion. The flow rate of the portion of the oxygen-containing stream heated by the retentate stream is greater than that heated by the flue gas stream to help minimize heat transfer area and thus, fabrication costs. Also, water is condensed from the flue gas stream during the heat exchange involved in the heat recovery to increase thermodynamic efficiency. | 5 |
RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 11/681,228 filed Mar. 2, 2007 which is hereby incorporated by reference herein.
FIELD
[0002] This relates generally to coke ovens, and more particularly to the walls of coke ovens and to methods of replacing those walls.
BACKGROUND
[0003] Coke oven batteries include a number of horizontal coke ovens that range up to twenty feet or more in height and up to fifty feet in length. An oven is approximately eighteen inches wide. Individual ovens are laterally arranged in groups to form a battery. A coke oven has a chamber with opposite open ends closed by doors. Positioned on both sides of a coke oven chamber are heating walls.
[0004] Internally of the heating walls are vertical heating flues in which combustion of air and gas takes place. The combustion produces heat which moves vertically through the flues. Heat is then supplied to the coking chambers from the adjacent heating flues through the heating walls.
[0005] The heating walls are heated to an elevated temperature to carry out the coking process. The coke oven doors at both the pusher side and the coke side are closed when coal is being coked within the coke oven chambers. These doors are removed when the coke is pushed out of the ovens. Thermal expansion and contraction of the bricks, and normal wear due to pushing the coke out of the coking chamber, results in spalling, deterioration, and eventually disintegration of entire brick sections of the heating walls.
[0006] One method of replacing the heating walls entails replacing one-by-one the old refractory brick with new refractory brick. The new bricks are laid in courses to form the new, replacement wall. Such a process is laborious, expensive, and time consuming, especially when an entire wall requires not just repair but wholesale replacement.
[0007] It is desirable to provide a method of replacing coke oven walls which is not nearly so laborious, expensive, and time consuming.
SUMMARY
[0008] Accordingly, methods of replacing a damaged wall of a coke oven having a height h and a length l are provided. In one aspect, the method comprises removing the damaged wall from the coke oven, casting, outside of the oven, a replacement wall section having a length equal to the length l of the damaged coke oven wall and a height equal to the height h of the damaged coke oven wall, and positioning, inside the coke oven, the replacement wall section.
[0009] In another aspect, the method comprises removing the damaged wall from the coke oven, casting, outside of the oven, a plurality of replacement wall sections, each replacement wall section having a length equal to the length l of the damaged coke oven wall and a height equal to a fraction of the height h of the damaged coke oven wall, and positioning, inside the coke oven, the plurality of replacement wall sections one on top of another, such that the plurality of replacement wall sections has a combined height equal to the height h of the damaged coke oven wall.
[0010] The plurality of replacement wall sections can comprise a lower half section and an upper half section.
[0011] In yet another aspect, the method comprises removing the damaged wall from the coke oven, casting, outside of the oven, a plurality of replacement wall sections, each replacement wall section having a length equal to a fraction of the length l of the damaged coke oven wall and a height equal to the height h of the damaged coke oven wall, and positioning, inside the coke oven, the plurality of replacement wall sections end to end, such that the plurality of replacement wall sections has a combined length equal to the length l of the damaged coke oven wall.
[0012] The plurality of replacement wall sections can comprise a pusher side section, a middle section, and a coke side section. Abutting ones of the pusher side, middle, and coke side sections can be formed to have mating, interlocking ends. The replacement wall sections can be cast with air/gas passages and vertical flues therein.
[0013] In still another aspect, a method of replacing a damaged wall of a coke oven comprises removing the damaged wall from the coke oven, casting, outside of the oven, a replacement wall section, providing first and second fixture plates, sandwiching the replacement wall section between the plates, lifting the replacement wall section by lifting the plates, positioning the plates and hence the replacement wall section inside the coke oven, and removing the plates from the replacement wall section.
[0014] The method can further comprise providing a layer of rubber on each of the fixture plates for contacting the replacement wall section so as to avoid damage to the wall section during installation of the wall section in the oven. The method can further comprise providing rolling trucks secured to the fixture plates for rolling movement of the replacement wall section and plates in the oven during installation of the wall section in the oven. The method can further comprise interconnecting the rolling trucks and the fixture plates with hydraulic cylinders to facilitate leveling and load distribution of the fixture plates and hence replacement wall section during installation of the replacement wall section in the oven. The method can further comprise providing a computer and a controller in operable association with the hydraulic cylinders to automate leveling and load distribution of the fixture plates and hence replacement wall section during installation of the replacement wall section in the oven. The method can further comprise casting holes through the replacement wall section, and compressing the replacement wall section between the fixture plates by compression pins which pass through the holes in the wall section and connect the fixture plates. The replacement wall section can be installed in the oven through an open end of the oven or through an open roof of the oven. The method can further comprise casting mortar joints in at least one of upper and lower surfaces of the replacement wall section. The method can further comprise providing a vertically movable leveling bed adjacent the coke oven, and at least partially supporting the replacement wall section and fixture plates with the leveling bed as the replacement wall section is installed in the oven. The method can further comprising providing a frame, and interconnecting the leveling bed and the frame with hydraulic cylinders to facilitate vertical movement of the leveling bed during installation of the replacement wall section in the oven. The method can further comprise providing a computer and a controller in operable association with the hydraulic cylinders to automate vertical movement of the leveling bed during installation of the replacement wall section in the oven.
[0015] In still a further aspect, a fixture for installing a replacement wall section into a coke oven comprises a pair of plates for sandwiching the replacement wall section therebetween, rolling trucks for rolling movement of the replacement wall section and the plates during installation of the wall section in the oven, hydraulic cylinders interconnecting the plates and trucks, and a computer/controller in operable association with the hydraulic cylinders to automate leveling and load distribution of the fixture plates and hence the wall section during installation of the wall section in the oven.
[0016] Each of the fixture plates can have a layer of rubber thereon for contacting the wall section so as to avoid damage to the wall section during installation of the wall section in the oven. Angle clips can be removably secured to bottoms of the plates to add support for the wall section during installation of the wall section in the oven. The upward facing surface of each of the angle clips can have a layer of rubber thereon for contacting a bottom of the wall section so as to avoid damage to the wall section during installation of the wall section in the oven. The fixture can further comprise a plurality of compression pin assemblies for securing the plates to the wall section. Each compression pin assembly can comprise a two-piece outer sleeve, and a two-piece inner pin. One portion of the two-piece inner pin can have a male threaded portion on one end which fits in a complimentary female threaded portion of the other portion of the two-piece inner pin. Bellville washers can be placed on the other end of the one portion of the two-piece inner pin, which can be threaded, and a nut can be placed on the other end of the one portion of the two-piece inner pin. The fixture plates can be side plates, and can further comprise a pair of end plates removably secured to ends of the side plates. The side plates and the end plates can each have a layer of rubber thereon for contacting the wall section so as to avoid damage to the wall section during installation of the wall section in the oven.
DRAWINGS
[0017] FIG. 1 is a side view of apparatus for installing replacement oven wall sections,
[0018] FIG. 2A is an exploded cross-sectional view taken along line 2 A- 2 A in FIG. 1 ,
[0019] FIG. 2B is an assembled view of the apparatus of FIG. 2A ,
[0020] FIG. 3 is an enlarged partial cross-sectional view of a compression pin assembly used in the apparatus of FIGS. 1 , 2 A, and 2 B,
[0021] FIGS. 4A-4C are successive steps in installing replacement oven wall sections,
[0022] FIG. 5 is an alternative method to the one shown in FIGS. 4A-4C for installing replacement oven wall sections,
[0023] FIG. 6 is a side view of an alternative embodiment of replacement oven wall sections, and
[0024] FIG. 7 is a side view of another alternative embodiment of replacement oven wall.
DESCRIPTION
[0025] Referring first to FIGS. 1 , 2 A, and 2 B, illustrated is a replacement coke oven wall section 10 and a fixture or an apparatus 40 for installing the replacement wall section 10 into a coke oven 30 . The coke oven replacement wall section 10 is cast outside of the oven with, for example, a zero expansion pourable and castable refractory material or mix. A suitable pouring fixture or mold (not shown) can be used to cast the replacement wall section 10 , and can include a pair of side plates, a pair of end plates removably bolted to the side plates, and a bottom plate removably bolted to the side plates. The pouring fixture plates can reinforced with suitable support beams as required. Forms (not shown) can be positioned in the pouring fixture or mold so as to form the replacement wall section 10 with air/gas passages and/or vertical flues 12 therein. The replacement wall section 10 can also be formed to include mortar joints 14 in lower wall surface 16 , in upper wall surface 18 , or in lower and upper wall surfaces 16 , 18 , depending on the height of the replacement wall section 10 . The replacement wall section 10 can also be formed to include holes 20 for securing apparatus 40 to the wall section 10 for lifting and placement of the wall section 10 . Once thusly formed, the replacement wall section 10 is then positioned inside the coke oven 30 ( FIGS. 4A-C ) and mortared/grouted as required.
[0026] In the embodiment shown in FIGS. 1 , 2 A, 2 B, 4 A-C, and 5 , the replacement wall section 10 has a length which is equal to the length l of the damaged coke oven wall to be replaced, and a height which is equal to a fraction of the height h of the damaged coke oven wall to be replaced, for example, one-half of the height h of the damaged coke oven wall. Alternatively, the replacement wall section 10 has a length which is equal to the length l of the damaged coke oven wall, and a height which is equal to the height h of the damaged coke oven wall, as shown in FIG. 7 . Yet still alternatively, the replacement wall section 10 has a length which is equal to a fraction of the length l of the damaged coke oven wall, for example, roughly one-third of the length l of the damaged coke oven wall, and a height with is equal to the height h of the damaged coke oven wall, as shown in FIG. 6 .
[0027] Referring back to FIGS. 1 , 2 A, and 2 B, the apparatus 40 for lifting the replacement wall section 10 and placing it in the oven 30 can comprise a pair of steel side plates 42 each of which can have a layer of rubber 44 on the inward facing surface of the plate 42 for contacting the sides of the replacement wall section 10 so as to avoid damage to the wall section during lifting and installation into the oven 30 . Each plate 42 can include one or more steel support beams 45 , for example I-beams, secured thereto to provide the required stiffness and strength for supporting the replacement wall 10 during installation, and to provide a travel platform, as will be described in more detail below. Lifting lugs 46 can be removably secured to the beams 45 for lifting the apparatus 40 and wall section 10 by, for example, cables 48 raised and lowered by a crane 50 ( FIGS. 4A-C ) thus lifting the wall section 10 by lifting the plates 42 . The lifting lugs 46 can be removed so as not to interfere with the beams 45 functioning as a travel platform, as will be described in more detail below. Removable end plates 52 can be bolted to the ends of the side fixture plates 42 for further stiffness and strength, each of which, like side plates 42 , can have a layer of rubber 44 on the inward facing surface of the plate 52 for contacting the ends of the replacement wall section 10 so as to avoid damage to the wall section during lifting and installation into the oven 30 . Each side plate 42 can have removable angle clips 54 bolted to the bottom thereof to add support for the wall section 10 during lifting and installation. The upward facing surface of each of the clips 54 can have a layer of rubber 56 thereon for contacting the bottom of the replacement wall section 10 so as to avoid damage to the wall section during lifting and installation into the oven 30 . Once the wall section 10 is positioned correctly horizontally and before the wall section 10 is lowered to mate with the oven floor the angle clips 54 are removed to provide access to the bottom of the wall section 10 to grout it to the oven floor. Once in position the plates 42 are removed from the wall section.
[0028] Each side plate 42 can have self leveling transport truck assemblies 60 to assist during the installation of the wall section 10 into the oven chamber. The truck assemblies 60 can each comprise a wheel housing 62 housing a plurality of wheels 64 . Hydraulic cylinders 66 can be interconnected between the rolling trucks 60 and their respective fixture side plate 42 . For example, a hydraulic cylinder 66 can have its piston end 68 pivotally connected to the upper end of the truck wheel housing 62 at 70 , and its cylinder end 72 pivotally connected to a support 74 at 76 , which support 74 can be secured to beam 45 (or otherwise to side fixture plate 42 ). The axes of the pivot connections 70 , 76 of the hydraulic cylinders 66 to the truck assemblies 60 and beams 44 , respectively as illustrated can be perpendicular to one another to thereby help to distribute the load of the wall section 10 evenly. The hydraulic cylinders 66 can be computer controlled via a computer processor/controller 80 ( FIGS. 4A-C ) to ensure that uniform pressure is applied to the floor of the oven during installation of the replacement wall section 10 . In the event that multiple wall sections are stacked one atop another as shown in FIGS. 4A-4C , the truck assemblies 60 of the uppermost wall section 10 and apparatus 40 can run on the support beams 45 of the lowermost wall section 10 and apparatus 40 .
[0029] FIG. 3 illustrates a two piece compression pin assembly 90 which can be used to secure the two fixture plates 42 to the replacement wall section 10 . The pins 90 pass through the holes 20 in the replacement wall section, which holes 20 can be purposely larger than the pin assembly 90 to make sure that the pin assembly 90 does not contact the wall section 10 . Each pin assembly 90 can comprise a two-piece outer sleeve 92 , 94 and a two-piece inner pin 96 , 98 . Pin portion 96 has male threaded portion 96 a which fits in complimentary female threaded portion 98 a of pin portion 98 . Bellville washers 100 are placed over the opposite threaded end 96 b of pin portion 96 to apply consistent pressure on each assembly and are tightened with nut 102 to apply pressure on the Bellville washers 100 .
[0030] As shown in FIGS. 4A-4C , a leveling bed 110 can be used to aid installation of replacement wall section 10 into the coke oven 30 . Leveling bed 110 can be interconnected to a frame 112 with hydraulic cylinders 114 , for example four such hydraulic cylinders 114 . The hydraulic cylinders 114 can be computer controlled via the computer/controller 80 to ensure the correct elevation of the replacement wall 10 and fixture 40 , and to ensure equalized, uniform loading of same. The leveling bed 110 can also be used during changing the cable hook up during installation of the wall section, as illustrated in FIGS. 4A-C .
[0031] Lastly, FIG. 5 shows installation of replacement wall sections 10 by being lowered through the top 120 of the oven 30 , which can be accomplished if the roof brick work is removed.
[0032] The embodiments shown and described are merely for illustrative purposes only. The drawings and the description are not intended to limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and alternative embodiments. All such changes, modifications and embodiments are deemed to be embraced by the claims. Accordingly, the scope of the right to exclude shall be limited only by the following claims and their equivalents. | Methods of replacing a damaged wall of a coke oven having a height h and a length l are provided. In one aspect, the method comprises removing the damaged wall from the coke oven, casting, outside of the oven, a replacement wall section having a length equal to the length l of the damaged coke oven wall and a height equal to the height h of the damaged coke oven wall, and positioning, inside the coke oven, the replacement wall section. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to a pneumatic pumping device in which a movable valve performs reciprocating movement by using air back pressure, and pumping operation is carried out by the reciprocating movement.
2. Description of Prior Art:
Hitherto, there has been proposed a pneumatic pumping device in which a bellows performing reciprocating movement by back pressure of air is disposed in a cylinder so that a liquid is drawn in and discharged by the reciprocating movement, as is disclosed in Japanese Patent Official Gazette under Publication No. 56-50116 and Japanese Utility Model Laying-Open Official Gazette under Laying-Open No. 61-29078.
In such a conventional pumping device, two bellows are respectively disposed in both left and right cylinder chambers, the bellows being connected with each other through the piston rod, so that when one bellows moves either forwardly in one direction or backwardly in the returning direction by the application of air back pressure, such movement is transmitted to the other bellows through the piston rod to make the other bellows move forwardly or backwardly, thus pumping operation takes place by such reciprocating movement of the bellows.
In the conventional pneumatic pumping device of the aforesaid construction, there are provided on the outer part thereof connecting members such as fittings for connecting pipes with an intake port and a discharging port of the cylinder; bolts and nuts for assembling the cylinder, bellows and other components; and mettalic members for providing rigidity to the components of the pump.
Accordingly, when the conventional pumping device is used in a liquid of strong acid or strong alkali, it becomes soaked and the aforesaid connecting members, bolts, nuts, metallic components, etc. become corroded, broken down and out of operation.
Furthermore, the conventional pumping device is necessarily composed of a pair of horizontally disposed pumps, so that contruction of a small-sized pumping device becomes substantially impossible.
Moreover, when the pressure associated with the feeding of a chemical liquid and the heat thereof generated by the chemical reaction are applied to the components of the pump, there arises a problem of stress relaxation at joining sections of the components. Accordingly, a gap may come out at the joining section between the bellows and the cylinder, otherwise a compressive creep may attack O rings and the like provided to maintain a sealing function, resulting in a decline of such function.
Another type of pumping device is disclosed in Japanese Patent Official Gazette No. 48-20807, and according to which the pumping device is driven by hydraulic pressure and therefore hydraulic driving means such as a hydraulic pump are needed, which makes the construction rather complicated.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to prevent components of a pumping device such as bellows, fittings from becoming corroded by composing all inner and outer parts of the pump in contact with chemical liquid of a fruororesin whose property is corrosion resistant.
Another object of the invention is to provide a small-sized pumping device by adopting a system in which either air for application of pressure or vacuum is supplied by changing over therebetween.
A further object the invention is to simplify a pumping structure by utilizing air for application of pressure and vacuum, both sources thereof usually installed in a workshop, as a driving source.
A still further object of the invention is to prevent the occurrence of a gap at joining sections between components of a cylinder chamber due to stress relaxation, thereby securely maintaining a sealing function in areas where the sealing function is needed.
In order to accomplish the foregoing objects, a feature of the pneumatic pumping device according to the invention consists in that chemical liquid contacting surfaces of inner and outer parts of the pump are formed of a simple substance such as a fluororesin or a compound thereof such as PTFE (polytetrafluoroethylene), PFA (polymer of tetrafluoroethylene - ethylene), CTFE (chlorotrifluoro- ethylene).
In the pneumatic pump of the above composition, since the chemical liquid contacting surfaces are all formed of the simple substance or compound of fluororesin, a satisfactory condition resistant consition is attained owing to the anti-corrosion property thereof, and therefore the chemical liquid contacting surfaces of the pump are protected from being attacked by the chemical liquid not only when some chemical liquid is drawn in and discharged by the pump, but also when the pump is soaking in the chemical liquid. As a result, there is no possibility that the pump will not work due to corrosion even if liquid leakage out of the pump should occur.
Another feature of the pneumatic pumping device according to the invention consists in that the movable valve is operated by a change-over between air for application of pressure and vacuum.
That is, in the pneumatic pumping device according to the invention, since a single movable valve can be reciprocatingly moved by both the air for application of pressure and vacuum, it becomes feasible to make a simple and compact pump. Moreover, since there is no need of any piston rod in the pump to drawn in and discharge liquid, it is also possible to attain a simple and small-sized pump by forming into a double pump.
A further feature of the pneumatic pumping device according to the invention consists in that the air passage of the pump is provided with a detector for detecting leakage of liquid, and a stopping device for stopping pumping operaion in accordance with a signal detected by the liquid leakage detector.
According to the pneumatic pumping device of above construction, when a strong acid otherwise a strong alkaline liquid leaks out to the air passage on the vacuum side due to the accidental breaking down of the movable valve composed of bellows and diaphragm, the liquid leakage detector detects the leakage and stops the pumping operation. As a result, the pumping device is prevented from continuing its pumping operation with the liquid leaking, and the air passage is also protected from corrosion by the leaking liquid. Thus, various components and accessories connected to the vacuum side are kept from corrosion due to liquid leakage.
A still further feature of the pneumatic pumping device according to the invention consists in that a highly corrosion resisitant filter is disposed in the air passage. The filter is gas-permeable but not liquid-permeable.
According to such a pneumatic pumping device, even if a leaking liquid of strong acid or strong alkali should be drawn in into the air passage on the vacuum side, the liquid is shut off by the filter, and the components and accessories located downstream of the filter are prevented from corrosion.
A yet further feature of the pneumatic pumping device according to the invention consists in that a joining section between the movable valve and a housing by which the movable valve is fixed to the pump body is circumferentially welded, and that a joining section between the housing and an air tube inserted in the housing are also circumferentially welded.
According to such a pneumatic pumping device, the back pressure chamber is perfectly closed and exactly prevented from entrance of liquid. Moreover, when the pumping device in use is used soaked into a liquid, the back pressure chamber is securely kept from entrance of the liquid surrounding the pump. Accordingly, a certain quantity of liquid flow can be continuously delivered at a specified transfer speed resulting in smooth and stable pumping operation. Moreover, since the components and accessories are joined by welding, the pump structure is so strong as to endure under high pressure necessary when transferring a liquid of high viscosity, thus the durability and transfer performance of the pumping device are improved.
Other objects and features of the invention will become apparent in the course of the following description together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings forming a part of the present application,
FIG. 1 is a plan view of a pneumatic pumping device according to a first embodiment of the invention;
FIG. 2 is a sectional view of the pneumatic pumping device shown in FIG. 1;
FIG. 3 is a plan view of a pneumatic pumping device according to a second embodiment of the invention;
FIG. 4 is a sectional view of the pneumatic pumping device shown in FIG. 3;
FIG. 5 is a plan view of a pneumatic pumping device according to a third embodiment of the invention;
FIG. 6 is an enlarged sectional view showing a welding section of an air tube;
FIG. 7 is an enlarged sectional view showing a welding section of a bellows;
FIG. 8 is a plan view of a pumping device according to a fourth embodiment of the invention;
FIG. 9 is a sectional view of the pneumatic pumping device shown in FIG. 8;
FIG. 10 is a diagram of an air change-over control circuit;
FIG. 11 is a diagram of a modified air change-over control circuit; and
FIG. 12 is a diagram of a further modified air change-over control circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A pneumatic pumping device shown in FIG. 1 and FIG. 2 is a vertical pumping device provided with pumps 1, 1 of the same structure on both left and right sides. Referring to one pump 1, a cylinder chamber 3 having a bottom extends from the upper side to the inner part of the cylinder 2 whose external appearance is like a square pillar. A bellows 4 is disposed in the cylinder chamber 3, and a flange 5 formed at the base portion of the bellows 4 is in contact with a step portion 6 of the cylinder chamber 3. A top end of a housing 7 is inserted inside the bellows 4, and a male thread 8 formed on the base portion of the housing 7 is engaged with a female thread 9 formed on the upper end portion of the cylinder chamber 3, thereby the bellows 4 being fixed to the cylinder chamber 3. An air passage 10 for applying back pressure to the bellows 4 is formed in the central portion of the housing 7. An outer end of the air passage 10 is connected to an air supply source by way of a pipe. An intake passage 11 is formed on the central bottom portion of the cylinder chamber 3, and a check valve 12 permitting intake of liquid is disposed in the passage 11. A valve seat 13 is mounted on the outside of the valve 12 by screwing. A discharging passage 14 is open on one side of the bottom of the cylinder chamber 3, and a check valve 15 permitting discharge of liquid is disposed in the passage 14.
Fitting 16, 16 are respectively engaged with ends of the discharging passages 14, 14 of the two pumps 1, 1, and the fitting 16, 16 being connected to each other through a pipe 17, and a discharging port 18 is formed at one end. In addition, the two pumps 1, 1 are fixedly connected to each other through a connecting plate 19 with bolts 20, 20.
The aforementioned pumps 1, 1 are all formed of a fluororesin. In particular, the cylinder 2, bellows 4, housing 7, connecting plate 19 and bolts 20 are made of PTFE (polytetrafluoroethylene) resin, and the check valves 12, 15, valve seat 13, fittings 16 and pipe 17 are made of either PFA (polymer of tetrafluoroetylene - perfluoroalkylvinyl ether) resin or PTFE (polytetrafluoroetylene). These resins can be replaced with CTFE (chlorotrifluoroetylene) resin when necessary. It is also preferable to coat the liquid contact faces inside and outside of the pump with aforementioned fluororesins, instead of composing the whole component of the aforementioned resins.
In the pumping device of the above construction, an air source for application of pressure is connected to one air passage 10, while a vacuum source is connected to the other air passage 10. The air source and the vacuum source are subject to change-over control. That is, referring to FIG. 2, the vacuum source is connected to the air passage 10 of the pump 1 on the left side, while the air source for application of pressure is connected to the air passage 10 of the pump 1 on the right side. Then, under such an arrangement, the air source is changed over to the vacuum source and vice versa, so that the bellows 4, 4 repeat alternately contraction and expansion, thereby carrying out the pumping operation. For example, when using the pumping device soaked in a liquid, the liquid is drawn in through the intake passage 11 and check valve 12 when the bellows 4 contracts, while the liquid is discharged out of the discharging port 18 through the discharging passage 14, check valve 15 and pipe 15 when the bellows 4 expands.
FIG. 3 and FIG. 4 show a vertical pumping device with diaphragms. In this pumping device, a diaphragm 23 is disposed in the cylinder chamber 22 of the cylinder 21, and the flange 24 of the diaphragm 23 is held between the step portion 25 and the housing 26. The air passage 27 for applying back pressure to the diaphragm 23 is formed in the central portion of the housing 26. The intake passage 28 and the discharging passage 29 communicate with to the cylinder chamber 22. The check valve 30 is disposed in the intake passage 28, and the valve seat 31 is mounted on the outside of the valve 30 by screwing. Another check valve 32 permitting discharge of liquid is disposed in the discharging passage 29, and a male connector 33 and a ferrule 34 are disposed on the outside of the valve 32.
In the same manner as the preceding first embodiment described above with reference to FIG. 1 and FIG. 2, the components of the pumps 1, 1 are all made of fluororesin, an air source for application of pressure is connected to one air passage 27 while a vacuum source to the other air passage 27, and the air source and the vacuum source are subject to chang-over control.
In the pumping device of this embodiment, the diaphragms 23, 23 alternately perform reciprocating motion by the aforementioned change-over control, as a result pumping operation is continued. Thus, a liquid is draw in through the inlet pasage 28 and check valve 30 when the diaphragm 23 moves upward, while the liquid is discharged through the discharging passage 29 and check valve 32 when the diaphragm 23 moves downward.
In a pump shown in FIG. 5, an air tube 35 is inserted through the central portion of the housing 7. A ferrule 36 is mounted on the outside of the air tube 35 and engages with a screwed portion of the housing 7, and the screwed portion is tightened with a union nut 37 to secure the ferrule 36 to the conical face of the screwed portion.
In the same manner as the preceding first embodiment described above with reference to FIG. 1 and FIG. 2, the components of the pumps 1, 1 are all made of fluororesin, an air source for application of pressure is connected to one air passage 10 while a vacuum source to the other air passage 10, and the air source and the vacuum source are subject to change-over control.
As shown in FIG. 7, the flange 5 of the bellows 4 and an annular projection 38 formed on the housing 7 are joined by welding circumferentially. As shown in FIG. 6, a cylindrical part 39 of the housing 7 and a peripheral edge of the top end portion of the air tube 35 are joined by welding circumferentially.
In the pneumatic pumping device of the above construction, since the bellows 4 and the housing 7 as well as the housing 7 and the air tube 35 are circumferentially joined by welding, the joined portions are perfectly closed and the entrance of liquid thereinto is exactly prevented. When operating the pumping device in a liquid, there is no possibility of entrance of the liquid from the outside.
FIG. 8 and FIG. 9 show a horizontal pumping device, wherein cylindrical concaves 41, 41 formed on both left and right end portions of the housing 40 located in the center are inserted into the flanges 43, 43 of the bellows 42, 42. Female threads 44, 44 are formed on the inner periphery of the concaves 41, 41 and male threads 46, 46 on the inner ends of the cylinder walls 45, 45 are engaged with the female threads 44, 44 so as to secure the flanges 43, 43 of the bellows 42, 42. A piston rod 47 is slidably inserted in the central portion of the housing 40, and the heads of the bellows 42, 42 are coupled with both ends of the piston rod 47. The coupling is established such that one bellows 42 is in its drawing in operation when the other bellows 42 is in its discharging operation. Outer housings 48, 48 whose external appearance is square are disposed on the outer ends of each cylinder wall 45, 45. A cylindrical concave is formed on the inside of each of the housings 48, 48, and male threads 50, 50 on the outer ends of the cylinder walls 45, 45 are engaged with female threads 49, 49 formed on the inner walls of the concaves.
Cylinder chambers 51 are formed with the housings 40, cylinder walls 45 and outer housings 48, one on the left side and the other on the right side, so that two pumps 1, 1 are formed. An intake passage 52 and a discharging passage 53 are formed in the outer housings 48, 48. A check valve 54 and a valve seat 55 permitting inhalation of liquid are disposed in the intake passage 52, while a check valve 56 permitting discharge of the liquid is disposed in the discharging passage 53. Furtheremore, fittings 57, 57 are fitted to the intake passages 52, 52 on both sides, and a pipe 58 is connected with the fittings 57, 57 thereby forming an intake channel port 59, while fittings 60, 60 are fitted to the discharging passages 53, 53 on both sides thereby forming a discharging channel port 62. Air passages 63, 63 communicating with each bellows 42, 42 on both sides are formed in the housing 40 located in the center.
In the same manner as the preceding first embodiment described above with reference to FIG. 1 and FIG. 2, the components of the pumps 1, 1 are all made of fluororesin, an air source for application of pressure is connected to one air passage 63 while a vacuum source to the other air passage 63, and the air source and the vacuum source are subject to change-over control.
In the pumping device of this embodiment, the bellows 42, 42 are alternately displaced between the intake side and discharging side by the aforementioned change-over control. Thus, liquid is drawn in through the intake passage 52 and by way of the check valve 54 when the bellows 42 is situated on the inhaling side, while the liquid is discharged through the discharging passage 53 and check valve 56 when the bellows 42 is situated on the discharging side.
The air change-over control circuit shown in FIG. 10 is provided with an electromagnetic five-port-two-position change-over valve 70. In the change-over valve 70, the air source for application of pressure is connected to a port C, and the vacuum source to ports V1 and V2. Ports A and B are connected to each air passage by way of filters 72, 72. The electromagnetic coils on both sides of the change-over valve 70 are alternately switched through change-over control by a timer circuit 73. Accordingly, in the pumps 1, 1, each air passage is alternately changed over to the air side and the vacuum side according to the change-over control of the change-over valve 70 by the timer circuit 73, resulting in pumping operation being continuously carried out.
FIG. 11 shows an embodiment in which the air change-over control circuit is provided with liquid leakage detectors. In a pilot operated five-port two-position change-over valve 70 of the air change-over control circuit, the air source for application of pressure is connected to the port C, while the vacuum source to the ports V1 and V2. Further, a pressure gauge 74 for measuring and indicating the air pressure, a pressure regulator 75 for regulating the air pressure to a setup pressure, and a filter 76 for eliminating dust contained in the air are respectively connected with an air pressure application line to the port C. Each port A, B is connected to each air passage of the pumps 1, 1 by way of the liquid leakage detectors 78 . . . , and the pilot port is also connected to the pumps 1, 1 by way of the liquid leakage detectors 78 . . . . The liquid leakage detectors 78 output liquid leakage detection signals when any liquid leakage occurs in the air passage. A solenoid operated five-port-two-position change-over valve 79 is provided upstream of the filter 76. A line from the filter 76 is connected to the port A of the change-over valve 79, and each port V1, V2 of the change-over valve 70 located downstream is connected to the port B. The air source is connected to the port C of the changeover valve 79 located upstream, and the vacuum source is connected to each port V1, V2.
A signal of the liquid leakage detector 78 is amplified by the amplifier 80, and the electromagnetic solenoid of the change-over valve 79 is operated by the amplified signal to change over the valve. Once the valve is changed over, the line for air and the vacuum is closed, and the pumps 1, 1 stop their operation. Air and vacuum are alternately fed to each air passage of the pumps 1, 1 with the change-over operation of the pilot port in the change-over valve 70.
In the control circuit of above construction, if a strong acid liquid or strong alkaline liquid should leak out and enter such parts as the air passages 19, 19 or pilot ports Pa, Pb situated on the vacuum side due to break down of the bellows of the pump, for example, the liquid is detected by the liquid leakage detector 78 and operation of the pumps 1, 1 stop. Accordingly, when the pumps are provided with some other air devices, those devices are exactly protected from deterioration caused by the liquid.
FIG. 12 shows an embodiment with filters 81 of a porous tetrafluoroetylene resin formed by drawing, which is mounted on the air change-over control circuit. The filters 81 are of highly corrosion resistant material and perform a function of permitting gas to get therethrough while inhibiting liquid from passing therethrough, i.e., gas-permeable but not liquid-permeable. In the pilot operated five-port-two-position change-over valve 70, the pilot ports are changed over to each other so that the air source and the vacuum cource are alternately communicated with each air passage of the pumps 1, 1, resulting in the pumps 1, 1 performing their pumping operation.
According to this embodiment, even if a strong acid or a strong alkaline liquid should enter the air passage or the pilot port being in the vacuum state, the liquid is shut off by the filters 81 . . . , and the air passsage portions downstream of the filters 81 . . . are protected from corrosion.
It should be understood by those skilled in the art that the foregoing relates to only preferred embodiments of the invention, and that various changes and modifications may be made in the invention without departing from the spirit and scope thereof. | A pneumatic pumping device incorporating a movable valve such as a bellows, are diaphragm, driven by air back pressure in a cylinder so that a liquid is drawn in and discharged by reciprocating movement of the movable valve, and in which surfaces contacting the liquid on the internal and external parts of the pumping device are formed of either a single substance or a compound of a fluororesin such as PTFE, PFA, CTFE in order to feed strong acid liquid or strong alkaline liquid without corrosion on components of the pumping device. | 5 |
FIELD OF THE INVENTION
The present invention relates to a lithium secondary battery and a method for manufacturing the lithium secondary battery.
BACKGROUND OF THE INVENTION
A lithium secondary battery that comprises a nonaqueous electrolyte and utilizes the transfer of lithium ions between a positive electrode and a negative electrode for charge and discharge of the battery has recently been used as one of new type high output and high energy density batteries.
A lithium secondary battery using a material which forms an alloy with lithium as a negative electrode active material is known. However, it is also known that an active material which forms an alloy with lithium increases and decreases in volume when lithium ions are occluded and released, and the active material is pulverized during charge and discharge cycles and separates from the current collector. This causes deterioration of current collecting characteristics (current collectability) and of charge and discharge cycle characteristics.
A negative electrode for a lithium secondary battery in which an active material layer comprising a silicon material and a binder is formed on a current collector comprising an electrically-conductive metal foil and is sintered on the current collector under a non-oxidizing atmosphere has been proposed (Japanese Patent application No. 2000-401501). The negative electrode provides excellent charge and discharge cycle characteristics.
It has also been found that when a thin amorphous or micro crystalline silicon film which is provided on a current collector comprising an electrically-conductive metal foil by sputtering method or CVD method is used as a negative electrode active material, excellent charge and discharge cycle characteristics are obtained (International Publication No. 01/31720).
However, a negative electrode increases and decreases in volume when an active material occludes and releases lithium ions, cracks occur in the active material layer, and contact resistance in the active material layer increases. This causes deterioration of current collecting characteristics (current collectability) and of charge and discharge cycle characteristics.
OBJECT OF THE INVENTION
An object of the present invention is to provide a lithium secondary battery and a method for preparing the lithium secondary battery which is capable of improving current collectability of an electrode and improving charge and discharge cycle characteristics.
SUMMARY OF THE INVENTION
The present invention relates to a lithium secondary battery comprising a nonaqueous electrolyte and an electrode in which an active material layer which includes an active material that electrochemically occludes and releases lithium is formed on a current collector, and wherein cracks in the active material layer are filled with the nonaqueous electrolyte in the form of a solid electrolyte.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section of the negative electrode of an embodiment of the present invention.
FIG. 2 is a plan view of the lithium secondary battery prepared in the Experiments.
FIG. 3 is a photograph taken by a scanning electron microscope from the top showing the condition of the negative electrode having cracks after charging and discharging.
FIG. 4 is a photograph taken by a scanning electron microscope showing the condition of a cross section of the negative electrode having cracks after charging and discharging.
FIG. 5 is a cross section of the electrode of another embodiment of the present invention.
FIG. 6 is a graph showing charge and discharge characteristics of an embodiment of the present invention.
FIG. 7 is a photograph taken by a scanning electron microscope showing the condition of a cross section of the electrode having cracks in the thin film after charging and discharging.
FIG. 8 is a graph showing charge and discharge characteristics of a battery of the present invention.
EXPLANATION OF ELEMENTS
1 : current collector
1 a: surface of current collector
2 : active material layer
2 a: active material particles
2 b: binder
3 : solid electrolyte
4 : cracks
5 : thin film
6 : cracks
DETAILED EXPLANATION OF THE INVENTION
When a solid electrolyte is provided in the cracks formed in the active material layer, current collectability of the electrode is improved and charge and discharge cycle characteristics are also improved. The solid electrolyte prevents the active material layer from separating from the current collector. It is also helpful in improving charge and discharge cycle characteristics.
In the present invention, the nonaqueous electrolyte can be a solid electrolyte. That is, the solid electrolyte provided in the cracks can be a part of a solid nonaqueous electrolyte. The nonaqueous electrolyte can also partially include the solid electrolyte. For example, the solid electrolyte can be provided only in the cracks, and the remainder of the nonaqueous electrolyte can be liquid.
As the solid electrolyte, there can be a solid electrolyte in which a polymer and an electrolyte containing a lithium salt are combined to make a gel. That is, a gel polymer in which the polymer supports the electrolyte containing a lithium salt can be illustrated. The solid electrolyte including a gel polymer has excellent adherence to the active material, and the adherence to the active material is not deteriorated by charging and discharging. Therefore, charge and discharge cycle characteristics can be significantly improved. As the polymer, polyether solid polymer, polycarbonate solid polymer, polyacrylonitrile solid polymer, copolymers thereof and crosslinked polymers can be illustrated.
As other polymers, fluoropolymer, for example, polyvinylidene fluoride, polyvinylidene fluoride-hexafluoropropylene copolymer, polytetrafluoroethylene, and the like, polyamide polymer, polyimide polymer, polyimidazole polymer, polyoxazole polymer, polymelamine-formaldehyde polymer, polypropylene polymer, polysiloxane polymer, and the like, can be illustrated.
The solid electrolyte of the present invention can be an entirely solid electrolyte having lithium ion conductivity. As the entirely solid electrolyte, an electrolyte comprising a lithium salt and a polymer can be illustrated. As the polymer for the entirely solid electrolyte, polyether polymer, polysiloxane polymer, and polyphosphazene polymer can be illustrated.
The surface of the current collector onto which the active material layer is provided preferably has a surface roughness (Ra) of at least 0.2 μm. A current collector having such surface roughness can provide a sufficient contact area for the active material layer and the current collector to improve the adhesion of the active material layer and the current collector. When a binder is included in the active material layer, the binder penetrates into the uneven surface of the current collector, and an anchor effect occurs between the binder and the current collector to increase adhesion. Therefore, peeling of the active material layer from the current collector can be prevented. When active material layers are provided on both surfaces of the current collector, both surfaces preferably have a surface roughness of at least 0.2 μm.
The surface roughness (Ra) and the average distance (S) between adjacent local peaks preferably satisfy the relationship 100 Ra≧S. The surface roughness (Ra) and the average distance (S) between adjacent local peaks are defined in the Japanese Industrial Standards (JIS B 0601-1994), and can be measured by a surface roughness tester.
A current collector treated to have a roughened surface can be used in the electrode of the present invention. As a method of roughening the surface, plating, vapor phase epitaxy, etching, polishing and the like can be illustrated. Plating and vapor phase epitaxy are methods for forming an uneven layer on the surface of the current collector. Plating can be electrolytic or non-electrolytic. As vapor phase epitaxy, there can be illustrated sputtering, chemical vapor deposition (CVD), evaporation, and the like. As etching, physical or chemical etching can be used. As polishing, there can be illustrated polishing with sand paper, blasting, and the like.
As the current collector for the present invention, an electrically conductive metal foil is preferable. As examples of such metal foil, a conductive metal foil composed of a metal such as copper, nickel, iron, titanium, cobalt and the like, and an alloy containing any combination thereof can be illustrated. The current collector preferably contains a metal element that easily diffuses into the particles of the active material. From this point of view, when the active material is silicon or the like, a metal foil containing copper is preferred because copper is easily diffused into silicon. Therefore, a copper metal foil and a copper alloy foil are more preferred.
It is also possible to use a metal foil having a layer containing copper on a surface as the current collector to improve adherence of the current collector and the active material layer. That is, a copper or copper alloy layer provided on the surface of a metal foil which does not include copper can be used. As the metal foil having a layer containing copper having a surface roughness (Ra) of at least 0.2 μm, a copper or copper alloy is provided by electrolytic plating on the metal foil. Concretely, an electrolytic copper foil on which a copper or copper alloy plating is formed by electrolytic plating, a nickel foil plated with copper or a copper alloy can be illustrated.
There is no limitation with respect to the thickness of the current collector (Y). However, a thickness of 10˜100 μm is preferable. There is no limitation regarding the upper limit of the surface roughness (Ra) of the surface of the current collector. However, the upper limit is preferably not greater than 10 μm because the thickness of the current collector (Y) is preferably in a range of 10˜100 μm.
The thickness (X) of the active material layer preferably satisfies relationships with the thickness (Y) of the current collector and the surface roughness (Ra) of the current collector of 5Y≧X, and 250Ra≧X. If such relationships are satisfied, deformation, for example, wrinkles, and the like, of the current collector can be prevented, and the active material layer can be prevented from peeling off of the current collector.
A thickness of the active material layer (X) of not greater than 100 μm is preferred, and a thickness in a range of 10˜100 μm is more preferred. The active material layer of the present invention can be active material particles adhered by a binder on the current collector, or can be a thin film deposited on the current collector.
When the active material layer comprises the active material particles and binder, the active material layer is formed by sintering under a non-oxidizing atmosphere after the active material layer is provided on the surface of the current collector. The binder preferably does not completely decompose after the heat treatment for sintering. If the binder remains after the heat treatment and is not decomposed, the binding ability of the binder, as well as sintering, increases adhesion between particles of the active material and between the active material and the current collector. If an electrically conductive metal foil having a surface roughness (Ra) of at least 0.2 μm is used as the current collector, the binder penetrates into the uneven surface of the current collector, and an anchor effect occurs between the binder and the current collector to increase adhesion. Even if the volume of the active material increases or decreases during occluding and releasing of lithium ions, peeling of the active material layer from the current collector can be prevented and excellent charge and discharge cycle characteristics can be obtained.
As the binder, a binder containing polyimide is preferred. Polyimide can be obtained by heat treatment of polyamic acid. Polyimide is obtained by heat treatment of polyamic acid by dehydration condensation to form polyimide. A yield of imide of the polyimide is preferably at least 80%. If the yield of imide of the polyimide is less than 80%, adherence of the active material particles and the current collecter may be deteriorated. The yield of imide means the mol % of the produced polyimide to the polyimide precursor (polyamic acid). Polyimide having an imide yield of at least 80% can be obtained when polyamic acid in N-methyl-2-pyrrolidone (NMP) is heated at 100˜400° C. for not less than one hour. If the temperature is 350° C., the imide yield is 80% for about a one hour heat treatment, and is 100% for about a three hour heat treatment. It is preferred in this invention that the binder is not completely decomposed after heat treatment for sintering. Therefore, if polyimide is used as the binder, it is preferred that the heat treatment for sintering is done at a temperature of not greater than 600° C.
An amount of the binder in the active material layer is preferably at least 5% based on the total weight of the active material layer. A volume of the binder is preferably at least 5% of the total volume of the active material layer. If the amount of the binder in the active material layer is too little, the binder may not be able to provide sufficient adhesion in the electrode. If the amount of the binder in the active material layer is excessive, resistance in the electrode increases to make the initial charge difficult. Therefore, the amount of the binder in the active material layer is preferably not greater than 50 weight % of the total weight of the layer, and the volume of the binder in the active material layer is preferably not greater than 50% of the total volume of the layer.
There are no limitations with respect to the negative electrode active material if a material is capable of occluding and releasing lithium. A material which forms an alloy with lithium is preferably used. As such material, silicon, germanium, tin, lead, zinc, magnesium, sodium, aluminum, gallium, indium, and alloys thereof can be illustrated. Especially, silicon, tin, germanium, aluminum, and an alloy thereof are preferable. Silicon is especially preferred because it has a large theoretical capacity. As the silicon alloy, a solid solution of silicon and at least one additional element, an intermetallic compound of silicon and at least one additional element, a eutectic alloy of silicon and at least one additional element, and the like can be illustrated. The alloy can be prepared by arc melting, liquid quenching, mechanical alloying, sputtering, chemical vapor deposition, calcining, or the like. As liquid quench, single roll quenching, double roll quenching, atomizing, for example, gas atomizing, water atomizing, disc atomizing, and the like, can be illustrated.
Particles of the active material coated with a metal or the like can also be used. The particles can be coated by electroless plating, electrolytic plating, chemical reduction, vapor deposition, sputtering, chemical vapor deposition, or the like. As the metal used to coat the surface of the particles, it is preferred to use the same metal as used for the electrically conductive metal foil. If the particles are coated with the same metal as the metal foil, the degree of bonding with the current collector dramatically improves, and excellent charge and discharge cycle characteristics can be obtained.
There are no limitations with respect to the mean diameter of particles of the active material. However, the mean diameter is preferably not greater than 100 μm, and more preferably, not greater than 50 μm, and further preferably, not greater than 10 μm. As the diameter of the active material particle is smaller, better cycle characteristics are obtained.
An electrically conductive powder can be mixed in the active material layer. The active material layer containing the electrically conductive powder can be formed by mixing the electrically conductive powder in a slurry of active material particles and binder. If an electrically conductive powder is mixed in the layer, an electrically conductive network is formed around the particles of the active material to increase current collectability of the electrode. As the electrically conductive powder, materials similar to the electrically conductive metal foil can preferably be used. Concretely, copper, nickel, iron, titanium, cobalt and the like, and an alloy or a mixture of these elements can preferably be used alone or in combination thereof. Copper powder is preferable as a metal powder. An electrically conductive carbon powder can also preferably be used.
As with the active material particles, there are no limitations with respect to the mean diameter of particles of the electrically conductive powder. However, the mean diameter is preferably not greater than 100 μm, and more preferably, not greater than 50 μm, and further preferably, not greater than 10 μm.
Sintering under a non-oxidizing atmosphere can be performed under, for example, a nitrogen atmosphere, an inert gas atmosphere (for example, argon or the like), and the like. It is also possible to perform the sintering under a reducing atmosphere, for example, a hydrogen atmosphere, or the like. The temperature used for the sintering is preferably lower than the melting point of the current collector and of the particles of the active material. For example, when a copper foil is used as the current collector, it is preferred that the sintering temperature is not greater than the melting point of copper, i.e., 1083° C. The temperature used for sintering is preferably in a range of 200˜500° C., and more preferably, in a range of 300˜400° C. As a method of sintering, spark plasma sintering, hot pressing, or the like, can be used.
In the present invention, preferably after the active material layer is provided on the current collector and prior to sintering, the active material layer with the underlying current collector is subject to rolling. Rolling can increase packing density in the active material layer and adhesion between particles of the active material and between the active material and the current collector to improve charge and discharge cycle characteristics.
As described above, the active material layer can be formed by depositing the active material in the form of a thin film on the current collector. The thin film of the active material can be formed by sputtering, chemical vapor deposition (CVD), evaporation, spray coating, electroless plating, electrolytic plating, and the like. As the active material to form the thin film, silicon, tin, germanium, aluminum, and an alloy containing these elements, and the like, can be illustrated. Silicon is most preferably used. When silicon is used, it is used in a form of an amorphous and micro crystalline silicon film.
As the solid electrolyte in the present invention, a gel electrolyte which is prepared from a polymer and an electrolyte including a lithium salt is preferred as described above. There is no limitation with respect to the solvent to be used for the nonaqueous electrolyte. Cyclic carbonates, for example, ethylene carbonate, propylene carbonate, butylene carbonate, and the like; chain carbonates, for example, dimethyl carbonate, methylethyl carbonate, diethyl carbonate, and the like, can be used alone or in combinations thereof. A mixture of the cyclic carbonate described above and an ether, for example, 1,4-dioxane, 1,2-dimethoxyethane, 1,2-diethoxyethane, and the like, can also be used.
As a lithium salt, LiPF 6 , LiBF 4 , LiCF 3 SO 3 , LiN(CF 3 SO 2 ) 2 , LiN(C 2 F 5 SO 2 ) 2 , LiN (CF 3 SO 2 ) (C 4 F 9 SO 2 ), LiC (CF 3 SO 2 ) 3 , LIC(C 2 F 5 SO 2 ) 3 , LiAsF 6 , LiClO 4 , Li 2 B 10 Cl 10 , Li 2 B 12 Cl 12 , and the like, can be used alone or in various combinations thereof. A mixture of LiXF y (where X is P, As, Sb, B, Bi, Al, Ga or In; when X is P, As or Sb, y is 6; and when X is Bi, Al, Ga or In, y is 4) and lithium perfluoroalkylsulfonylimide, LiN(C m F 2m+1 SO 2 ) (C n F 2n+1 SO 2 ) (where m and n are each independently an integer of 1˜4), or lithium perfluoroalkylsulfonylmethide, LiC (C p F 2p+1 SO 2 ) (C q F 2q+1 SO 2 ) (C r F 2r+1 SO 2 ) (where p, q and r are each independently an integer of 1˜4) can preferably be used. Especially, a mixture of LiPF 6 and LiN(C 2 F 5 SO 2 ) 2 is preferred.
As the positive electrode active material for the lithium secondary battery, lithium-containing transition metal oxides, for example, LiCoO 2 , LiNiO 2 , LiMn 2 O 4 , LiMnO 2 , LiCo 0.5 Ni 0.5 O 2 , LiNi 0.7 Co 0.2 Mn 0.1 O 2 , and the like, and metal oxides not containing lithium, for example, MnO 2 , and the like, can be illustrated. In addition to the materials described above, if the material is electrochemically capable of occluding and releasing lithium, the material for the positive electrode is not limited.
As the solid electrolyte, a combination of an electrolyte, including a lithium salt, and polymer and which is gelatinized is preferably used. It is preferable that a monomer of the polymer is added into the electrolyte to gelatinize the electrolyte by polymerization of the monomer.
In a method for manufacturing the lithium secondary battery of the present invention, a negative electrode, a positive electrode and an electrolyte including a lithium salt are housed in a container to prepare a temporary-battery, and the temporary-battery is charged and discharged to create cracks in the active material layer, and then a monomer of a polymer is added to the electrolyte to polymerize the monomer and to gelatinize the electrolyte to prepare a solid electrolyte.
Stated differently, the method for manufacturing the lithium secondary battery of the present invention is a method to prepare the battery including a negative and positive electrode wherein an active material layer including an active material electrochemically capable of occluding and releasing lithium is formed on a current collector of an electrode and cracks formed in the active material layer created by occluding and releasing lithium are filled with the solid electrolyte prepared from the polymer and electrolyte. The method comprises preparing a temporary-battery comprising the negative electrode, positive electrode and electrolyte in the container, wherein the electrolyte includes a lithium salt, forming cracks in the active material layer by charging and discharging the temporary-battery, and forming in the cracks, the solid electrolyte that is prepared by gelatinizing the electrolyte by polymerization of the monomer added to the electrolyte in the temporary-battery after formation of the cracks.
According to the method of the present invention, the temporary-battery containing the electrolyte before gelatinization of the electrolyte is charged and discharged to form cracks in the active material layer of the negative electrode. The electrolyte penetrates into the cracks formed in the active material layer. The monomer is added into the electrolyte and is polymerized to form the solid electrolyte by gelatinizating the electrolyte. Therefore, the solid electrolyte can be easily filled in the cracks in the active material layer.
FIG. 1 is a cross section of a negative electrode of the present invention comprising an active material layer comprising active material particles and a binder. As shown in FIG. 1 , a surface 1 a of a current collector 1 is unevenly formed, and an active material layer 2 is formed on the current collector. The active material layer 2 comprises active material particles 2 a and binder 2 b, and includes cracks 4 in a direction of thickness. The cracks 4 are formed by the occlusion and release of lithium from the active material particles 2 a. A solid electrolyte 3 is penetrated into the cracks 4 . Each part of the active material layer 2 separated by the cracks is covered by the solid electrolyte 3 .
The solid electrolyte 3 having lithium ion conductivity fills the cracks 4 of the active material layer 2 to prevent the active material layer 2 from peeling off or separating from the current collector 1 , and improves charge and discharge cycle characteristics.
The active material layer 2 is held together by the mechanical strength of the solid electrolyte 3 . Therefore, the active material layer 2 is prevented from coming off the current collector 1 , and charge and discharge cycle characteristics are improved.
According to another aspect of the present invention, at least one of the active material layers of the positive electrode and the negative electrode is formed by deposition of the active material as a thin film on the current collector, and the solid electrolyte is filled in cracks formed in the active material layer by occluding and releasing lithium.
A lithium secondary battery according to the another aspect of the invention includes positive and negative electrodes, in which an active material layer includes an active material electrochemically capable of occluding and releasing lithium, and a nonaqueous electrolyte, wherein at least one of the active material layers of the positive and negative electrodes is formed as a thin film on the current collector by deposition of an active material, and cracks formed in the active material layer by occluding and releasing lithium are filled with a solid electrolyte.
The lithium secondary battery of the other aspect of the present invention can be manufactured by preparing a temporary-battery comprising the positive electrode, the negative electrode and the electrolyte comprising a lithium salt; forming cracks in the active material layer by charging and discharging the temporary-battery; adding a monomer of a polymer to the electrolyte in the temporary-battery; and then polymerizing the monomer to prepare the solid electrolyte by gelatinization of the electrolyte and to form the solid electrolyte in the cracks.
FIG. 5 is a cross section of an electrode of a second aspect of the present invention. As shown in FIG. 5 , a surface 1 a of the current collector 1 is unevenly formed. A thin film 5 as an active material layer is formed on the uneven surface of the current collector. Cracks 6 are formed in a direction of thickness of the thin film 5 . The cracks 6 are formed by occluding and releasing lithium from the thin film 5 . The thin film 5 was continuous before the cracks were formed and the surface of the thin film was uneven corresponding to the surface of the current collector. The thin film 5 increases and decreases in volume when lithium ions are occluded and released, and stress generated by change of volume creates cracks 6 starting from a valley of the surface of the thin film toward a direction of the thickness. The thin film 5 has a pillar structure divided by cracks 6 .
As shown in FIG. 5 , the solid electrolyte is filled into the cracks 6 . Each portion of the thin film 5 divided by the cracks is covered by the solid electrolyte. Therefore, current collectability of the electrode can be improved because the solid electrolyte having lithium ion conductivity fills the cracks 6 of the thin film 5 .
The thin film 5 is held together by the mechanical strength of the solid electrolyte 3 . Therefore, the thin film 5 is prevented from coming off the current collector 1 , and charge and discharge cycle characteristics are improved.
DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention are explained in detail below. It is of course understood that the present invention is not limited to these embodiments and can be modified within the spirit and scope of the appended claims.
Experiment 1
[Preparation of Negative Electrode]
81.8 parts by weight of the silicon powder (purity 99.9%) was added to 8.6 weight % of a N-methyl-2-pyrrolidone solution containing 18.2 weight parts of polyimide as a binder and the components were mixed and kneaded by a pestle in a mortar to prepare a negative electrode mixture slurry.
The slurry was coated on one surface of an electrolytic copper foil (thickness: 35 μm) having a surface roughness (Ra) of 0.5 μm which is a current collector, and was rolled after drying. The coated copper foil was sintered by heating at 400° C. for 30 hours under an argon atmosphere to prepare a negative electrode. The thickness of the electrode (including the current collector) was 50 μm. Therefore, the thickness of the active material layer was 15 μm. Thickness of the active material layer (X)/surface roughness of the copper foil (Ra) was 30. Thickness of the active material layer (X)/thickness of the copper foil (Y) was 0.43.
In the negative electrode, the density of the polyimide was 1.1 g/cm 3 , and the volume of polyimide was 31.8% based on the total volume of the active material layer including polyimide.
[Preparation of Positive Electrode]
Li 2 CO 3 and CoCO 3 were measured to an atomic ratio of 1:1 and were mixed in a mortar. The mixture was pressed in a mold having a diameter of 17 mm, and was sintered at 800° C. for 24 hours in air to obtain sintered LiCoO 2 . It was ground in a mortar to particles having a mean diameter of 20 μm.
90 parts by weight of the LiCoO 2 powder and 5 parts by weight of artificial carbon powder as a electrically conductive agent were mixed with 5 weight % of N-methyl-2-pyrrolidone solution containing 5 parts by weight of polyfluorovinylidene as a binder to prepare a positive electrode mixture slurry. The slurry was coated on aluminum foil which was a current collector, and was rolled after drying to prepare a positive electrode.
[Preparation of Electrolyte]
1 mol/l LiPF 6 was dissolved in a mixture (3:7) of ethylene carbonate and diethylene carbonate and 5 weight % of vinylene carbonate was added to prepare an electrolyte.
[Preparation of Pregel Solution]
Tripropylene glycol diacrylate (molecular weight 300) and the electrolyte were mixed in a ratio by mass of 1:7, and 5000 ppm of t-hexyl peroxy pivalate as a polymerization initiator was added to the mixture to prepare a pregel solution.
[Assembly of Battery]
The positive and negative electrodes with positive and negative electrode current collecting tabs mounted thereon and a separator made of porous polyethylene were rolled and placed in an outer battery can made of an aluminum laminate to prepare a temporary-battery having an outer measurement of 35 mm in width, 50 mm in length and a thickness of 3.5 mm. The temporary-battery was charged to 4.2 V at a current of 50 mA, and then was discharged to 2.75 V at a current of 50 mA. Then the same weight of the pregel solution as the electrolyte in the temporary-battery was added into the battery and the solution and the electrolyte were mixed and left for four hours to provide a uniform mixture. The battery was heated at 60° C. for three hours to gelatinize the mixture to prepare a battery A 1 . The polymerizable compound (monomer) in the pregel solution, tripropylene glycol diacrylate, was polymerized by heating of the mixture, and the electrolyte was held in a mesh structure of the polymer to form a so-called gel polymer solid electrolyte.
FIG. 2 is a plan view of the lithium secondary battery prepared above. The lithium secondary battery is sealed by heat sealing of outer edge of the outer battery can 11 made of an aluminum laminate to form sealed opening 12 . The positive electrode current collecting tab 13 and the negative electrode current collecting tab 14 are mounted on an upper part of the outer battery can 11 . The set of electrodes separated by the separator made of porous polyethylene is inserted in the outer battery can 11 .
[Observation of Negative Electrode After Charge and Discharge of Temporary-battery]
FIGS. 3 and 4 are photographs taken by a scanning electron microscope showing the condition of the negative electrode after charging and discharging of the temporary-battery. As is clear from FIGS. 3 and 4 , a crack in a direction of thickness of the active material layer was formed by charging and discharging of the temporary-battery. In this example, the pregel solution was added after the cracks were formed and then the gel polymer solid electrolyte was formed. Therefore, the gel polymer solid electrolyte formed to fill the cracks.
Experiment 2
Battery B 1 was prepared in the same manner as in Experiment 1 except that the temporary-battery was not charged and discharged.
Battery B 2 was prepared in the same manner as in Experiment 1 except that an electrolyte without a monomer and a polymerization initiator was used instead of the pregel solution.
Charge and discharge cycle characteristics of batteries A 1 , B 1 and B 2 were evaluated. Each battery was charged to 4.2 V at a current of 100 mA and 25° C., and then was discharged to 2.75 V at a current of 100 mA and 25° C. (this is considered to be one charge and discharge cycle). The number of cycles to reach 80% of the discharge capacity of the first cycle was measured to determine the cycle life of the battery. The results are shown in Table 1. The cycle life of each battery is shown as an index when the cycle life of the battery A 1 is taken as 100.
TABLE 1
Charge/Discharge of
Pregel
Battery
Temporary-battery
Solution
Cycle Life
A1
Yes
Yes
100
B1
No
Yes
23
B2
Yes
No
69
In battery A 1 , the temporary battery was charged and discharged to form cracks in the active material layer, and then the electrolyte was gelatinized. In contrast, the solid electrolyte was formed before battery B 1 was charged and discharged, and cracks in the active material layer were formed after the solid electrolyte was formed. Therefore, the solid electrolyte did not penetrate into the cracks.
The battery B 2 was charged and discharged after the temporary-battery was assembled, but the pregel solution was not used. The electrolyte was not gelatinized, i.e., the electrolyte was in a normal liquid condition.
As is clear the results shown in Table 1, battery A 1 of the present invention had a longer cycle life in comparison with battery B 1 . It is believed that the solid electrolyte filled the cracks in the active material layer, current collectability of the electrode was increased and the active material was efficiently used. The solid electrolyte in the cracks held the active material layer together to prevent the active material layer from separating from the current collector and to improve charge and discharge cycle characteristics.
Experiment 3
The effect of surface roughness (Ra) of the current collector was evaluated.
Batteries A 2 and A 3 were prepared in the same manner as Experiment 1 except that electrolytic copper foils having a surface roughness (Ra) of 0.2 μm and 0.17 μm, respectively, were used instead of the electrolytic copper foil having a surface roughness (Ra) of 0.5 μm.
Cycle characteristics of batteries A 2 and A 3 were evaluated in the same manner described above. Cycle life is described as an index when the cycle life of battery A 1 is taken as 100. Table 2 also includes the cycle life of battery A 1 .
TABLE 2
Roughness of Surface
of Current Collector
Battery
(μm)
Cycle Life
A1
0.5
100
A2
0.2
87
A3
0.17
76
As is clear from the results shown in Table 2, batteries A 1 and A 2 prepared using a current collector having a surface roughness (Ra) of at least 0.2 μm have excellent cycle characteristics as compared to battery A 3 prepared using a current collector having a surface roughness (Ra) of less than 0.2 μm. It is believed that the contact area of the particles of the active material and the surface of the current collector is increased by using a metal foil having a surface roughness (Ra) of at least 0.2 μm. Additionally, sintering effectively increases adhesion of the particles of the active material and the current collector, and the binder penetrates into uneven portions of the surface of the current collector, and the adhesion increases because of an anchor effect occurring in the binder and the current collector to increase current collectability of the electrode.
Experiment 4
The effect of sintering conditions of the electrodes on cycle characteristics was evaluated. Battery A 4 was prepared in the same manner as Experiment 1 except that the electrode was treated at 550° C. for ten hours. Battery B 3 was prepared in the same manner as Experiment 1 except that the electrode was not treated by heat.
Cycle characteristics of batteries A 4 and B 3 were evaluated in the same manner as described above. Cycle life is described as an index when the cycle life of battery A 1 is taken as 100. Table 3 also includes the cycle life of battery A 1 .
TABLE 3
Battery
Heat Treatment Condition of Electrode
Cycle Life
A1
400° C., 30 hrs
100
A4
550° C., 10 hrs
75
B3
None
32
As is clear from the results shown in Table 3, batteries A 1 and A 4 have excellent cycle characteristics as compared to battery B 3 prepared without heat treatment of the electrode. It is believed that the particles of the active material and the current collector were sintered by heat treatment and adhesion of the active material layer and current collector increased to improve the current collectability of the electrode.
Battery A 4 in which the electrode is treated at 550° C. for ten hours reduced the cycle characteristics as compared to battery A 1 in which the electrode is treated at 400° C. for 30 hours. It appears that the binder was decomposed by the heat treatment at 550° C., and adhesion resulting from the binder in the electrode was significantly reduced to decrease the current collectability.
Experiment 5
The effect of an electrically conductive powder added to the active material layer was evaluated.
Battery A 5 was prepared in the same manner as Experiment 1 except that 20 weight % (based on the weight of the copper powder and the silicon powder) of copper powder of a mean diameter of 3 μm was added to the silicon powder. Cycle characteristics of battery A 5 were evaluated in the same manner as described above. Cycle life is described as an index when the cycle life of battery A 1 is taken as 100. Table 4 also includes the cycle life of battery A 1 .
TABLE 4
Battery
Electrically-Conductive Powder
Cycle Life
A1
None
100
A5
Copper Powder
103
As is clear from the results shown in Table 4, battery A 5 in which copper powder is added to the active material had better cycle characteristics than battery A 1 which did not include electrically conductive powder in the active material. The electrically conductive powder is believed to have formed a network around the particles of active material to improve the current collectability in the active material layer.
Experiment 6
[Preparation of Negative Electrode]
Copper was deposited by electrolysis on a surface of a rolled copper film of a thickness of 18 μm to prepare a copper film having a roughened surface (thickness of 26 μm, surface roughness Ra of 0.21 μm). An amorphous silicon thin film was deposited by sputtering to a thickness of 5 μm. Direct current pulse was used as power for sputtering. Conditions of sputtering are as follows:
Frequency of direct current pulse: 100 kHz Width of direct current pulse: 1856 ns Power of direct current pulse: 2000 W Argon flow rate: 60 sccm Pressure of Gas: 2.0~2.5 × 10 −1 Pa Time: 146 minutes
The obtained silicon thin film was cut with the current collector to 25 mm×25 mm to prepare a negative electrode.
[Preparation of Positive Electrode]
A positive electrode mixture slurry was prepared in the same manner as Experiment 1. The slurry was coated on aluminum foil which was a current collector, and was rolled after drying. A 20 mm×20 mm piece was cut out from the coated aluminum foil to prepare a positive electrode.
[Preparation of Electrolyte]
An electrolyte was prepared in the same manner as in Experiment 1.
[Preparation of Pregel Solution]
A pregel solution was prepared in the same manner as in Experiment 1.
[Assembly of Battery]
A temporary-battery was prepared in the same manner as in Experiment 1. The temporary-battery was charged to 4.2 V at a current of 1.3 mA, and then was discharged to 2.75 V at a current of 1.3 mA. Then the same weight of the pregel solution as the electrolyte in the temporary-battery was added into the battery, the solution and the electrolyte were mixed and left for four hours to provide a uniform mixture. The battery was heated at 60° C. for three hours to gelatinize the mixture to prepare a battery A 6 . The polymerizable compound (monomer) in the pregel solution, tripropylene glycol diacrylate, was polymerized by the heating of the mixture, and the electrolyte was held in a mesh structure of the polymer to form a so-called a gel polymer solid electrolyte.
Experiment 7
A battery B 4 was prepared in the same manner as in Experiment 6 except that the temporary-battery was not charged and discharged after being assembled.
[Evaluation of Charge and Discharge Characteristics]
Charge and discharge cycle characteristics of batteries A 6 and B 4 were evaluated. Each battery was charged to 4.2 V at a current of 1.3 mA and 25° C., and then was discharged to 2.75 V at a current of 1.3 mA and 25° C. This is considered to be one charge and discharge cycle.
The initial discharge capacity (discharge capacity at the first cycle) and capacity maintenance rate after ten cycles are shown in Table 5. After the tenth cycle was completed, discharge capacity was measured and measurement of capacity maintenance rate was calculated according to expression (2) below.
Capacity Maintenance Rate (%)=(discharge capacity after ten cycles/initial discharge capacity)×100 (2)
The charge and discharge cycle characteristics are shown in FIG. 6 .
TABLE 5
Capacity
Charge/
Initial
Maintenance
Discharge
Charge
Rate
of Preliminary
Capacity
after 10 Cycles
Battery
Battery
(mAh)
(%)
A6
Yes
11.9
93.3
B4
No
10.6
86.1
As is clear from FIG. 6 and Table 5, battery A 6 of the present invention has better charge and discharge cycle characteristics as compared to the comparative battery B 4 .
[Observation of Negative Electrode After Charge and Discharge of Temporary-battery]
FIG. 7 is a photograph taken by a scanning electron microscope showing the condition of the negative electrode after charging and discharging of the temporary-battery. As is clear from FIG. 7 , cracks in a direction of thickness of the active material layer were formed by charging and discharging of the temporary-battery. In this example, the pregel solution was added after the cracks were formed and then the gel polymer solid electrolyte was formed. Therefore, the gel polymer solid electrolyte formed and filled the cracks.
Experiment 8
[Preparation of Positive Electrode]
The negative electrode in Experiment 6 was used as a positive electrode.
[Assembly of Battery]
A temporary-battery was prepared in the same manner as in Experiment 1 except for the use of the positive electrode described above and the use of a negative electrode made of lithium metal. Battery A 7 was prepared from the temporary-battery in the same manner as Experiment 6.
Experiment 9
Battery B 5 was prepared in the same manner as in Experiment 8 except that the temporary-battery was not charged and discharged after being assembled.
[Evaluation of Charge and Discharge Characteristics]
Charge and discharge cycle characteristics of batteries A 7 and B 5 were evaluated. Each battery was charged to 0 V at a current of 4 mA and 25° C., and then was discharged to 2.0 V at a current of 4 mA and 25° C. This is considered to be one charge and discharge cycle. The initial discharge capacity and capacity maintenance rate after ten cycles are shown in Table 6. Cycle characteristics during the charge and discharge test are shown in FIG. 8 .
TABLE 6
Capacity
Charge/
Initial
Maintenance
Discharge
Charge
Rate
of Preliminary
Capacity
after 10 Cycles
Battery
Battery
(mAh)
(%)
A7
Yes
14.4
99.3
B5
No
12.5
92.5
As is clear from FIG. 8 and Table 6, battery A 7 of the present invention has excellent charge and discharge cycle characteristics.
ADVANTAGES OF THE INVENTION
The present invention improves current collectability of an electrode, and provides a lithium secondary battery having excellent charge and discharge cycle characteristics. | A lithium secondary battery comprising an electrode in which an active material layer which includes an active material that electrochemically occludes and releases lithium is formed on a current collector, wherein cracks are formed in the active material layer by occlusion and release of lithium ions and thereafter a solid electrolyte is formed in the cracks in the active material layer. | 7 |
FIELD OF THE INVENTION
The present invention relates to apparatus for singularizing drop-wires in warp-thread drawing-in machines. It is concerned particularly with apparatus having a selecting member for drop-wires fed in the form of a stack, which selecting member separates individual drop-wires from the stack so that individual drop-wires may be prepared for the drawing-in of the warp threads.
BACKGROUND OF THE INVENTION
In hitherto known devices for singularizing drop-wires, the selecting member is formed by a selecting blade entering the drop-wire stack from above. Such selecting member penetrates into the drop-wire stack directly after the frontmost drop-wire of the stack and displaces the frontmost drop-wire lengthwise of the drop-wire stack to the drawing-in position. In such systems, if the drop-wires are to be reliably selected, it must be ensured that successive drop-wires of the drop-wire stack have various points of application for the selecting blade. This is achieved by virtue of the fact that drop-wires having a bevelled head are used and these drop-wires are lined up alternately with regard to the bevelling. This means that drop-wires different from these said drop-wires could not hitherto be drawn in automatically.
SUMMARY OF THE INVENTION
An object of the present invention is to provide universally usable apparatus for singularizing drop-wires, which apparatus enables all types of drop-wires to be selected without these drop-wires having to be lined up in a specific manner.
In accordance with an aspect of the invention, the selecting member is formed by a means acting on the front end of a drop-wire stack and fractionally transporting the actual frontmost drop-wire from the drop-wire stack into an intermediate position. Owing to the fact that the selecting member acts on the front end of the drop-wire stack and does not penetrate laterally into the same, the drop-wires do not need to have a specific configuration at a penetration point, and they also do not need to be lined up or arranged in a specific manner. On the contrary, the selecting member contacting the drop-wires at the front end of the stack is able to singularize all types of drop-wire.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail below with reference to an exemplary embodiment and the drawings, in which:
FIG. 1 shows a perspective overall representation of a warp-thread drawing-in machine;
FIG. 2 shows a side view of a device according to the invention for singularizing drop-wires, partly in section;
FIG. 3 shows a view in the direction of arrow III in FIG. 2;
FIG. 4 shows a section along line IV--IV in FIG. 2;
FIG. 5 shows a section along line V--V in FIG. 2; and
FIG. 6 shows a view in the direction of arrow VI in FIG. 2.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
According to FIG. 1, the drawing-in machine consists of a mounting stand 1 and various subassemblies arranged in this mounting stand 1. Each of these sub-assemblies represents a functional module. A warp-beam truck 2 with a warp-beam 3 arranged thereon can be recognized in front of the mounting stand 1. In addition, the warp-beam truck 2 contains a lifting device 4 for holding a frame 5 on which the warp threads KF are clamped. This clamping is effected before the actual drawing-in machine and at a location separate from the drawing-in machine, the frame 5 being positioned at the bottom end of the lifting device 4 directly next to the warp-beam 3. For the drawing-in, the warp-beam truck 2 together with warp-beam 3 and lifting device 4 is moved to the so-called setting-up side of the drawing-in machine and the frame 5 is lifted upwards by the lifting device 4 so it then assumes the position shown.
The frame 5 and the warp beam 3 are displaced in the longitudinal direction of the mounting stand 1. During this displacement, the warp threads KF are directed past thread-separating apparatus 6 and as a result are separated and selected. After the selection, the warp threads KF are cut off and presented to a drawing in needle 7, which forms a component of the so-called drawing in module. The selecting equipment employed for this operation may be of the type used heretofore in the warp tying machine sold under the designation USTER TOPMATIC by Zellweger Uster AG of Switzerland. USTER is a registered trademark of Zellweger Uster AG.
Next to the drawing in needle 7, there is a video display unit 8, which belongs to an operating station and serves to display machine functions and machine malfunctions and to input data. The operating station, which forms part of a so-called programming module, also contains an input stage for the manual input of certain functions, such as, for example, creep motion, start-stop, repetition of operations, and the like. The drawing-in machine is controlled by a control module which contains a control computer and is arranged in a control box 9. Apart from the control computer, this control box contains a module computer for every so-called main module, the individual module computers being controlled and monitored by the control computer. The main modules of the drawing-in machine, apart from the modules already mentioned (drawing-in module, yarn module, control module and programming module), are the heald, drop-wire, and reed modules.
The thread-separating apparatus 6 which presents the warp threads KF to be acted upon by the drawing-in needle 7, and the path of movement of the drawing-in needle 7 transverse to the plane of the clamped warp threads KF defines a plane in the area of a support 10 forming part of the mounting stand 1. This plane separates the setting-up side already mentioned from the so-called taking-down side of the drawing-in machine. The warp threads and the individual elements into which the warp threads are to be drawn-in are fed at the setting-up side, and the so called harness (healds, drop-wires and reed) together with the drawn-in warp threads can be removed at the taking down side. During the drawing-in, the frame 5 having the warp threads KF and the warp beam truck 2 for the warp beam 3 are moved to the right past the thread-separating apparatus 6. In the course of this movement, the drawing in needle 7 successively removes from the frame 5 the warp threads KF clamped on the latter.
When all warp threads KF are drawn in and the frame 5 is empty, the latter, together with the warp beam truck 2, the warp beam 3 and lifting device 4, are located on the taking-down side.
Arranged directly behind the plane of the warp threads KF are the warp-stop-motion drop-wires LA. Behind the latter are the healds LI, and the reed is further to the rear. The drop-wires LA are stacked in hand magazines. The full hand magazines are hung in sloping feed rails 11, on which they are transported to the right towards the drawing in needle 7. At this location they are separated and moved into the drawing-in position. Once drawing-in is complete, the drop-wires LA pass on drop-wire supporting rails 12 to the taking-down side.
The healds LI are lined up on rails 13 and shifted manually or automatically on the latter to a separating stage. The healds LI are then moved individually into their drawing-in position and, once drawing-in is complete, they are distributed over the corresponding heald shafts 14 on the taking down side. The reed is likewise moved step-by-step past the drawing-in needle 7, the corresponding reed gap being opened for the drawing-in. After the drawing-in, the reed is likewise located on the taking-down side. A part of the reed WB can be recognized to the right next to the heald shafts 14. This representation is to be understood as illustrative, since the reed, at the position shown of the frame 5, is of course located on the setting-up side.
A so-called harness truck 15 is provided on the taking-down side. This harness truck 15, together with the drop-wire supporting rails 12, fixed thereon, heald shafts 14 and a holder for the reed, are pushed into the mounting stand 1 into the position shown. After the drawing-in, the truck 15 carries the harness having the drawn-in warp threads KF. At this moment, the warp beam truck 2 together with the warp beam 3 is located directly in front of the harness truck 15. By means of the lifting device 4, the harness is now reloaded from the harness truck 15 onto the warp beam truck 2, which then carries the warp beam 3 and the drawn-in harness and can be moved to the relevant weaving machine or into an intermediate store.
The functions described are distributed over a plurality of modules which represent virtually autonomous machines which are controlled by the common control computer. The cross-connections between the individual modules run via this higher-level control computer and there are no direct cross-connections between the individual modules. The main modules already mentioned are themselves also of modular construction and as a rule include submodules. This modular construction is described in Swiss Patent Application No. 03 633/89-1 and corresponding International Application PCT/CH 90/00227, the disclosures of which are incorporated herein by reference in their entirety.
The drop-wire separating submodule of the drop-wire module is now to be described below. This submodule, which is shown in various views in FIGS. 2-6, follows in the transport direction of the drop-wires LA after the submodule drop-wire storing, which is described in U.S. application Ser. No. 07/702,020, the disclosure of which is incorporated herein by reference in its entirety.
It can be gathered from the last-mentioned patent application that the submodule drop-wire storing includes a movable elongated stand in which feed rails 11 for hand magazines carrying the drop-wires LA (FIG. 1) are mounted. The hand magazines are loaded with drop-wires and hung in the feed rails 11 in which they are transported towards a separating station where singularizing of the drop-wires takes place. This separating station is now to be described with reference to FIGS. 2-6.
The separating station is designed in the form of an elongated box, whose one front end (FIG. 2, left) is provided as feeding side and whose other front end (FIG. 2, to right of center) is provided as delivery side for the drop-wires. At the feeding side, the drop-wires are pushed from the hand magazines of the submodule drop-wire storing into the separating station, and at the delivery side they are separated from their stack, the individual drop-wires being delivered sequentially from the separating station. Thus the separating station is connected at is left-hand side in FIGS. 2, 5 and 6 to the stand forming the submodule drop-wire storing, and in fact preferably by an appropriate coupling, which is indicated in FIG. 6 by a recess 16 provided for accommodating a coupling nose of the said stand. With regard to FIG. 2, a functional stage (not shown in further detail) is arranged above the separating station, which functional stage receives drop-wires delivered from the separating station and transfers them to a distributing station which positions the drop-wires in the warp-thread drawing in position.
The box-shaped part of the separating station, in which part the drop-wires LA are guided from the feeding side to the delivery side, includes a rectangular base plate 17, three guide rods 18 arranged in the base plate 17 at each of three corner points of the separating station, a top plate 19 and an intermediate plate 20. The top and intermediate plates 19 and 20 are carried and guided by the guide rods 18. The fourth corner point of the rectangle is not occupied by a point of the rectangle is not occupied by a guide rod 18, since the connection between the separating station and the submodule drop-wire storing is made in the area of this corner point (FIG. 6, recess 16). The intermediate plate 20 is vertically adjustable for adapting to the various lengths of drop-wire. For this purpose, two for the guide rods 18 are provided with spaced grooves 21 in which corresponding fixing screws 22 engage.
One pair of guide rails 23 is screwed to the inner surfaces, facing one another, of the top plate 19 and the intermediate plate 20. Between the guide rails is an alley which is slightly wider than the drop-wires LA and in which the drop-wires are displaced towards the delivery side. Strip brushes 24 for the exact lateral guidance of the drop-wires LA are screwed onto the guide rails 23. These strip brushes extend from the feeding side of the separating station up to vertically arranged rotating brushes 25, which displace the drop-wires passing into their effective area in the transport direction (arrow A) up to a stop. This stop is located in the connecting plane of the axes of the two guide rods 18 arranged to the right (as viewed in FIG. 2) of the rotating brushes 25 and it is formed by top, center and bottom webs 26, 27 and 28.
A nose 30 is adjustably mounted in spaced relation to the top web 26 by means which includes a crank 29 through the operation of which the distance of the nose 30 from the web 26 can be set to predeterminable values. As a result, a slit of defined width is formed between web 26 and nose 30. This width is at least as great as the thickness of a single drop-wire LA and less than the combined thickness of two of the drop-wires LA in the stack of drop-wires being processed, so that only one drop-wire at a time can be delivered from the stack up through the said slit.
The frontmost drop-wire LA in each case, pressed by the rotating brushes 25 against the stop 26, 27, 28, is separated from the drop-wire stack by a friction wheel 31. The latter is mounted on a lever 33 which is swingable about a pivot at its upper end portion and which is moved by a pneumatic cylinder 32. The friction wheel 31 is continuously driven via a flexible shaft 34 (FIG. 4). The pneumatic cylinder 32 alternatively presses the friction wheel 31 against the drop-wire to be selected or swings it away from the same. The frequency of this pivoting movement is controlled with reference to the warp thread drawing-in frequency which is set at the machine. During contact between the friction wheel 31 and the frontmost drop-wire, the latter is conveyed by the friction wheel 31 (rotating clockwise with regard to FIG. 2.) up through the slit between web 26 and the nose 30. The drop-wire separated in this way stops at a sensor, and in fact in a position where about one-third of its length has passed the slit. In this position, the drop-wire is received by a flight of a conveyor chain and then moved into a defined transfer position. The conveyor chain is driven intermittently via a suitable coupling.
The rotating brushes 25 and the friction wheel 31 are driven by a common motor 34 (FIG. 2) which is fastened to the base plate 17. The motor 34 directly drives the flexible shaft 34 and indirectly drives the rotating brushes 25 via a belt and gear drive 35. This belt and gear drive 35 acts on drive shafts 36 which carry the rotating brushes 25 and are mounted at their top end in the top plate 19 in such a way that their mutual spacing is adjustable so that the space between the brushes 25 can be set to the width of the respective drop-wires LA. The drive shafts 36 carrying rotating brushes 25 are preferably pressed together so that the brushes 25 press flexibly against the side edges of the drop-wire stack.
When the frontmost drop-wire is separated from its stack, such drop-wire slides along the next drop-wire during the entire separating operation and relatively high friction has to be overcome. This friction can be drastically reduced if the bottom stop 28 is of stepped design and has a step-like projection protruding beyond the vertical stop plane in the area of the bottom end of the drop-wires LA. The drop-wires are then no longer positioned exactly vertically at the stop 26, 27, 28 but are slightly tilted, in which case they are set back with the bottom end in transport direction A towards the stop plane apparent from FIG. 2.
With this arrangement, the frontmost drop-wire to be separated bears against the next drop-wire only as long as its bottom end bears on the projection of the bottom stop 28. As soon as the drop-wire has passed this projection, its bottom end springs forward towards the vertical stop plane and the drop-wire is released over most of its length. As a result, the separating is substantially facilitated.
If required, after the drop-wire is released, the selecting operation can also be assisted by a blade-like member reaching into the gap which then exists between the vertically hanging frontmost drop-wire and the tilting drop-wire stack and pulling the drop-wire stack to the rear against the transport direction A to such an extent that there is only slight friction between the frontmost drop-wire and the drop-wire stack, so that in particular the head edge of the drop-wire just pushed up out of the drop-wire stack does not damage the next drop-wire. | A drawing-in machine for threading weaving machine harnesses is provided with apparatus for separating one at a time the drop-wires to be threaded from a stack of drop-wires. The stack of drop-wires is moved toward a stop located adjacent a slit. A selecting member (31) in the form of a friction wheel contacts the front face of the forwardmost drop-wire of the stack of drop-wires to urge that drop-wire transversely into the slit so as to separate that drop-wire from the stack. The selecting member moves the front drop-wire from the drop-wire stack into an intermediate position from which it can be separated completely from the stack and threaded with a warp thread. The drop-wires do not need to have any specific configuration at the point of application of the selecting member and they also do not need to be lined up or arranged in a specific manner. The friction wheel contacting the drop-wires at their front face is able to singularize all types of drop-wires. | 3 |
FIELD OF THE INVENTION
[0001] The present invention provides modular barrier apparatus for protecting households or premises from flood damage or to provide a barrier for the containment of fluids. The barrier is simple, easy and rapid for users to assemble and it can be used in a number of scenarios without the need for in-situ preparation. It is based on modular units for assembly in end-to-end abutting relationship and connectable using slide-in keys to create a flexible watertight barrier.
BACKGROUND TO THE INVENTION
[0002] Globally flooding is becoming more and more frequent due to climate change and the increase in development on floodplain. Nearly 2 million properties are situated in flood risk areas within the UK. It is estimated that flooding has the potential to inflict damage to assets of over £200 billion. Some evidence of this can be seen in 2000, when insurance claims regarding flood damage were as high as £800 million.
[0003] Over 5% of people in England live lower then 5 metres above sea level. These locations are susceptible to frequent flooding. It has also been suggested that about 7% of the country is likely to flood at least once every 100 years from rivers. In addition, 1.5% of the country is at risk from direct flooding from the sea. Insurance companies charge huge sums to insure properties against flooding. In many instances they are not willing to insure a property at all, if located on a flood plain and at risk from regular flooding.
[0004] A number of flood defence products are currently on the market. However, only a handful of these carry the relevant kite mark relating to flood defence.
[0005] Sandbags still remain the most common method for protection and have the advantage that contours can be met, whether it is spanning a gap or assembling a defensive wall around a number of buildings. However thy have number of disadvantages, which include the following:
Time-consuming to assemble into barriers. Prone to leakage. Viral and bacterial infections are often present in flood water and can in turn be transferred onto used sandbags. Large amount of material required to form a defensive wall. Large amount of manpower required to assemble a barrier in sufficient time.
[0011] The lengthy time needed to assemble a sandbag barrier and the manpower requirements significantly reduce the chances of a defence being erecting in time to protect against rising flood waters.
[0012] A product called Rapidam made by Flood Guards International has been displayed on Tomorrows World, where it received an award for innovation. It has been produced in a free-standing version which does not require in situ preparation, but a substantial time is needed for establishing a watertight seal and in use the resulting barrier requires a large number of sandbags.
[0013] Another product called Aqua-Barrier (Aqua Barrier International Limited) is based on a modular design and is portable and easy to deploy. It employs a linkage system that forms a watertight seal when in contact with water. However, the barrier requires in situ preparation in the form of bolts in the ground, and requires a considerable workforce to move the units into place.
[0014] GB-A-0600582 (Rowbotham) was concerned with the problem of flood protection and aimed to improve on simple banks of earth or other loose spoil which were stated not only to be laborious to construct but also to require time for settlement before they were fit for use. The proposed solution was to provide prefabricated segments which were capable of being assembled to form a bank and/or to be moved so as to enable an existing bank to be rapidly and easily re-erected on a new site. The prefabricated segments were of molded concrete and each comprised a base, a front, and two side walls, each of the side walls being formed on its outer face with a shoulder which extended from the crown to the base of the segment. One of the shoulders was arranged to face forwardly of the segment whereas the other shoulder was arranged to face rearward of the said segment. Thus by arranging a number of the segments in side-by-side relationship with their fronts in alignment, the rearward facing shoulder of each segment overlapped the forwardly facing shoulder of an adjoining segment, and a substantially watertight barrier was easily and quickly erected.
[0015] GB-A-2269618 (Tavner) disclosed a temporary anti-flood barrier comprising a water-filled wall formed by a combination of standard segments each consisting of a box section rectangular body of resilient rubber. The water filled wall was stabilized by fins built into the wall segments and by metal ribs and brackets externally on either side of the segments. A rubber under-mat formed an underseal. The wall was filled e.g. with mains water that flowed from segment to segment via water connector tubes.
[0016] GB-A-2364730 (Stuart) disclosed a portable flood barrier comprising a plurality of interlocking rubber panel segments held together at their ends by means of male/female connectors and locking arms that lock ed on to studs provided on an adjacent segment. The flood barrier was held in position by suction pads provided at the base of the segments and held in a vertical orientation by means of bracing arms.
[0017] GB-A-2397606 (Edler) disclosed a movable flood barrier comprising a watertight wall, a tank connected to the wall and an inlet in the tank for receiving water. The inlet and at least a portion of the tank were located below the top of the watertight wall. The tank could form an integral part of the wall such that the flood barrier had a substantially triangular cross-section. The base of the tank could be formed from reinforced sheeting which molded to the surface on which the tank is positioned. An air vent 4 and 5 may be provided above the level of the inlet to allow air to escape from the tank as flood water enters the tank though the inlet. Either end of the wall may be provided with means ( 14 and 17 , FIG. 3 ) to connect water tightly to the end of another removable flood barrier.
[0018] GB-A-2398331 (Drury) disclosed a flood barrier unit comprising a tank formed of resilient material and having opposed front and rear walls with adjoining side walls and a base. The front wall had one or more openings at a low level to permit the inflow of water while the rear and side walls were watertight. The side walls were also shaped to co-operate with a side wall of another such unit to assist in forming a watertight seal. The base was elastic and/or flexible to conform closely to the ground under the loading provided by water in the tank. The tank could be formed as a prismatic shape with trapezoidal or triangular side walls narrower at the top than at the base. Each side wall could have a protruding section such as a generally upright corrugation or rib or a complementary recess to receive such a section.
[0019] U.S. Pat. No. 5,623,573 (Baker) disclosed a wall-like structure for flood protection, swimming pools, watering ponds for animals or other water containment purposes made of wedge-shaped plastics segments that could be coupled together to make a dam or supporting wall for containment of liquids and which found their weight by filling with water or other liquid.
[0020] US-A-2004/0190993 (Archer-Simms et al; see also WO 02/011154) disclosed a liquid barrier assembly for the prevention of flow of liquid from one area to an adjacent area The assembly comprised a plurality of hollow segments each of a plastics material e.g. polyethylene or polypropylene and each defining a substantially rigid chamber. Each segment was formed with a front concave wall against which, in use, liquid was intended to be incident. The front wall of at least one of the segments had a plurality of apertures that allowed the passage of liquid into and out of the chamber. Adjacent segments were corrected to one another in a side by side relationship by an elongate connector of bilobal or “dog-bone” section.
SUMMARY OF THE INVENTION
[0021] The present invention provides a modular flood barrier that can protect households or premises from flood damage. It is simple and easy for users to assemble and can be used in a number of scenarios. No in situ preparation is required, the barrier being formed as units connected by slide-in keys to create a flexible watertight barrier. In an embodiment, the units have been designed to nest together, one upside down on the other, to minimize storage space when not in use.
[0022] In one aspect, the invention provides a flood or other water barrier comprising hollow self-filling units placed end-to-end and connected at their ends by keys inserted into sockets at the ends of the units, wherein the keys incorporate ballast for negative buoyancy.
[0023] The invention also provides a set or kit of units and keys for forming a water barrier as aforesaid.
[0024] The invention further provides, for use in a barrier as aforesaid, a bilobal downwardly tapered key defined by a hollow plastics body filled with concrete or other ballast.
[0025] The invention yet further provides, for use in a barrier as aforesaid, a self-filling hollow plastics barrier unit having ends for abutment with ends of adjoining units to form a barrier, the ends being formed with downwardly tapering sockets for receiving interconnection keys.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] How the invention may be put into effect will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0027] FIG. 1 is a view showing major components of a flood barrier or device for holding a body of water according to the invention;
[0028] FIG. 2 is front oblique view of a straight modular unit for forming part of the flood barrier, FIG. 3 shows the unit in plan view and FIG. 4 is a view of the unit from one side and from below;
[0029] FIGS. 5 and 6 are front and oblique views of a key for fastening together units of the flood barrier;
[0030] FIG. 7 is an exploded view showing the major components of the key;
[0031] FIG. 8 shows part of an assembled barrier; and
[0032] FIG. 9 shows straight modular units for a second embodiment of the barrier of greater overall height.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] FIG. 1 is a general view of the major components that may be used to form a flood barrier according to the invention. These include a straight modular unit 10 shown in front and rear oblique views, a shorter or “spanning” modular unit 12 , an inwardly-facing curved modular unit, an outwardly-facing curved modular unit 16 and a tapered universal key 18 for connecting adjacent units together. The units may be assembled together end-to-end to create a barrier to water ingress e.g. as a flood defense, for water containment e.g. to create a pool or pond and as a linear barrier e.g. to span a gap in a wall, in the latter case a small number of sandbags being used to provide a water-tight connection at either end of the barrier.
[0034] In one embodiment, which will be described in detail below, the barrier has a height of 500 mm, but it will be appreciated that other dimensions are possible, e.g. an overall height of 1 meter.
[0035] The modular units used in the present flood barrier may be made of molded plastics, rotational molding being a convenient process for articles such as the modular units used for the present barrier. In rotational molding, a pre-determined quantity of polymer powder is placed into a mould. With the powder loaded, the mould is closed, locked and loaded into an oven. Once inside the oven, the mould is rotated around two axes, tumbling the powder. The process is not centrifugal one and speeds of rotation are relatively slow, typically less than 20 rev/min. As the mould becomes hotter the powder begins to melt and stick to the inner walls of the mould, and melting of the powder gradually builds up an even coating over the entire surface. When the melt has been consolidated to the desired level, the mould may be cooled either by air, water or a combination of both, and the polymer solidifies to the desired shape, in this instance of a modular unit. When the polymer has cooled sufficiently to retain its shape and be easily handled, the mould can be opened and the modular unit can be removed. At this point powder can once again be placed in the mould and the cycle repeated. Materials which can be molded in this way include polyethylene, polypropylene, EVA and PVC, although for present purposes HDPE is preferred on the grounds of high stiffness, toughness and scratch resistance e.g. Icorene, available from ICO polymers. Although rotational molding is a preferred route, other techniques e.g. blow molding may also be used.
[0036] Straight modular units 10 when viewed from the front may have an aspect ratio of about 2, their height being about 500 mm, their length being about 1000 mm and their wall thickness about 7 mm. The depth of the units approximately equals their height, in this instance also being 500 mm. The units each have a front wall 20 which slopes rearward at about 10° to the vertical and pairs of front and rear sidewalls 22 , 24 each facing oppositely at about 4° to that front-to-back direction so as to give each sidewall in plan a slight protruding lozenge shape. With this shape, when adjoining units abut, the angle between them can be angularly adjusted within a small range of travel, in this instance ±4° to allow the barrier to follow a height contour in land. At the junction of sidewalls 22 , 24 , there are provided passageways 30 , 32 leading to sockets 26 , 28 tapering downwardly at a small acute angle, the angle of taper in this embodiment being 1.6°. The walls defining passageway 30 are in this embodiment parallel, whereas those in passageway 30 diverge in the direction of the side of the unit so as to permit a key inserted therein to be rotated through the above indicated small angular range of travel, in this instance ±4°. The rear of the unit is formed with a recess defining a horizontal ledge 34 for placement of local ballast e.g. a sandbag if required by flood conditions. Openings or self-filling holes 36 adjacent the base of front wall 20 and air release holes 38 at the top or crest of the unit admit water to the unit, so that as flood conditions are encountered, the water enters the unit and acts as ballast. FIG. 4 shows the sealing arrangements that are provided at the underside of the unit and that include a flexible front seal 40 of e.g. rubber matting about 3 mm thick and front and rear bottom seals 42 , 44 spaced apart along the front and rear edges of the unit as shown and formed of a foamed material conveniently about 40 mm in height and e.g. of foamed NBR/PVC (Tec-O-Cel 400 low density sealing material available from Foam and Rubber Products lip of Wellingborough, Northants, UK). It will be understood that other foamed plastics materials e.g. a closed cell polyurethane foam may be used. The weight of the unit conforms the foam of the bottom seals 42 , 44 to the contours of the ground and the flexible rubber seal 40 redirects flow of flood water to the self-filling holes 36 rather than to the bottom seals 40 , 42 . The front seal 40 and the bottom seals 42 , 44 may be adhered to the polyethylene body of the unit by means of double-sided water-resistant adhesive tape or by an adhesive or cement known in the art. The front seal 40 is formed with holes by which it may be pegged down in soft ground. The internal volume of the unit is approximately 0.1 m 3 and its weight when not filled with any water is about 21 kg which is sufficiently low for the unit to be carried easily. In the example shown, the front edge has two self-filling holes 36 which can double as carrying handles.
[0037] The spanning modular units 12 and the inner and outer modular units 14 and 16 are similarly constructed, but of somewhat smaller overall dimensions and weight. The inner modular units have a convex front wall and the outer modular units have a concave front wall as shown.
[0038] The modular units do not themselves incorporate ballast and can therefore be manhandled by a single individual or in the case of larger units by a pair of individuals. Minimal ballast is required because the units are provided with internal cavities that can become filled with rising floodwater through the self-filling holes 36 , which as previously explained double as handles.
[0039] Components of the tapered key are shown in more detail in FIG. 4 . The key is based on a generally bi-lobal body 46 which is conveniently a rotational molding in HDPE of 3 mm wall thickness and has a relatively small straight central region 48 and tapered lobes 50 , 52 for fitting into the sockets of adjacent units so as to interconnect them. A closed cell foam overmolding 54 e.g. of phenolic resin and of thickness e.g. about 5 mm is formed on and becomes strongly adhered to the exterior face of the key to give a watertight seal within the sockets of the modular units. Phenolic foam acts as a gasket but more importantly has good wear resistance, which is desirable as the keys may be used for assembly on a number of occasions. Concrete 53 is then poured into the body 46 , after which handle 56 is set into it, giving a combined weight for the completed key of about 23 kg. The keys not only provide interconnection between the modular units of the barrier, but also they provide ballast so that the barrier as a whole has negative buoyancy and is not displaced by at least moderate speeds of flood water without the need for additional sandbags or the like. The further the keys are pushed into the sockets in the units that they are to connect, the stronger and more watertight the join that they make. Carrying and assembly/removal of the keys is facilitated by the built-in handle 56 .
[0040] A flood barrier is readily assembled, as shown in FIG. 8 , by positioning modular units end to end and connecting them with the keys described and in the present embodiment should be able to accommodate irregularities in ground contour of ±30 mm in height, though greater contour irregularities could be handled using thicker bottom seals 42 , 44 . If the flow of the flood is greater than 0.5 m/s extra ballast will need to be applied to the modular unit ledges 34 . This can be in the form of anything to hand e.g. sandbags, sand, rubble etc. For example one or more sandbags or other local ballast may be placed on the ledge 34 of each unit. In real-life situations, it is uncommon for flood flows to be greater than 0.5 m/s, but this can happen e.g. when protecting against sea/tidal flooding, in which case the above mentioned additional ballast may be needed. The units of the barrier have approximately neutral buoyancy but when assembled using the concrete-filled keys the barrier as a whole is heavier than water and resists flood water through the weight of the concrete keys and the weight and mass of the water that fills each unit as the flood level rises. The barrier may be further weighted, as described above, to withstand faster-moving flood water.
[0041] Embodiments of the barrier have the features that they are
Highly functional Assembled using only a small amount of manpower, and without extensive training Easy and rapid to assemble Useful on ground not previously prepared Flexible and able to match varying ground contours Inexpensive Formed of units that can nest together to assist storage. For example, in the case of the 500 mm high embodiment described above a 7.5 ton box van of load space dimensions 6 m×2.3 m×2.2.m can carry 240 of the straight modular units for transit.
[0049] The invention is applicable for a range of purposes in addition to flood protection, including containment of fluids, temporary containment for fish, containment of a cleansing pool for disease prevention, containment of a paddling pool, containment of sewage or toxic spills.
[0050] Various modifications may be made to the embodiment described herein without departing from the invention. For example, the body 46 could be extended upwardly to provide built-in handles, in which case the key after insertion could be filled locally with earth, stones or other locally available ballast. However this construction is not presently preferred because it would add to the work involved in erecting the barrier. FIGS. 9 a and 9 b are views of modular units for a barrier 1 meter high according to a second embodiment of the invention. Apart from their block-like shape to withstand the forces from the greater depth of flood water and increase the weight of water that enters the unit by the self-filling mechanism, they are essentially similar to the modular units of the previous embodiment and may be assembled and used in a similar way. Like the units of the previous embodiment, they each incorporate a shelf for placement thereon of a sandbag or other local ballast. The air release holes are located at the top of the each front face of each unit which allows the units to be stacked as well as assembled side by side, or to allow the lighter 500 mm units of the earlier embodiment to be stacked thereon giving barrier heights of 1.5 meters or 2 meters. | A flood barrier comprises hollow self-filling units ( 10, 12, 14, 16 ) placed end-to-end and connected at their ends by downwardly tapered bilobal ( 46 ) keys inserted into sockets ( 26, 28 ) at the ends of the units, wherein the keys incorporate concrete or other ballast for negative buoyancy. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
FIELD OF THE INVENTION
[0003] The present invention relates generally to an apparatus, such as a shooting bench, for shooting a firearm, taking photographs with a camera, or watching nature with an optical instrument such as binoculars or a telescope. More specifically, the invention concerns to an elevation adjustment mechanism that allows the user to quickly acquire a target with a firearm, camera or optical instrument.
BACKGROUND OF THE INVENTION
[0004] An apparatus to stabilize and aim a device is often used by marksman to improve their shooting accuracy, by photographers to obtain a desired photograph and by nature lovers to see an elusive animal. One example of such an apparatus is a shooting bench. In order to change the line of sight or aim of the device being supported by the apparatus, a means for changing the position of the device is required.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention is directed towards an elevation adjustment mechanism which has a mechanism for coarsely aiming a device that comprises a coarse adjustment lever, a coarse adjustment rod and a clamping assembly. The coarse adjustment mechanism is constructed and arranged so that depression of the coarse adjustment lever lifts the clamping assembly away from the coarse adjustment rod thereby allowing the user to translate the coarse adjustment rod and to adjust the aim of the device.
[0006] The invention is also directed towards elevation adjustment mechanism comprising a housing, a coarse adjustment lever, a coarse adjustment rod, a clamping assembly, a fine adjustment washer, a fine adjustment nut and a fine adjustment rod. The housing is comprised of a sleeve and a ram cylinder. The sleeve and the ram cylinder are hollow tubes with at least a portion of the sleeve being disposed within the ram cylinder. The coarse adjustment rod has a first portion extending into a first end of the housing so that the housing encircles at least a portion of the coarse adjustment rod. The clamping assembly is engaged to the coarse adjustment lever which is engaged to the housing. The clamping assembly is positioned at least partially within an opening defined by the housing so that it is releasably engaged to a portion of the coarse adjustment rod disposed within the housing. In some embodiments, the fine adjustment washer is slipped onto one end of the sleeve and the fine adjustment nut is slipped onto the other end of the sleeve before being engaged to one another and to the sleeve. In other embodiments, the fine adjustment nut is engaged to the sleeve by set screws. The fine adjustment rod has a first portion that extends through an end of the sleeve and a second portion that is disposed within the sleeve.
[0007] In at least one embodiment, the invention is directed towards an apparatus, such as a shooting bench for example, that supports a device such as a firearm, a camera, or an optical device and that has an elevation adjustment mechanism to aim the device. The apparatus comprises a vertical support member, at least one leg, a platform to support a device such as a firearm, camera or binoculars, and an elevation adjustment mechanism. A portion of the at least one leg and a portion of the platform is engaged to the vertical support member. A portion of the elevation adjustment mechanism is engaged to a portion of the vertical support member and a portion of the elevation adjustment mechanism is engaged to a portion of the platform. The elevation adjustment mechanism is constructed and arranged to adjust the pitch rotation of the platform, thereby adjusting the pitch rotation of the device supported by the platform. The elevation adjustment mechanism comprises a mechanism for coarsely adjusting the pitch rotation comprising a lever actuated clamping assembly, and a mechanism for finely adjusting the pitch rotation comprising a threaded rod mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a view of an elevation adjustment mechanism.
[0009] FIG. 2 is an exploded view of an embodiment of the elevation adjustment mechanism of FIG. 1 .
[0010] FIG. 3 is a view of the sleeve and the ram cylinder.
[0011] FIG. 4 is an exploded view of another embodiment of the elevation adjustment mechanism of FIG. 1 .
[0012] FIG. 5 is the elevation adjustment mechanism, engaged to a platform and a vertical support of a bench, that has a single rod for both the coarse adjustment mechanism and the fine adjustment mechanism.
[0013] FIG. 6 is a view of a bench with the elevation adjustment mechanism of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0014] While this invention may be embodied in many forms, there are described in detail herein specific embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.
[0015] For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated.
[0016] FIG. 1 is a side view of an elevation adjustment mechanism 10 that has a coarse adjustment mechanism 16 and a fine adjustment mechanism 22 . As shown in the figures, portions of both the coarse adjustment mechanism 16 and the fine adjustment mechanism 22 are disposed within a housing 12 . In some embodiments, the housing 12 comprises a sleeve 13 and a ram cylinder 14 , shown in FIG. 3 . At least a portion of the sleeve 13 is disposed within the ram cylinder 14 . Thus, the diameter of the sleeve 13 is smaller than the diameter of the ram cylinder 14 . When the sleeve 13 is disposed within the ram cylinder 14 , the sleeve 13 and the ram cylinder 14 are engaged to one another by any means, including, but not limited to, screws. In other embodiments, the housing 12 is a single cylinder, the ram cylinder 14 .
[0017] In at least one embodiment, the coarse adjustment mechanism 16 is a linear slide mechanism. In this embodiment, the coarse adjustment mechanism 16 comprises a coarse adjustment lever 18 , a coarse adjustment rod 20 and a clamping assembly 34 . It is within the scope of the invention for the coarse adjustment rod 20 to have any length and diameter. In some embodiments, the coarse adjustment rod 20 is a threaded rod. In other embodiments, the coarse adjustment rod 20 is a smooth rod. It is within the scope of the invention for the clamping assembly 34 to be any means that releasably engages the coarse adjustment rod 20 . In some embodiments, the clamping assembly 34 is a half-nut assembly. In other embodiments, the clamping assembly 34 is a half-cylinder. Note that the clamping assembly 34 has a configuration that is complementary to the configuration of the coarse adjustment rod 20 so that the clamping assembly 34 can releasably engage the coarse adjustment rod 20 .
[0018] In some embodiments, the coarse adjustment mechanism 16 comprises a clamping assembly 34 that is a half-nut assembly and a coarse adjustment rod 20 that is a threaded rod. In other embodiments, the coarse adjustment mechanism 16 comprises a clamping assembly 34 that is a half-cylinder and a coarse adjustment rod 20 that is a smooth rod. Both of these embodiments have the configuration shown in FIG. 1 . In some embodiments, the clamping assembly 34 is a half-cylinder which is not threaded and which is lined with a high friction material. In other embodiments, the clamping assembly 34 is made of a high friction material. In at least one embodiment, the materials used to make the smooth rod and the half-cylinder provide adequate friction in order to eliminate translation of the smooth rod once the half-cylinder is engaged with the smooth rod. Examples of high friction material, include, but are not limited to, elastomer rubber compounds such as nitrile, silicone, neoprene, viton, and ethylene propylene diene monomer rubber (EPDM). In this embodiment, sufficient spring force on the coarse adjustment lever provides quick coarse adjustment.
[0019] As shown in FIGS. 2 and 4 , in some embodiments, one end of the coarse adjustment rod 20 is engaged to a clevis mount 32 by a cap screw 30 b . Thus, in this embodiment, end of the coarse adjustment rod 20 engaged to the clevis mount 32 has a threaded opening for the cap screw 30 b . The other end of the coarse adjustment rod 20 is within the housing 12 of the elevation adjustment mechanism 10 . Thus, at least a portion of the coarse adjustment rod 20 is disposed within the housing 12 . The coarse adjustment lever 18 is engaged to a clamping assembly 34 by a cap screw 30 a . In this embodiment, the coarse adjustment lever 18 is releasably engaged to the coarse adjustment rod 20 by the clamping assembly 34 . The coarse adjustment lever 18 is engaged to the ram cylinder 14 of the housing 12 by a spring 40 and by a mounting assembly 46 . In some embodiments, the clamping assembly 34 engages the coarse adjustment rod 20 through an opening in the housing 12 . As shown in FIG. 3 , the opening in the housing 12 is comprised of an opening in the sleeve 13 that is aligned with an opening in the ram cylinder 14 when the sleeve 13 is disposed within the ram cylinder 14 .
[0020] In other embodiments, the clamping assembly 34 engages the coarse adjustment rod 20 adjacent to the housing 12 . Note that any distance can separate the side of the clamping assembly 34 from the side of the housing 12 so long as the movement of the clamping assembly 34 , e.g. when the coarse adjustment lever 18 is depressed, is not hindered by contact with the housing 12 . In this embodiment, an interface guides the interaction between the coarse adjustment rod 20 and the clamping assembly 34 .
[0021] FIGS. 2 and 4 are views of the component parts of the elevation adjustment mechanism 10 of FIG. 1 showing two different methods of engaging the fine adjustment mechanism 22 to the housing 12 . In at least one embodiment, the fine adjustment mechanism 22 is a threaded mechanism. In this embodiment, the fine adjustment mechanism 22 comprises a fine adjustment rod assembly 24 , a fine adjustment nut 26 and a fine adjustment washer 28 , as shown in FIG. 2 . In one embodiment, the fine adjustment washer 28 and the fine adjustment nut 26 are slipped over opposite ends of the sleeve 13 and engaged to one another by cap screws 30 d , as discussed in greater detail below. The fine adjustment rod 24 extends through the end of the sleeve 13 so that a first portion of the fine adjustment rod 24 is disposed within the sleeve 13 of the housing 12 and a second portion of the fine adjustment rod 24 extends from the sleeve 13 . In some embodiments, the second portion is engaged to a platform 108 , as discussed in greater detail below. It is within the scope of the invention for the fine adjustment rod 24 to have any length and any diameter. In some embodiments, the fine adjustment mechanism 22 has zero backlash adjustability. In one embodiment, tapered pin guides for the screws 42 provide the zero backlash adjustability.
[0022] An alternative manner of engaging the fine adjustment mechanism 22 to the ram cylinder 14 is shown in FIG. 4 . In this embodiment, the fine adjustment nut 26 is engaged to the ram cylinder 14 by set screws 42 . It is within the scope of the invention for two or more set screws 42 engage the fine adjustment nut 26 to the ram cylinder 14 . Thus, there can be two, three, four, five, six, seven, eight or more set screws 42 . Note that except for the manner of engaging the fine adjustment nut 26 to the ram cylinder 14 , the other aspects of the elevation adjustment mechanism 10 are the same as in FIG. 2 .
[0023] Assembly of the elevation adjustment mechanism 10 shown in FIG. 2 is as follows: First the fine adjustment rod assembly 24 is inserted into the proximal opening of sleeve 13 so that it exits through the distal opening of the sleeve 13 . The fine adjustment nut 26 is threaded onto the fine adjustment rod 24 from the right or distal end of the fine adjustment rod 24 and the fine adjustment washer 28 is slid over the sleeve 13 from the left or proximal end until the fine adjustment nut 26 and the fine adjustment washer 28 are side by side at the right or distal end of the fine adjustment rod 24 . Note that the diameter of the distal end region of the sleeve 13 has a first diameter and a second diameter. The first diameter is greater than the second diameter and both diameters are greater than the diameter of the rest of the sleeve 13 . Thus, the first diameter corresponds to the diameter of the fine adjustment nut 26 and the second diameter corresponds to the diameter of the fine adjustment washer. The fine adjustment washer 28 and the fine adjustment nut 26 are then engaged to one another. Note that because the second diameter is less than the first diameter, the position of the fine adjustment washer 28 and the fine adjustment nut 26 is maintained. In one embodiment, cap screws 30 are used to engaged the fine adjustment washer 28 and the fine adjustment nut 26 together.
[0024] Then the proximal end of the sleeve 13 /fine adjustment mechanism 24 is inserted into the distal opening of the ram cylinder 14 , as shown in FIG. 3 . The sleeve 13 and the ram cylinder 14 are engaged to one another. In some embodiments, set screws 42 engage the sleeve 13 and the ram cylinder 14 together, as shown in FIG. 1 for example. Spring 40 is inserted into a relief in the ram cylinder 14 then the clamping assembly 34 and coarse adjustment lever 18 are engaged to each other and to the ram assembly 14 with cap screws 30 a,c and washers 38 and/or hex nuts 44 . Then the coarse adjustment lever 18 is engaged and the proximal end of the housing 12 is slid over the coarse adjustment rod 20 .
[0025] Assembly of the elevation adjustment mechanism 10 shown in FIG. 4 is as follows: First the fine adjustment rod assembly 24 is inserted into the proximal opening of sleeve 13 so that it exits through the distal opening of the sleeve 13 . The fine adjustment nut 26 is threaded onto the fine adjustment rod 24 from the proximal end of the fine adjustment rod 24 so that a portion of the fine adjustment nut 26 is disposed about an end region of the sleeve 13 . Then the fine adjustment nut 26 is engaged to the sleeve 13 . Then the proximal end of the sleeve 13 /fine adjustment mechanism 24 is inserted into the distal opening of the ram cylinder 14 . Assembly of the rest of the elevation adjustment mechanism 10 proceeds as described above.
[0026] In at least one embodiment, the coarse adjustment mechanism 16 changes the pointing elevation, i.e. rotation about a horizontal pivot, otherwise known as the pitch, +/−20 degrees from horizontal. In some embodiments, the coarse adjustment mechanism 16 has a pointing resolution of approximately 1.0 degree. In at least one embodiment, the fine adjustment mechanism 22 , provides precision elevation alignment, either upwards or downwards. In some embodiments, the precision elevation alignment of the fine adjustment mechanism 22 is infinite.
[0027] In at least one embodiment, the elevation adjustment mechanism 10 has a combined fine and coarse adjustment mechanisms 16 , 22 with one threaded rod 20 , 24 used for both the fine adjustment mechanism 22 and coarse adjustment mechanism 16 of the elevation adjustment mechanism 10 , as shown in FIG. 5 . Thus, in this embodiment, the fine adjustment rod 24 and the coarse adjustment rod 20 are different regions of a single rod 20 , 24 . It is within the scope of the invention for the rod 20 , 24 to have any length and any diameter. In addition, it is within the scope of the invention for the different regions of the single rod 20 , 24 , i.e. the coarse adjustment rod 16 and the fine adjustment rod 24 , to have the same length or different lengths. In some embodiments, the clevis mount 32 forms a part of the housing 12 , as shown in FIG. 5 .
[0028] As shown, for example, in FIG. 6 , in at least one embodiment, the elevation adjustment mechanism 10 is engaged to a bench 100 . In some embodiments, the elevation adjustment mechanism 10 is engaged to a vertical shaft 104 of a bench 100 and to the platform 108 of a bench 100 . It is within the scope of the invention for the elevation adjustment mechanism 10 to be engaged to the bench 100 in any manner, for example, but not limited to, a clevis mount 32 , a yoke, or other mounting configuration.
[0029] A non-limiting example of an apparatus to which the inventive elevation adjustment mechanism 10 can be engaged is the bench 100 , shown in FIG. 6 . The bench 100 has legs 102 , a vertical shaft 104 to which a seat 106 is engaged, a platform 108 and an elevation adjustment mechanism 10 . One portion of the elevation adjustment mechanism 10 is engaged to the vertical shaft 104 and a second portion of the elevation adjustment mechanism 10 is engaged to the platform 108 . It is within the scope of the invention for the elevation adjustment mechanism 10 to be engaged to the bench 100 by a clevis mount 32 , yoke and/or other mounting configuration. Thus, the two portions of the elevation adjustment mechanism 10 , e.g. the coarse adjustment rod 20 and the fine adjustment rod 24 , can be engaged in the same manner, e.g. a clevis mount 32 , or in different manners.
[0030] In at least one embodiment, the seat 106 rotates 360 degrees about the vertical shaft 104 . It is within the scope of the invention for the platform 108 to support any device, for example, but not limited to, a weapon, a camera, or an optical device. Examples of optical devices include, but are not limited to, monoculars, binoculars, and telescopes. As shown in FIG. 6 , the platform 108 is configured to support a firearm. In at least one embodiment, the platform 108 rotates 360 degrees. In some embodiments, the seat 106 and the platform 108 move in unison. In other embodiments, the seat 106 and the platform 108 move independently.
[0031] To adjust the platform 108 , and thereby adjust the device supported by the platform 108 , the user pushes down on the coarse adjustment lever 18 so that the coarse adjustment lever 18 moves closer to the ram cylinder 14 of the housing 12 . In this movement the spring 40 is compressed and the clamping assembly 34 is raised away from the coarse adjustment rod 20 as the coarse adjustment lever 18 pivots about the cap screw 30 c which engages the coarse adjustment lever 18 to the mounting assembly 46 . The cap screw 30 c is kept in position by a hex nut 44 , as shown in FIG. 2 . When the clamping assembly 34 is away from the coarse adjustment rod 20 , the coarse adjustment rod 20 can be moved into or out of the housing 12 . When the coarse adjustment rod 20 is moved into the housing 12 the platform 108 pivots vertically downwards. When the coarse adjustment rod 20 is moved out of the housing 12 , the platform 108 pivots vertically upwards. After the coarse adjustment mechanism 16 has been set to the desired position, the fine adjustment mechanism 22 can be used for precise positioning of the platform 108 , upwards or downwards. Thus, adjustment of the platform 108 by the elevation adjustment mechanism 10 allows the user to adjust the aim/line of sight of the device upwards or downwards and rotation of the platform 108 about the vertical shaft 104 of the bench 100 allows the user to adjust the aim/line of sight of the device about a vertical axis, otherwise known as yaw. | The invention is directed towards an elevation adjustment mechanism which has a mechanism for coarsely adjusting the pitch rotation comprising a lever actuated clamping assembly and a mechanism for finely adjusting the pitch rotation comprising a threaded rod mechanism. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention The present invention relates to a device for a motorized shutter assembly, particularly a louver blade positioning device of a motorized shutter assembly.
[0002] 2. Description of the Prior Art
[0003] Referring to FIG. 1A , a conventional motorized shutter assembly 11 primarily includes a plurality of louver blades 13 and a push rod 12 driven by a motorized module 10 in order to drive the plurality of louver blades 13 in linkages and to adjust an angle of louver blades in a motorized manner through a remote control 101 .
[0004] Referring to FIG. 1B , the motorized module 10 includes a motor 102 and a transmission mechanism 103 to drive in reversible movement of the louver blades 13 through a driving shaft 104 . In addition to motorized operations, ordinary motorized shutter assembly can be manually operated by pushing the push rod 12 in order to adjust an angle of louver blades as shown in FIGS. 1C and 1D . However, when one manually pushing the push rod 12 upward to close the plurality of louver blades 13 , the louver blades 13 become titled toward Position “b” from the manually closed Position “a” due to the dead weight in response to the weight of the louver blades 13 and the push rod 12 and/or the clearance inherent between elements of the transmission mechanism in the motorized module 10 as shown in FIG. 1D . Consequently, this causes the disadvantage of unsatisfactory manual closure. Moreover, during motorized operations, several sets of motorized shutters may encounter an angular variance under the same control command possibly due to the clearance among the elements.
SUMMARY OF THE INVENTION
[0005] The object of the present invention is to provide a louver blade positioning device of a motorized shutter assembly, such that the louver blades can be effectively positioned at a specific angle, for example, full-closed or at a specific angle as desired.
[0006] The present invention provides a louver blade positioning device of a motorized shutter assembly, including an indented positioning portion or a protruded portion formed upon a driving shaft for driving louver blades and a resilient member formed on a suitable position of the shutter assembly. The predetermined portion of the resilient member moves toward the driving shaft and is inserted into the indented positioning portion or the protruded portion when the louver blades connected to the driving shaft are rotated to approach a specific angle. Through the resilient force exerted by the resilient member on the indented positioning portion or the protruded portion, the driving shaft rotates to approach a specific angle, such that the louver blades are rotated automatically toward a predetermined angle and become positioned when being rotated to approach the angle, thereby becoming free from the angular clearance among transmission components of the motorized shutter assembly.
[0007] The advantage of the present invention is that the louver blades of the louver blade positioning device of the motorized shutter assembly made according to the present invention can automatically be positioned at a specific angle through manual or electrical operations in order to become free from the clearance between the motor and the transmission mechanism. In this way, the louver blades are manually closed tightly or a plurality of louver blades of the motorized shutter assembly is easily positioned at a consistent, specific angle under motorized or manual operations.
[0008] Further scope of the applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCIPTION OF THE DRAWINGS
[0009] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein.
[0010] FIG. 1A shows a schematic perspective view of a conventional louver blade positioning device of the motorized shutter assembly.
[0011] FIG. 1B is a schematic view illustrating the structure of the motorized module capable of adjusting louver blades made according to FIG. 1A .
[0012] FIG. 1C and FIG. 1D are schematic views illustrating the adjusting performance of the louver blade of the motorized module made according to FIG. 1A .
[0013] FIG. 2 is a structural view illustrating a first embodiment of the resilient member made according to the present invention.
[0014] FIG. 3 illustrates a perspective view of a driving shaft made according to FIG. 2 .
[0015] FIGS. 4A and 4B are schematic views illustrating the structure and the function of a resilient member made according to a first embodiment of the present invention.
[0016] FIG. 5A to FIG. 5E illustrate different configurations of an elastic element and an inserted element of the resilient member made according to the first embodiment of the present invention.
[0017] FIG. 6A is a view illustrating a resilient member made according to a second embodiment of the present invention.
[0018] FIG. 6B and FIG. 6C are schematic views illustrating the structure and the function of a resilient member made according to the second embodiment of the present invention.
[0019] FIG. 7A is another embodiment illustrating variations of an elastic element in the resilient member made according to the second embodiment of the present invention.
[0020] FIG. 7B and FIG. 7C are schematic views illustrating variations in the structure and the function of an elastic element in the resilient member made according to the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] As shown in FIG. 2 to FIG. 4B , they are schematic views illustrating the structure of a resilient member of a louver blade positioning device of a motorized shutter assembly according to the first embodiment of the present invention. A motorized module 10 of a shutter assembly 11 includes a first housing 21 and a second housing 22 coupled together, housing a transmission mechanism 23 , including a motor 231 and a gear 232 , as well as a driving shaft 24 therein. In conjunction with the driving shaft 24 , a louver blade 30 is driven to rotate. The motor 231 is a direct current, an alternating current or a stepper motor capable of reversible motions, such that the louver blade 30 rotates forward or backward accordingly. The transmission mechanism 23 , usually having a torque limiter or a clutch means (not shown in the drawing), facilitates the manual operations and rotations of the louver blade 30 , without damaging the motor 231 or the transmission mechanism 23 .
[0022] To adjust and restore the louver blade 30 and the driving shaft 24 to their respective original positions when approaching a specific angle, the driving shaft 24 of the present invention includes a shaft 242 , rotated and pivotally formed between the first housing 21 and the second housing 22 , with an end of the driving shaft 24 formed into a louver blade-connecting end 243 capable of connecting a louver blade to another louver blade. A gear 241 formed on an end of the shaft 242 engages with the transmission mechanism 23 . One (or more than one) indented positioning portion 41 is arranged and disposed on a circumference of the shaft 242 . A set of resilient members 50 , formed in a spring slot 53 of the second housing 22 , includes an elastic element 51 and an inserted element 52 . Constantly being pushed against the elastic member 51 , the inserted element 52 moves toward the shaft 242 but it only moves back and forth along a longitudinal axis of the spring slot 53 , without departing from the spring slot 53 .
[0023] In this embodiment, the elastic element 51 is in the form of a helical spring and the inserted element 52 is in the form of a bearing ball. The longitudinal axis of the spring slot 53 is perpendicular to an axis of the driving shaft 24 . A guided portion is an arc constituted on a surface of the bearing ball. The longitudinal axis of the spring slot 53 or the movement direction of the inserted element 52 is defined as an included angle not perpendicular (oblique) to an axis of the driving shaft 24 so as not to affect the desirably positioning of the driving shaft 24 at a specific angle.
[0024] Referring to FIG. 4A , a spring formed in the spring slot 53 pushes against the inserted element 52 such that the spring is exactly inserted into an indented positioning portion 41 of the driving shaft 24 , because the force F 0 perpendicularly exerted by the spring on the center of rotation of the driving shaft 24 fixes the driving shaft 24 at a predetermined angle.
[0025] When the driving shaft 24 rotates to approach the predetermined angle (for example, at the location shown in FIG. 4B ), the force F 0 exerted by the spring pushes against the inserted element 52 , such that the inserted element 52 comes into contact with a contact point 411 on an outer circumference of the driving shaft 24 close to the indented positioning portion 41 through an arc-shaped guided portion. The contact point 411 makes an angle of deflection with the force F 0 , such that the force F 0 produces a component of force F 1 , driving the driving shaft 24 to rotate and reach a stable positioning state as shown in FIG. 4A . In other words, when the driving shaft 24 rotates to approach the specify angle, the driving shaft 24 automatically becomes positioned.
[0026] FIGS. 5A to 5E illustrate variations of the resilient member made according to the present invention. The inserted element 52 is formed in the shape of a cone (thereby forming the guided portion with an inclined plane on a top thereof) as shown in FIG. 5A , while the indented positioning portion 41 has a square-shaped cross-section, while the inserted element 52 is a cuboid having a lead angle as shown in FIG. 5B . Referring to FIG. 5C , a plurality of the indented positioning portions 41 are formed upon the driving shaft 24 to create more fixed angles. Referring to FIG. 5D , the indented positioning portion 41 of the driving shaft 24 is constituted into a protruded part 244 such that the inserted element 52 is transformed into a shallow indented portion. Referring to FIG. 5E , the elastic element 51 and the inserted element 52 are formed into an oblique angle, thus forming an indented positioning portion 41 in conjunction with the driving shaft 24 .
[0027] FIG. 6A is a view illustrating a resilient member made according to a second embodiment of the present invention. The elastic element 51 of the resilient member 50 in the shape of a spring and the inserted element 52 integrated in the form of a protrusion on the spring respectively replace the spring and bearing ball in the previous embodiments. The spring is fixed on the first housing 21 at two ends thereof, to support the deformation under the operation of an external force as shown in FIG. 6A , thereby producing a force F 0 .
[0028] FIG. 6B and FIG. 6C are schematic views illustrating the function of a resilient member made according to the second embodiment of the present invention. In FIG. 6B , the protrusion on the spring exactly fits into the indented positioning portion 41 of the driving shaft 24 . Given the force F 0 acted upon by the protrusion perpendicular to the center of rotation of the driving shaft 24 , the driving shaft 24 is maintained at a steady state as soon as it rotates to a specific angle. When the driving shaft 24 rotates to approach to the specific angle (in the location as shown in FIG. 6C ), the force F 0 produces a component of force F 1 due to the force F 0 acted by the protrusion on a contact point 54 at a corner of the indented positioning portion 41 as well as the angle of deflection between the contact point 54 and the force F 0 . At that instant, the driving shaft 24 is made to rotate to approach to a stable positioning state as shown in FIG. 6B . In other words, when the driving shaft 24 rotates to approach a steady angle, the resilient member 50 forces the driving shaft 24 to continue rotating until it reaches a stable location for positioning.
[0029] FIG. 7A is another embodiment illustrating variations of an elastic element in the resilient member made according to the second embodiment of the present invention. In FIG. 7A , the elastic element 51 a of the resilient member 50 a in the shape of a spring and the inserted element 52 a integrated in the form of an indented opening on the spring, respectively replace the spring and the bearing ball as shown in the first embodiment. The spring is fixed on the first housing 21 at two ends thereof, in order to support the deformation under the operation of an external force as shown in FIG. 7A , thereby producing a force F 0 . The indented positioning portion 41 on a circumference of the driving shaft 24 is formed into a protrusion corresponding to the indentation.
[0030] FIG. 7B and FIG. 7C are schematic views illustrating variations in the function of an elastic element in the resilient member made according to the second embodiment of the present invention. In FIG. 7B , the inserted element 52 a on the spring exactly fits into the positioning portion 41 of the protruded part 244 of the driving shaft 24 . Given the force F 0 acted upon by the inserted element 52 a toward the center of rotation of the driving shaft 24 , the driving shaft 24 is steadily formed into a specific angle. When the driving shaft 24 rotates to approach to the specific angle (in the location as shown in FIG. 7C ), the force F 0 of the inserted element 52 a pushes against a contact point 54 a on a circumference of the driving shaft 24 near the positioning portion 41 . The contact point 54 a makes an angle of deflection with the force F 0 , such that the force F 0 produces a component of force F 1 , driving the driving shaft 24 to rotate and reach a stable positioning state as shown in FIG. 7C . In other words, when the driving shaft 24 rotates to approach the specify angle, the resilient member 50 a forces the driving shaft 24 to continue rotating to a steady location for positioning.
[0031] The present embodiment is formed into an indented positioning portion 41 or a protruded part 244 of a driving shaft 24 , such that the driving shaft 24 is horizontally extended. For practical applications, the driving shaft 24 is formed relative to more than two positioning portions with a predetermined angle with the axis of the driving shaft. For example, one angle makes the louver blade 30 in a closed position while another angle makes the louver blade 30 horizontally open. Given this structure, when the louver blade 30 is manually or electrically rotated to approach the specific angle, the louver blade 30 automatically approaches the specific angle and becomes positioned, thereby overcoming the drawback of having clearance between the motor and the transmission mechanism. In this way, the louver blade is maintained manually closed or a plurality of the louver blades of the motorized shutter assembly can easily become positioned at a specific angle by motorized or manual operations. The aforesaid positioning portion and the inserted element can be formed on a driving shaft (for example, the transmission mechanism) outside the driving shaft 24 . Moreover, the present invention can be applied for slats positioning of conventional blind products too.
[0032] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A louver blade positioning device of a motorized shutter assembly includes an indented positioning portion or a protruded portion formed upon a driving shaft and a resilient member coming into contact with the driving shaft and the indented positioning portion or the protruded portion in a radically movable manner at a fixed angle. When the louver blades are rotated to approach a specific angle, the resilient member moves into the indented positioning portion or the protruded portion. Through the resilient force exerted by the resilient member on the indented positioning portion or the protruded portion, the driving shaft rotates to approach the specific angle, such that the louver blades become positioned at the specific angle when being rotated to approach the specific angle, thereby becoming free from the angular clearance inherent among transmission components of the motorized shutter assembly. | 4 |
This is a continuation of application Ser. No. 07/793,418 filed Nov. 4, 1991, now U.S. Pat. No. 5,244,329.
TECHNICAL FIELD
The present invention relates to a pipe handling system, especially a new preferably electrically operated pipe handling system.
The invention also relates to a new type of fingerboard, especially for co-operating with an electrically driven preferably pipe-shaped pipe handling machine.
The invention also relates to a sidestep retraction system.
BACKGROUND OF THE INVENTION
The object of the invention is to provide an improvement in a pipe handling system. The object is achieved by the inventive features as defined in the appended claims and as described in the following.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view illustrating an embodiment of an arrangement in a pipe handling system according to the present invention.
FIGS. 2A and 2B are side views of a pipe handling machine included therein.
FIG. 3 is a top view of a pipe handling fingerboard included therein.
FIG. 4a illustrates a prior art fingerboard.
FIGS. 4b-4d illustrates alternative fingerboards according to the invention.
FIGS. 5a-5d depict the principle function of the pipe handling according to the present invention, i.e.:
FIG. 5a illustrates pipe handling machine grips pipe at well center.
FIG. 5b illustrates pipe handling arm retracted for bringing pipe into finger locking ring groove.
FIG. 5c illustrates pipe handling arm rotating to select finger.
FIG. 5d illustrates pipe handling arms extended for bringing pipe into fingers.
FIGS. 6a-6c are various views of the locking ring of the fingerboard according to the present invention.
FIGS. 7a-7d illustrate the principles of the operation of the sidestep retraction system according to the present invention.
FIG. 8 is a side view of a derrick equipped with a drill block in accordance with the invention, shown centrally placed over the drill pipe.
FIG. 9 is a side view where the drill block is retracted from the central position to have connected thereto additional drill pipe sections.
FIG. 10 shows the arrangement in same position as FIG. 9, but where the drill block and connected equipment are in upper position.
FIG. 11 shows the arrangement in plan view and horizontal section.
DESCRIPTION OF EMBODIMENTS
With reference to the enclosed drawings, various embodiments of the present invention and various concepts relating thereto, will be described.
The pipe handling system and the machine included therein will be built to fit into the derrick or rig floor design 1A. The main principles of the design are illustrated especially in FIGS. 1 and 2A and 2B.
The machine is based on a tower 1 built from for example 700 mm diameter pipe with two operating arms 2a, 2b built into the tower 1. This gives a very clean outside design. The tower 1 will be fixed in a position in the derrick and rig floor to handle all pipe operations between the well center--fingerboard--mouse hole.
The main load is taken on the rig floor. The pipe is handled by the two independently operated arms 2a, 2b, which may be compared with scissor arms.
The scissor arm principle used gives a horizontal in-out movement. This principle is easy to control with regard to position accuracy.
Using the scissor arm principle gives a very controlled extended reach. The forces imposed on the tower/arm/carriages are less than on other designs, by using this principle.
All drives are preferably based on A.C. motors with disc brakes driving through gear boxes, which operate on rack and pinion, driving the arms up and down--in and out. The A.C. motors are speed controlled by invertors. Proposed supplier of motor, brake, gear box, invertors is S.E.W. Eurodrive, using standard components. Using A.C. motor drives will give a controlled high speed and a very clean pipe handling machine (no hydraulic leaks).
The pipe handling machine is an independent unit not mechanically connected to the iron roughneck. This has caused problems in other designs including too much downtime due to units connected together. Prior designs also required the pipe handling and iron roughneck work to be carried out very close to the well center, creating the potential for clash problem in pipe handling with top drive/block. An independent unit, only connected together with the other machines through the control system, iron roughneck, and top drive is a better solution.
The upper and lower arms 2a, 2b are generally of the same design. They are, in the illustrated embodiment, not mechanically connected together, only electrically by the control system. The arms can be operated as independent arms if so required. They can operate at different angles of the pipe. (Other designs have problems with connected arms, as they can only be operated mechanically and are very limited).
A preferred embodiment may be based on a 5" pipe claw (3a) with 2 tons lift. The pipe handling machine is designed for high speed tripping of drillpipe. For handling drill collars the machine will only position the drill collars in the set-back using the drawworks to lift the load. This will give a faster pipe handling for more than 95% of the operating time.
Based on 2 tons lift at 2.5 m, it is estimated that the total weight of the machine with supports and fingerboard will be 14,403 Kg.
The claw design is based on a slip principle with an air operating cylinder. This is a fail-safe device. The load has to be removed before the slips can operate. Only the bottom claw 3a holds the load. The top claw 3b is only used to hold the pipe into position. A load cell is built into the pipe handling machine to give the operator and control system information on weight in the claw. The claws 3a, 3b will also have a sensor for sensing pipe inside claw.
The control system may be based on a Siemens robotic control system "SIROTEC RMC" and a "SIMATIC S 51354" for operator communication and interfacing with other systems (e.g., iron roughneck, fingerboard, top drive, block position, slips, etc.).
The pipe handling machine is designed to work in a robotic semiautomatic mode with one operator. The operator can also operate in a remote manual mode if so required. The control system is designed for high accuracy, high operating speed, high security--with very good control over interface between other systems.
Maintenance equipment has been considered by using standard motor/gear box/rack and pinion drives, so as to give the rig mechanics and electricians a rapid understanding of the equipment.
The design will reduce the number of personnel working close to the drill pipe 4P. The operator will have a very good communication with the driller. With all pipe positions programmable, the pipe handling controls are very easy to operate. This leads to less work and lower stress which, in turn, increases the safety and efficiency of the operation.
The overall design provides an improved automatic unit compared with existing pipe handling units which are in operation today. The present invention provides especially a favourable combination of electrical and mechanical equipment and control systems to make an effective automatic pipe tripping machine.
FIGS. 3-6 illustrate star fingerboard concept, in which the top element 4 includes fingers 4a, 4n which are all pointing towards the center of the pipe handling machine 1.
The reason for orientating the fingers 4a-4n in this manner, is to have the pipe handling machine 1 mounted in a fixed position with a minimum of movements, the machine 1 will turn around its "stationary" vertical axis of rotation 1c, and thus manoeuvre its arms 2a, 2b towards the well center or towards the actual finger, the arms 2a, 2b then being manoeuvered straight into and out of the pipe holding finger slots 4x.
The star fingerboard concept will fit into all types of derricks or masts and the benefits thereof can be listed as follows:
The star fingerboard concept allows a fixed position of the pipe handling machine 1.
A fixed position provides benefits as to:
a) Less movements, easy control
b) Slim design, due to less forces, less weight, less space
c) Faster and safer pipe handling
The star fingerboard 4 will give a good racking capacity.
Locking of fingers will be done very easily with a locking ring 4R around the top of the pipe handling tower 1.
d) The fingers 4a-4n will be strong with slim tips 4T and wide root 4Y.
e) The star fingerboard will also be easy to operate manually.
FIG. 4a illustrates a prior art fingerboard, in which a mobile unit or wagon 4M must be used for handling the pipes.
FIGS. 4b-4c illustrate various embodiments of fingerboards adapted to various pipe types and dimensions.
FIGS. 5a-5d depict the principle function of the pipe handling according to the present invention, i.e:
FIG. 5a illustrates pipe handling machine arm 2b gripping pipe 4P at well center.
FIG. 5b illustrates pipe handling arm retracted for bringing pipe 4P into finger locking ring groove 4G.
FIG. 5c illustrates pipe handling arm rotating to selected fingers or finger slot 4x.
FIG. 5d illustrates pipe handling arm 2b extended for bringing pipe 4P into fingers.
FIGS. 6a-6c illustrate details of a locking ring 4R.
In FIGS. 7-11 there is illustrated a sidestep retraction system which is designed for use with a top drive drilling system.
A top drive drilling system is functioning with a wire block system in the top of the drilling tower. It serves the purpose of lifting and lowering various equipment. An example of such equipment is a drilling machine for the drill pipe to be rotated, which equipment is connected through a joint to the block taking the form of a wagon which is guided by vertical guide rails.
When drilling for water, gas or crude oil it is necessary to bring the drilling block with connected equipment up and down while the drill pipe maintains its drilling position.
Today this problem is solved by retracting the block with equipment between the guide rails and the drill pipe.
This is space consuming and results in unwanted wire bend. The moment of force will, while drilling, become larger and create larger stress factors. This results in increased dimensioning.
This invention can solve some of these problems and make it possible to design a smaller space demanding derrick. It will reduce the moment of force on the guide rails as well as avoid the bended wires when retracting from a symmetric position over the drill pipe.
This is achieved primarily by arranging the drill block decentralized and designed as characterized in the appended claims.
By decentralized design of the drill block, the retracting operation will demand less space. It is of greater importance in space critical area and will result that the construction can be significantly dimensionally reduced compared with previous methods. With this invention the wires will not have negative stress factors.
With reference to enclosed drawings and descriptions, the following will describe an embodiment of a sidestep retraction system.
In FIGS. 7 through 11 of the drawings, reference number 11 is a drill block in the derrick. The drill block 11 is connected through a joint link 12 with the equipment unit 13, for example a drilling machine for drilling of the drill pipe 14.
The equipment 13 is guided by a wagon 15 on by vertical guide rails 16.
In drilling position the drill block 11 and equipment 13 connected thereto are kept in a central position over the drill pipe 14.
Wires 17 are connected to and from the top block 18 in the top of the derrick.
A hydraulic cylinder operated skid mechanism 19 is connected to the drill block 11, which in turn is mounted on the wagon 15.
In order to change directions of the wire closest to the vertical centerline of the derrick, the top block 18 comprises a turnable roller 20, which by a joint arm 21 is connected to the top block 18. A skid system is arranged by guiding the roller 20 with a hydraulic cylinder 22 connected with a top block 18. The block 18 and the guide roller 20 can exert pressure on the adjacent wire, with the effect of decentering the direction of the wire to a position of choice. This is particularly so when the drill block 11 is in retracted position, see FIGS. 9 and 10, and shown in a broken line FIG. 11.
When the drill block 11 with connected equipment 13 is retracted to give space for a new drill pipe section 14', the hydraulic cylinder 19 is activated and will bring the drill block 11 decentralized (sideways) position away from the central area over the drill pipe. This opens the possibility to connect new drill pipe sections 14' even before the drill block 11 is retracted to upper position.
In order to also move the wire 17 in the same direction as the drill block 11 and bring this also sideways away from the central area in the derrick, the hydraulic cylinder 22 at the top block 18 moves the skid roller 20 against the adjoining pair of wires 17.
When the drill block with connected equipment including the wire is brought to a retracted position, the parts shown in FIGS. 9 and 10 will take the position as shown by the broken line in FIG. 11.
FIG. 11 illustrates the platform deck 23, the derrick 24 and the fingerboard 25 where drill pipe sections 26 are stored in a vertical position. The various drill pipes can be transported between the fingerboard 25 and the mousehole with the use of the pipe handling machine previously discussed, and with a fingerboard arrangement as illustrated in FIGS. 5a-5d.
In accordance to the invention the retracted drill block 11 is laterally decentralized, which means that the center axis is parallelly moved.
This movement, as shown in FIG. 11, will take place by moving the drill block 11 parallel to the guide rails 16 as well as the fingerboard slots 25'.
This system creates less moment forces and demands less space than conventional known methods where the drill block is retracted between the guide rails 16 and the drill pipe 14 towards the outer limits of the derrick.
With the guided wires at the top block, no negative factors will occur, as with the normal techniques. | The invention relates to an arrangement in a pipe handling system, especially for handling pipes (4P) in connection with a derrick 1A, wherein the arrangement comprises a tower (1) and two preferably individually controlled operating arms (2a, 2b). The pipe handling system operates favorably in connection with a finger board (4) in which all fingers (4a, 4n) are pointing towards the center of the pipe handling system and especially towards a disc-shaped locking unit (4R) mounted on the top of the tower (1), and in connection with a side-step retraction system designed for use with a top drive drilling system. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent Application No. 61/275,869 filed Sep. 3, 2009 and U.S. Provisional Patent Application No. 61/336,240 filed Jan. 19, 2010, which are hereby incorporated by reference in their entireties.
TECHNICAL FIELD
The present invention generally relates to natural material extraction, and more particularly to microwave-enhanced natural material extraction.
BACKGROUND
The most widely used conventional method of oil extraction is by steam distillation, which works in the following way. Boilers are used to create steam by heating water. The steam and a target material are combined in a flash chamber. The target material releases its oils into the steam, which is then condensed and collected into a secondary vessel, where it is allowed to separate and the oil removed and utilized. This method usually requires the burning of fossil fuels or wood to begin the process (boilers making steam) and it uses large amounts of energy and time to achieve the desired outcome.
Current microwave-assisted methods of exposing materials directly to microwave energy achieve a similar outcome as steam distillation, but require less time and energy. Most microwave extraction techniques are small batch processes used only for analysis, and they have no direct commercial value. However the larger batch techniques use up to twenty or more magnetrons and require repeated exposures to microwaves to achieve the desired results. The common oil extraction techniques by microwave-assisted distillation are hydro-distillation and dry-distillation. Hydro-distillation is accomplished by heating the target material in a container of liquid. Dry-distillation is accomplished by percolating steam through a grid holding the target material. Solvents can be included in these prior art processes to accelerate the extraction process.
Present approaches to natural material extraction suffer from a variety of drawbacks, limitations, disadvantages and problems, including processing time, and energy consumption. There was a need for an improved microwave-enhanced natural material extraction that would overcome the drawbacks, limitations, disadvantages and problems of the prior art.
SUMMARY OF THE INVENTION
The enhanced flash chamber of the present invention includes a microwave source in communication with the flash chamber for providing a quantity of energy to a plurality of antenna within the flash chamber; a fluid chamber positionable within the flash chamber capable of holding a liquid and the plurality of antennas; and transport tubing for transporting a target material for extraction through the fluid chamber where the quantity of energy from the microwave source interacts with the array of antennas to heat the liquid media held in the fluid chamber to a superheated state and the liquid media in the superheated state interacts with the target material to extract an extraction product from the target material.
Further features of this embodiment include the target material not including a solvent, the flash chamber being maintained at atmospheric pressure, and the microwave source being magnetrons, klystrons, switching power supplies, solid state sources or various combinations of these. The apparatus may also include a separation vessel where the extraction product is subjected to at least one separation process. The system of transport tubing may further include a pump positioned approximate the material supply and/or a thermocouple positioned close to an outlet of the fluid chamber. The extraction product may further include a quantity of essential oils and the essential oils are substantially insoluble in water.
Another embodiment of the present invention is a method for using a microwave enhanced flash chamber including providing a flash chamber with a microwave source, a fluid chamber, at least one antenna, and a fluid pathway; creating a quantity of energy from the microwave source effective to interact with the at least one antenna to heat a liquid media held in the fluid chamber to a superheated state; providing a processed target material; moving the processed target material through the fluid pathway to interact with the liquid media in the superheated state in the fluid chamber positioned within the flash chamber; providing an extracted suspension of the processed target material; moving the extracted suspension of the processed target material from the flash chamber; and performing at least one secondary process on the extracted suspension of the processed target material.
Further features of this embodiment include at least one secondary process including separating an extraction product from the extracted suspension and/or extraction, cooling distillation, cold distillation, entraining, material addition, decanting, evaporation, collection and various combinations. The carrier fluid separated during the secondary process(es) may be recycled. The processed target material may be a mixture of a target material and a carrier fluid and providing the processed target material may include pumping the mixture from a target material source. The pump may be a peristaltic pump.
A yet further embodiment of the present invention is an apparatus with a means for generating a quantity of microwave radiation within a flash chamber; a means for subjecting a fluid chamber with at least one antenna to the quantity of microwave radiation; a means for inducing a flow of a target material through a fluid pathway; a means for controlling the inducing of the flow of the target material; a means for sensing parameters; and a means for recovering an extracted portion of the target material where the microwave radiation interacts with the antenna to produce a superheated state within the fluid chamber and where the flow of the target material interacts with the superheated state within the fluid chamber to produce the extracted portion of the target material.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic diagram of an enhanced flash chamber of the present invention.
FIG. 2 is an enlarged view of the enhanced flash chamber of FIG. 1 .
FIG. 3A is an enlarged side view of the antenna of the enhanced flash chamber of FIG. 1 .
FIG. 3B is a perspective view of the antenna of FIG. 3A .
FIG. 4 is a flow diagram for an extraction process using the microwave enhanced flash chamber of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein, are contemplated that would normally occur to one skilled in the art to which the invention relates.
With reference to FIG. 1 , one preferred embodiment of the present invention is a microwave enhanced flash chamber 10 . Microwave enhanced flash chamber 10 has a flash chamber 20 . A material supply source 30 is connected to a fluid chamber 70 within flash chamber 20 through supply tubing 50 . A pump 35 may be used to aid in the transfer of material from supply source 30 through supply tubing 50 and into fluid chamber 70 . Fluid chamber 70 in flash chamber 20 includes four antennas 75 . A microwave source 25 directs microwave radiation at antennas 75 thereby creating a hot spot of superheated liquid contained within fluid chamber 70 . A system of collection tubing 60 is also connected to fluid chamber 70 to allow post-flashed material to flow from flash chamber 20 to a collection vessel 40 . A thermocouple 65 or other temperature reading device may be used to measure the temperature of the post-flashed material leaving flash chamber 20 . A fiber optic thermometer may provide an measurement of temperatures inside flash chamber 20 .
In one embodiment, the hot spot is created by directing microwave radiation on an array of antennas submerged in a liquid media contained in the flash chamber apparatus. The submerged antennas create this hot spot. The arrangement of high electro-negativity antennas allows for the movement of electrons which superheats the liquid media in the flash chamber. An extraction system of the present invention may allow for a more efficient extraction of larger volumes of target material.
FIG. 2 is an enlarged view of fluid chamber 70 . Fluid chamber 70 in the preferred embodiment is to date a glass round bottom flask, but fluid chamber 70 may be any container that is microwave transparent, heat resistant and will contain a suitable liquid media without reacting with the carrier liquid or the material during the microwave enhanced flash chamber process.
A stopper 74 is placed within the opening of fluid chamber 70 . While stopper 74 is a neoprene stopper in the preferred embodiment to date, other suitable caps or lids may be used to seal the opening of the container used for fluid chamber 70 . Stopper 74 has two holes constructed from a top flat surface 74 A of stopper 74 through to a bottom flat surface 74 B of stopper 74 . Glass tubes 76 , 78 are inserted through the holes 74 A, 74 B in stopper 74 . Input glass tubing 76 is connected to supply tubing 50 and output glass tubing 78 is connected to collection tubing 60 . Target material in a carrier fluid is able to flow from supply source 30 through supply tubing 50 and into fluid chamber 70 through input glass tubing 76 . Post-flashed material is then forced out of fluid chamber 70 through output glass tubing 78 through collection tubing 60 and into collection vessel 40 .
To accommodate placement of fluid chamber 70 in flash chamber 20 with the tubing 50 , 60 , 76 , 78 ; two holes are drilled through the top center of flash chamber 20 . The holes are spaced identical to the holes of stopper 74 . A microwave field monitor may be used to check the tube openings for glass tubing 76 , 78 at the top of flash chamber 20 for safety purposes. Ferrite filters may also be added to the tube openings. Fluid chamber 70 contains antennas 75 submerged in a liquid media 72 . Four antennas are shown in the preferred embodiment to date though other quantities of antenna may be used.
The microwave energy of the present invention is focused by an array of antennas. The antennas may be quarter wavelength antennas for one embodiment and other lengths such as but not limited to half wavelength antennas for other embodiments. The antennas may include a material with high electro-negativity that is still economically available such as but not limited to tungsten, an aluminum/zinc/silver base with zinc plating or a carbon rod. The antennas are submerged in a liquid media in a fluid chamber creating a hot spot within the flash chamber of the apparatus when microwave radiation is directed toward the antenna in one embodiment. The arrangement and selection of the materials for the antennas may allow for the movement of electrons to superheat the liquid media within the flash chamber. The superheated liquid media is enabled to provide heat to the target material which then releases the natural oils within the target material.
FIG. 3A is a side view of a preferred embodiment of an antenna 300 of the present invention and FIG. 3B is a perspective view of a preferred embodiment of antenna 300 of the present invention. For this preferred embodiment to date, a 30 mm diameter circle 310 was cut from aluminum plate material to create the base of antenna 300 . A nail 320 or carbon rod was pushed through the center of circle 310 . A ¾ inch washer 330 was added to the base of antenna 300 . Antenna 300 was placed in the bottom of fluid chamber 70 as shown in FIG. 2 .
Nail 320 , aluminum circle 310 , and washer 330 may be cemented to each other with silver solder. The antenna wavelength may be adjusted by known techniques to one skilled in the art, and the size of the fluid chamber may be adjusted to accommodate various applications. The power of the microwave source, such as but not limited to magnetrons, klystrons, switching power supplies, and solid state sources, may vary from the 1 kw used in the preferred embodiment to date. In one most preferred embodiment to date, four quarter wavelength antennas produced a maximum output temperature with a 1 kW magnetron. Optimization for other systems is easily accomplished by varying properties such as fluid chamber size, wavelength, microwave radiation source and strength, and flash chamber size.
One embodiment of the present invention is an enhanced flash chamber with a microwave source arranged to position a fluid chamber inside. A fluid pathway of flexible tubing leads from a target material supply to the fluid chamber. The fluid pathway starts at the target material supply and continues through a wall of the flash chamber into a stopper placed in the fluid chamber. The stopper includes two holes to accommodate the tubing of the fluid pathway. The first hole is for the flexible tubing of the fluid pathway from the target material supply to the fluid chamber. Flexible tubing may be attached to rigid rods such as but not limited to borosilicate glass where the glass tubing runs through the opening in the flash chamber through the hole in the stopper and into the fluid chamber. The second hole is for the flexible tubing of the fluid pathway running from the fluid chamber to the collection vessel outside of the flash chamber. Tubing from the inside of the fluid chamber through the stopper and through the opening in the flash chamber may include rigid tubing as discussed above.
The fluid pathway from the target material supply may include a pump such as but not limited to a peristaltic pump. The pump may induce and regulate the flow of target material from the target material supply through the fluid pathway to and from the fluid chamber.
For fluid chamber assembly 200 as shown in FIG. 2 , the holes in stopper 74 can be made by rotating and pushing glass tubing 76 , 78 in and out of stopper 74 . This action helps in moving glass tubing 76 , 78 through the top of flash chamber 20 and into stopper 74 . Fluid chamber 70 may be positioned in the center of flash chamber 20 . Input glass tubing 76 may be pushed past the neck of fluid chamber 70 and output glass tubing 78 may be pushed to the bottom of stopper 74 . The flask size used for fluid chamber 70 of other embodiments may be increased to accommodate a larger wavelength antenna such as a half wavelength antenna.
When attaching collection tubing 60 to output glass tubing 78 , the tip of thermocouple 65 may be placed between collection tubing 60 and output glass tubing 78 . Collection tubing 60 may empty into collection vessel 40 . The temperature of liquid media 72 may be measured during the collection part of the process at thermocouple 65 .
A field monitor may be used to check for microwave radiation leakage. There may be negative effects to boiling off the contents of fluid chamber 70 . Microwave source 25 may be the first part of the process turned on and off.
The microwave enhanced flash chamber apparatus and process of another embodiment may also allow for greater amounts of material to be exposed and extracted through a continuous process. The size, power (i.e. antenna wavelength along with 1 kW, 3 kW magnetrons and the like) and number of flash chambers may be increased to accommodate larger volumes of target material.
FIG. 4 includes a flow diagram of the preferred embodiment to date of the present invention. An apparatus according to the present invention is assembled with a flash chamber, a microwave source, a fluid chamber, at least one antenna and a fluid pathway. A pump is activated in operation 410 to start the flow of target material through the fluid pathway to the fluid chamber. The flow fills the fluid chamber past the tops of the antennas.
The microwave source is also activated in operation 420 with the microwave radiation directed toward the antennas. The microwave-radiated antennas begin to superheat the fluid in the fluid chamber in operation 430 . The superheated fluid begins to boil and steam forms. The pump may be adjusted so the steam reaction occupies half of the fluid chamber. The target material is pumped through the hot spot created by the superheated fluid and the extraction process takes place in operation 440 . As the pump continues to transport the target material into the fluid chamber, the extraction suspension is transported out of the fluid chamber into a collection vessel. Secondary processing such as but not limited to extraction, cooling or cold distillation, entraining, material addition, decanting, evaporation, collection and various combinations may be performed in operation 450 .
The microwave-enhanced device of the present invention may be capable of larger industrial applications where oil extraction or steam generation is required. The microwave enhanced flash chamber may provide a design for moving oil-bearing material through a hot spot and thereby heating the target material and separating the oil from the target material.
One embodiment of the present invention is a novel natural material extraction apparatus and process. In one preferred embodiment to date, a microwave enhanced flash chamber apparatus and process may be powered by a 1 kw magnetron to produce microwave radiation. In other embodiments, the microwave radiation may vary with the application. For this embodiment, the extraction process takes place in one chamber without a solvent at atmospheric pressure. Another embodiment may include solvent being added downstream of the microwave enhanced flash chamber process.
In another embodiment, the microwave enhanced flash chamber apparatus and process works in the following way. Oil-bearing materials (i.e. plants, algae etc.) are processed with a carrier fluid, such as but not limited to water, and moved through a hot spot in a flash chamber. The hot spot making a continuous flow of material possible is created by antenna exposed to microwave radiation. The heat from the hot spot is transferred to the oil-bearing material in the carrier fluid. The heat extracts the oil from its associated components.
Simultaneously, the pressure of the material and carrier fluid flowing through the apparatus may force the mixture out of the microwave enhanced flash chamber to cool and separate in a secondary or post extraction processing vessel. The oil may be removed once allowed to separate from the residual target material, or if needed in a further embodiment, secondary processing such as but not limited to solvent addition and centrifuge may be applied during this part of the process. In the microwave enhanced flash chamber process of the present invention, the target material is not heated directly when producing a distillate/oil mixture.
EXAMPLE
Two studies were conducted using peanut material and soybean material following the same method as described in FIG. 4 . 500 g of media were reduced to a 1.5 mm particle size solid substance using the deburring grinder and added to 6 L of 95% ethanol (solvent) in a 5 gallon carboy to provide a target material for the microwave enhanced flash chamber. The target material was processed through the microwave enhanced flash chamber apparatus as described in FIG. 1 . The antennas used in this example had the aluminum plate removed to reduce the potential of electrical arcing igniting the ethanol solvent. The antennas were able to appropriately heat the flash chamber.
The target material solids were reduced to finer particles following processing in the enhanced flash chamber. The target material mixture was re-circulated through the microwave enhanced flash chamber at 91° Celsius for 30 minutes. The temperature of the post-flashed material was measured using a type K thermocouple as the material moved through the output glass tubing. The flow rate was measured using a graduated cylinder. The temperature was controlled by the flow rate at a pump supplying the target material to the microwave enhanced flash chamber. No external pressure was added to raise the temperature.
The input tube coming from the carboy to the pump was placed near the top of the liquid layer of ethanol and media. The output tube coming from the flash chamber was placed at the bottom of the carboy. Post-flashed material coming from the output tubing in the form of steam provided agitation to the solids at the bottom of the carboy.
The media being processed through the flash chamber became a fine white powder. After 30 minutes of circulation (3.5 liters every 4 minutes), the pump was stopped. The mixture was allowed to settle for 1 hour. There were two layers: a layer of solids at the bottom and a layer of liquid (majority ethanol) at the top. The ethanol was recovered by decanting and then filtering the layer of solids which had formed a micelle. The micelle of solids was mixed with water and allowed to settle for 3 hours. Three layers resulted from the water separation. The top layer of extracted oil was skimmed and placed into a separatory funnel. Additional oil extract was separated from the remaining layers with the separatory funnel. The target material circulated through the microwave enhanced flash chamber became a fine white powder as the oil was extracted and made available for separation. Extraction results are shown in Table 1.
TABLE 1
Media
Oil extracted
% of oil by weight
% of oil extracted
Peanuts
195.69 g
39.3%
19.6%
Soybeans
64.89 g
18%
6.49%
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary. | An enhanced flash chamber with a flash chamber; a microwave source in communication with the flash chamber for providing a quantity of energy to a plurality of antennas within the flash chamber; a fluid chamber positionable within the flash chamber capable of holding a liquid and the plurality of antennas; and transport tubing for transporting a target material for extraction through the fluid chamber where the quantity of energy from the microwave source interacts with the plurality of antennas to heat the liquid held in the fluid chamber to a superheated state and the superheated state of the liquid transfers a portion of the quantity of energy to the target material to extract an extraction product from the target material. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wearable wireless devices. In particular, the present invention relates to wearable wireless devices using electromechanical polymer (EMP) transducers as sensors and actuators.
2. Discussion of the Related Art
Existing “wearable” devices reveal that most devices are developed for the following categories of applications: information-entertainment, fitness-wellness, and health-medical.
Users of wireless devices rely on the wireless devices for many applications, including messaging, voice calls, texting, time check, music, gaming, social media, camera, alerts, alarms, calendar, web browsing and searches. In many of these applications, the amount of information being transmitted to a user or received from a user is relatively small. Nevertheless, for the most part, sending or receiving such small amount of information still requires the user to reach for the wireless device. Therefore, efficient hands-free operations for many of these applications are highly desirable.
To address some of these needs, many types of wearable devices have been developed. For the most part, these wearable devices are quite expensive, have very limited applications, are bulky and are not attractive to wear.
SUMMARY OF THE INVENTION
According to one embodiment of the present invention, a wearable haptic device includes (a) a substrate having provided thereon a fastener (e.g., an adhesive) for attachment to a user; (b) one or more EMP transducers attached to the substrate, such that a mechanical response in each EMP transducer may provide a haptic response of sufficient magnitude to be felt by the user; and (c) a control circuit controlling the vibration frequency, the time of operation and the duration for each activation of the EMP transducer. In one embodiment, the wearable haptic device further includes a wireless communication circuit (e.g., a Bluetooth transceiver) for receiving a message from an external device (e.g., a smartphone). The control circuit interprets the message received and according to the interpreted message provides an electrical stimulus to cause the mechanical response of the EMP transducer.
According to one embodiment of the present invention, the wearable haptic device may serve as a bandage. The EMP actuators may provide vibration at different frequencies and intervals. The frequencies and intervals may be programmed during manufacturing and customized, if necessary, for the bandage in the field. Such a bandage may be particularly effective in treating ulcerated tissues or it may enhance blood flow and the exchange of oxygen.
According to one embodiment of the present invention, the EMP transducer may also serve as a sensor, such that a mechanical stimulus on the EMP transducer provides an electrical response that is detected by the control circuit. The wearable haptic device may include amplification circuitry for conditioning the electrical stimulus or response between the control circuit and the EMP transducer. The control circuit may create a message based on the detected electrical response from the EMP transducer and may send the message via the wireless communication circuit to the external device.
The present invention is better understood upon consideration of the detailed description below in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1( a ) is a block diagram of haptic patch 100 , in accordance with one embodiment of the present invention.
FIG. 1( b ) shows an exemplary external appearance of haptic patch 100 , in accordance with one embodiment of the present invention.
FIG. 2 shows exemplary system 200 in which haptic patch 100 may be deployed in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention takes advantage of the properties of thin electromechanical polymer (EMP) transducers to create wearable devices that provide, when activated, haptic response to the wearer and to provide sensing signals from the wearer to a local or remote signal processing device. EMP transducers have been disclosed, for example, in copending U.S. patent application (“Copending Application”), Ser. No. 13/683,963, entitled “Localized Multimodal Electromechanical Polymer Transducers,” filed Nov. 21, 2012. The disclosure of the Copending Application is hereby incorporated by reference in its entirety.
In one embodiment, an EMP transducer may be incorporated on a small patch (“haptic patch”) which may be fastened or attached by adhesive, for example, onto the skin of the wearer, his clothing or another wearable close to the wearer's body (e.g., as a pendant or provided on a pendant to be worn with a necklace). The haptic patch may be used, for example, as a wound dressing, or be attached on a wound dressing. As a wound dressing, the haptic patch is attached directly to a wound. The haptic patch may have an external protective wrapping or substrate that may be provided, for example, in a form similar to those patches used for delivering transdermal medication. As an actuator, the EMP transducer may provide a mechanical stimulus (e.g., a vibration) at the wearer's skin of suitable frequency content or strength (e.g., 25-250 Hz, or any other frequency, including ultrasound frequencies). Alternatively, the frequency content or strength of the mechanical stimulus may encode a predetermined message to the wearer. As a sensor, the wearer may cause sensing signals (e.g., by applying pressure) to be sent from the EMP transducer. In this manner, the wearer may exchange any of a large number of tangible emotions and silent messages with others. FIG. 1( a ) is a block diagram of haptic patch 100 , in accordance with one embodiment of the present invention. FIG. 1( b ) shows an exemplary external appearance of haptic patch 100 , in accordance with one embodiment of the present invention.
As shown in FIG. 1 , haptic patch 100 includes power source 101 (e.g., a conventional or solar-charged battery), ultra-low power wireless communication device 102 (e.g., a Bluetooth transceiver with antenna), controller 103 , amplifier 104 , and EMP transducer 105 . Power source 101 may supply, for example, a 0.4 watts, 150-volt voltage source for use with EMP transducer 105 . Under control of controller 103 , amplifier 104 may provide an electrical stimulus that activates a mechanical response in EMP transducer 105 . Alternatively, when a mechanical stimulus is impressed on EMP transducer 105 , an electrical response is provided on EMP transducer 105 . Amplifier 104 may amplify the electrical response to a suitable signal level to allow controller 103 to capture the electrical response. Amplifier 104 may include not only circuitry for amplification or attenuation, but also circuitry for providing and conditioning signals so as to be compatible with signal requirements of EMP transducer 105 and controller 103 , such as an analog-to-digital converter and a digital-to-analog converter. As discussed above, by suitable use of frequency and mechanical or electrical signal strengths, many types of messages may be sent to or received from haptic patch 100 .
FIG. 2 shows exemplary system 200 in which haptic patch 100 may be deployed, in accordance with one embodiment of the present invention. As shown in FIG. 2 , wearer 201 has a haptic patch (e.g., haptic patch 100 ) attached to a location of his body which is sensitive to haptic responses. The existing EMP transducer technology allows such a location to be practically any location on the approximately two square meters of skin on a typical human adult. Through the on-board ultra-low power wireless communication device 102 , a communication link is maintained between haptic patch 100 and wireless mobile device 202 (e.g., a smartphone), which is also connected to wireless communication network 203 (e.g., a cellular telephone network). Of course, haptic patch 100 is not limited to having just one EMP transducer; in fact, having multiple EMP transducers may allow haptic patch 100 to provide many additional effects not available to a haptic patch having a single EMP transducer.
During operation, for example, controller 103 communicates via ultra-low power wireless communication device 102 with wireless mobile device 201 . Another user (e.g., a user of wireless mobile device 204 ) may send a message to wireless mobile device 202 , which is intercepted by an application program running on wireless mobile device 202 . For example, the application may recognize the message from the sender to be a request providing a gentle reminder tap to wearer (e.g., to reminder the wearer of the patch to take a scheduled dose of medication). Wireless mobile device 202 then invokes an appropriate command in controller 103 to actuate EMP transducer 105 to deliver the intended gentle tap. In the opposite direction, for example, EMP transducer 105 , acting as a mechanical sensor, may provide a stream of electrical signals read periodically by controller 103 . The stream of electrical signals may be interpreted by wireless mobile device 202 as, for example, measurements of blood pressure, heart rate or temperature. Wireless mobile device 202 may transmit the result, for example, to an interested party at wireless mobile device 204 (e.g., an emergency response team).
Patch 100 may be provided at minimal cost (e.g., less than $10) and operates substantially hands-free. As the cost is relatively low, patch 100 may be provided as a disposable device, desirable for reasons of hygiene. Patch 100 may also be provided by a large number of inexpensive materials, which can be colored or textured to achieve a very attractive external packaging.
In many applications, each patch may be associated uniquely with a single sender so that the sender and the wearer may agree on their private encoding of the haptic response (e.g., a gentle tap on a first patch associated with one's mother may have a different meaning than the same gentle tap on a second patch associated with one's significant other). Many encodings of suitable emotions may be expected. For example, different activations of EMP transducer 105 may encode, patting, giggle, encouragement, agitation, anger, fear, excitement, and intimacy (e.g., kiss, “you are in my thoughts right now,” and arousal). Many encodings of silent messages are similarly possible. For example, different activations of EMP transducer 105 may encode a task reminder, an indication of readiness to act in concert, silent agreement or disagreement with a colleague during a negotiation session, and turn-by-turn directions. A user may select the message from an application program (or “App”) running on a wireless mobile device (e.g., wireless mobile device 204 ), which would send instructions to the haptic patch to activate the corresponding software routines running on controller 103 to effectuate the haptic response or responses conveying the selected message. In some embodiments, the user may customize the haptic responses for a message by associating and orchestrating one or more haptic responses to that message. (Here, orchestrating refers to setting certain parameters of the haptic response, such as duration, delay, frequency, and strength).
In the case where multiple EMP transducers are provided, the EMP transducers may be activated in concert, for example, to convey directionality. Alternatively, the alternating activation of two EMP transducers creates a “blinking” sensation that may be used to represent a message appropriately expressed by such a blinking sensation. The EMP transducers may have structural differences that allow each EMP transducer to specialize in a particular modality or force regime. For example, one EMP transducer may be used to provide vibrational haptic responses, while another EMP transducer may be used to provide deformation-based haptic responses and while a third EMP transducer may provide an audio response.
Activation of a haptic response need not be controlled by wireless remote control. For example, a haptic patch may be programed to provide stretching or to provide vibration or massage for a predetermined time (e.g., two hours) on the skin to which the haptic patch is attached. The programmed operation may be initiated or stopped, for example, by a predetermined mechanical stimulus provided by the user on the patch.
The haptic patch may also be used as a programmable active bandage or dressing. It is known that ulcerated tissue may benefit from vibrations that promote oxygen exchange and that enhance blood flow. Certain vibrational frequencies and treatment intervals may be programmed for this application. The haptic patch provides a low-cost, location-specific device and does not require administration by a trained practitioner, unlike conventional ultrasound equipment, which also requires a substantial capital investment. The haptic patch also avoids the whole body vibration treatment in the prior art, which is administered by placing the patient on a vibrating platform for a prescribed time period.
The detailed description above is provided to illustrate specific embodiments of the present invention and is not intended to be limiting. Numerous modifications and variations within the scope of the present invention are possible. | A wearable haptic device includes (a) substrate having provided thereon a fastener (e.g., adhesive) for attachment to a user; (b) one or more EMP transducers attached to the substrate, such that a mechanical response in each EMP transducer may provide a haptic response of sufficient magnitude to be felt by the user; and (c) control circuit controlling the vibration frequency, the time of operation and the duration for each activation of the EMP transducer. The wearable haptic device may include a wireless communication circuit (e.g., Bluetooth transceiver) for receiving message from an external device (e.g., smartphone). The control circuit interprets message received and according to the interpreted message provides an electrical stimulus to cause the mechanical response of the EMP transducer. The EMP transducer may also serve as a sensor, such that a mechanical stimulus on the EMP transducer provides an electrical response that is detected by the control circuit. | 7 |
REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 60/619,012, filed Oct. 18, 2004, whose disclosure is hereby incorporated by reference in its entirety into the present disclosure.
FIELD OF INVENTION
[0002] The present invention generally relates to a lighting apparatus and more specifically to a high brightness solid-state lighting apparatus for navigational aids.
BACKGROUND OF THE INVENTION
[0003] Lighting is an integral part of the safety system for airports as well as helipads and waterways, providing guidance, signaling, and demarcation of aircraft runways and taxiways. The lighting system includes those elevated/in-pavement taxiway and runway lights, medium and high intensity approach lights, which can be further configured as edge, centerline, threshold/end, hold-line, stop bar, and runway guard lights. Light emitting diode (LED) sources have been identified to be the replacement for the conventional incandescent lighting apparatus as they offer many advantages including high energy efficiency, long lifetime, low maintenance cost, enhanced reliability and durability, and no lumen loss induced by filtering.
[0004] The prior art related to LED lighting systems includes U.S. Pat. Nos. 5,926,115, 6,086,220, 6,489,733, 6,902,291 and U.S. Patent Application Nos. 2002/0114161, 2003/0193807, 2004/0095777. In U.S. Pat. No. 6,489,733, Schmidt et al. disclose a multi-purpose lighting system for airport, roads or the like. The lighting system is composed of a group of incandescent or LED light sources and a central control unit to monitor and control the operation of the light sources. In U.S. Pat. No. 5,926,115, Schleder et al. disclose a microprocessor-controlled airfield series lighting circuit communications system and the corresponding method that allows bi-directional communication between the controlling microprocessor and the airfield lamps. In U.S. Pat. No. 6,086,220, Lash et al. disclose a marine safety light consisting of a plurality of LEDs arranged in a star configuration. In U.S. Pat. No. 6,902,291, Rizkin et al. disclose an in-pavement directional LED luminaire, which utilizes multiple high flux LEDs with thermostabilization and uses a single non-imaging element as a secondary optic. In U.S. Patent Application No. 2002/0114161, Barnett discloses a rotating warning lamp having an LED based planar light source. In U.S. Patent Application No. 2003/0193807, Rizkin et al. disclose an LED-based elevated omni-directional airfield light. In U.S. Patent Application No. 2004/0095777, Trenchard et al. disclose a high flux marine safety light having a plurality of high flux LEDs mounted on a heat sink and surrounded by a diffuser.
[0005] The LED lighting apparatuses disclosed in those references have a luminous intensity of < 100 candelas. That luminous intensity does not meet the needs for runway edge lighting, approach lighting, threshold/end lighting, and obstruction/beacon lighting.
[0006] For some airport lighting/signaling applications, it is also desirable that the color of the lamp can be easily changed or switched within the same light fixture. As an example, a taxi way may be reconfigured to a temporary runway by switching the light color from blue to white. That is difficult to achieve in a conventional incandescent lamp, where the color is usually defined by the color of the glass cover.
[0007] The color of the light used in navigation and airport applications is governed by various standards and regulations. The utility of an installed light is defined not only by its intensity, but also by its chromatic characteristics (optical spectral distribution). Unfortunately, during the lifetime of an LED, not only will the light intensity decay gradually, but also, its chromatic characteristics will change, which can further shorten the useful lifetime of the LED. It is also true that the chromatic property of the LED is further affected by the environmental temperature. The LED will be red shifted with an elevated temperature and blue shifted with a reduced temperature. It is thus desirable that the chromatic characteristics may be varied during the useful lifetime of an LED.
[0008] Many LED based airport lights are currently modulated in their output at a rate of about 50-60Hz in order to reduce the thermal load. That helps to maintain the performance of the LED and prolong the lifetime, especially for a battery operated lighting unit. However, even though the naked human eyes can not sense the fast flickering (modulation), the modulation creates an artificial illusion to a pilot wearing night vision goggles and may cause dizziness and vertigo.
SUMMARY OF THE INVENTION
[0009] It is therefore an objective of the present invention to provide an airport/navigational lighting apparatus which can solve all the above mentioned problems.
[0010] To achieve the above and other objectives, the current invention in at least some of its embodiments utilizes newly developed high intensity LEDs or LED arrays with a chip-on-board (COB) package, in which the LED chips are directly surface-mounted on a thermal conductive substrate for improved heat dissipation. In one aspect, the COB package allows much higher current to be applied on the LED chip to increase its output power. In another aspect, the packing density of the LED chips can be greatly increased by over one order of magnitude. As a result, the LED lighting apparatus disclosed in the current invention achieves a luminous intensity of several hundred or even several thousand candelas.
[0011] In various preferred embodiments, the following description will provide detailed optical and mechanical design for unidirectional, bidirectional as well as omni-directional navigational lights that are built on COB packaged LEDs or LED arrays to meet high luminous intensity requirements. Color control and chromatic management is realized by integrating multiple wavelength LED chips into one lighting apparatus and controlling the relative intensity of those LED chips. Due to its improved heat dissipation capability, the LED lighting apparatus disclosed in the current invention can work in continuous mode with no modulation, thus completely eliminating the risk of vertigo.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a chip-on-board (COB) LED package;
[0013] FIG. 2 illustrates an omni-directional lighting apparatus constructed with COB LED arrays;
[0014] FIG. 3 illustrates a bidirectional lighting apparatus constructed with COB LED arrays;
[0015] FIG. 4 illustrates a unidirectional glide slope light constructed with two COB LED arrays with different colors;
[0016] FIG. 5 ( a ) illustrates the illumination pattern of a glide slope light formed by two COB LED arrays with different colors;
[0017] FIG. 5 ( b ) illustrates the illumination pattern of another glide slope light formed by three COB LED arrays with different colors;
[0018] FIG. 5 ( c ) illustrates the illumination pattern of a centerline light formed by COB LED arrays with different flash patterns; and
[0019] FIG. 6 illustrates a traditional LED package.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Preferred embodiments of the present invention will now be set forth in detail with reference to the drawings, in which like reference numerals refer to like elements throughout.
[0021] A traditional LED light utilizes a small LED chip mounted on a reflector cup as shown in FIG. 6 . That kind of package is generally referred to as T-pack. In the traditional LED light 600 , an LED chip 602 and a gold wire 604 are enclosed in an epoxy lens 606 . The LED is attached by a cathode 608 and an anode 610 to a printed circuit board (substrate) 612 .
[0022] The traditional LED light 600 has very high thermal resistance (>200K/W) due to a poor heat sink. Thus, its input power is limited to <0.1-Watt to keep the operating temperature of the PN junction at <120° C. safety level. Due to the limitation of achievable individual LED brightness, a large number of LED lights are required to meet the luminous intensity requirements, which results in a large footprint due to the size of each T-pack device (several millimeters) and only 1-5% of the total LED array surface is light emitting.
[0023] An illustration of the COB packaged high intensity LED array is shown in FIG. 1 as 10 . In that approach, multiple LED chips 102 are densely mounted on a common thermally conductive substrate 104 made of fiberglass-filled epoxy, ceramic, or metal with a small spacing such as 100 μm. Electrical connections are provided via electrodes 106 and gold wires 108 .
[0024] That high packing density results in a light emitting surface of up to 85% of the total LED array surface. Thus, the luminous intensity of the LED array is greatly increased (by over one order of magnitude). More importantly, the COB approach provides superior thermal control over conventional T-pack devices as the LED chips are directly attached on the substrate with their whole surfaces as the heat dissipation channel. In comparison, the T-pack LED can only dissipate its heat through the electrodes. The improved heat-sinking keeps the temperature of the LED PN junction as low as possible, which makes the LED capable of operating at higher currents or output levels. It also leads to long lifetime as well as wavelength (color) and intensity (brightness) stability. Other advantages of the COB approach include compact size, high uniformity, and capability for color management by integrating LED chips with different colors. The goal of the present invention is to utilize the COB packaged LEDs or LED arrays to build high intensity lighting apparatus for navigational aids.
[0025] In one preferred embodiment of the current invention, as shown in FIG. 2 , an omni-directional lighting apparatus is constructed on COB LED arrays, which can be used as an elevated runway edge light, or obstruction/beacon light. The lighting apparatus comprises one or more high intensity COB LED arrays 10 mounted on a thermally conductive substrate 11 . The light beam emitted from the LED arrays is first collected and collimated by a group of lenses 12 and then transformed into a horizontal beam with a 360° C. illumination angle by a cone shaped reflector 13 . The divergence of the LED beam in the vertical plane is collimated to an application required angle, such as <10° C. for a runway edge light. The LED arrays 10 , the lens sets 12 and the reflector 13 are enclosed in a waterproof housing composed of a cover 14 , a cylindrically shaped transparent window 14 , and an electronic compartment 16 holding all the electronic driver and control circuits. For reason of simplicity, the electronic wire connections are not shown in the figure. A beam homogenizer, such as a holographic diffuser described by Lieberman et al. in U.S. Pat. No. 6,446,467, can be inserted between the lenses 12 and the reflector 13 to further improve the uniformity of the LED beam and control the vertical illumination angle. By alternatively placing LED chips with different colors (such as red, green and blue) on the substrate to form a color matrix and controlling the relative intensity of those LED chips, the color of the lighting apparatus can be adjusted for lighting reconfiguration or to maintain/adjust the chromatic property of the lighting apparatus during its lifetime. In a slight variation of the current embodiment, the COB LED arrays further comprise invisible LED chips such as in the infrared wavelength region that are placed alone or alternatively with the visible LED chips to provide navigational aids during dark conditions for pilots wearing night vision goggles.
[0026] In another embodiment of the current invention, as shown in FIG. 3 , a bidirectional lighting apparatus is constructed as an elevated threshold light. The lighting apparatus comprises two COB LED arrays 20 and 21 with different emission wavelengths (colors) such as green and red, which are mounted on a heat sink 22 in opposite directions. The light beams from the two LED arrays 20 and 21 are collected and collimated by the lens sets 23 and 24 , respectively. The spread angle of the LED beams is set according to the application requirements. In the current embodiment, the LED lighting apparatus exhibits a luminous intensity of >2000 cd in a divergence angle of <10° C. The LED arrays and the lens sets are enclosed in a waterproof housing composed of a cover 25 , a cylindrical shaped transparent window 26 , a heat sink 27 , and an electronic compartment 28 . As a slight variation of the above embodiment, two kinds of LED chips with different colors such as green and red may be integrated in the same COB array. By simply turning on/off a particular color, the beginning or end of runway can be reconfigured so that aircraft can be directed in different directions. A unidirectional lighting apparatus with COB LED arrays emitting at one direction can be constructed similarly, which can be used as an airport strobe light.
[0027] In yet another embodiment of the current invention as shown in FIG. 4 , the COB LED array is employed to build a unidirectional glide slope light to guide the landing path of an aircraft. In the present embodiment, the lighting apparatus is composed of two COB LED arrays 30 , 31 mounted on a heat sink 32 . Each LED array is assigned a unique emission color, such as green and red in the current embodiment. The two LED arrays emit in slightly diverged angles. The divergence angles of the two LED beams are controlled by the two lens sets 33 , 34 in such a way that the two beams mix in the central region to form a yellow color as shown in FIG. 5 ( a ). That yellow color region represents a range of safe glide slope for the approaching aircraft to land. If the pilot sees the red or green color, it means that the glide path is either too deep or too shallow. Due to the high brightness of the COB LED array, the light can be seen by the pilot from a long distance away. The whole lighting unit is enclosed in a waterproof housing comprising a cover 35 , a cylindrical shaped transparent window 36 , a heat sink 37 , and an electronic compartment 38 . In a slight variation of the current embodiment, three LED arrays with different emission colors, such as green, yellow and red, are used instead. In that scheme, the LED beams are collimated to very small divergence angles so that a quasi three-color illumination pattern, as shown in FIG. 5 ( b ) is formed by the three LED arrays. In another variation of the current embodiment as shown in FIG. 5 ( c ), three COB LED arrays with different flash patterns are employed to build a centerline light to guide the aircraft to the centerline of the runway. In that scheme, the central LED array emits in a steady color such as red, while the left and right LED arrays emit in flashing red color with different flash patterns. The pilot determines the position of the aircraft from the flash pattern he or she observed. In both of the two above-mentioned embodiments for glide slope light and centerline light, the flash pattern and emission color of the LED arrays can be used in a combined manner as position indicators. The color of the LED arrays can be extended from visible to infrared regime to be seen through night vision goggles.
[0028] Since the COB LED array has much smaller thermal resistance than the T-pack LED clusters, the lighting apparatus disclosed in the current invention can operate with no modulation, which completely eliminates the risk of vertigo. In cases where ultra high luminous intensity is required, the LED array can be modulated at a high frequency such as several hundred to several thousand Hertz to reduce the thermal load while minimizing the vertigo risk.
[0029] While some preferred embodiments of the present invention have been set forth in detail, those skilled in the art who have reviewed the present disclosure will readily appreciate that other embodiments can be realized within the scope of the invention. For example, the COB light emitting chip array may also comprise vertical cavity surface emitting laser (VCSEL) diode chips. The color and luminous intensity of the LEDs cited in the specific embodiments are illustrative rather than limiting. Therefore, the present invention should be construed as limited only by the appended claims. | A high intensity solid-state lighting apparatus is disclosed for the application of navigational aids. In various embodiments based on the approach of chip-on-board packaged semiconductor light emitting elements, unidirectional, bidirectional as well as omni-directional navigational lights are configured to meet high luminous intensity requirements. They also provide additional utilities for generating multiple colors and flash patterns with the same light unit for lighting reconfiguration as well as creating new means of signaling. Another purpose of the current invention is to provide a light source which will not cause vertigo effects. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process and apparatus for enhancing the growth of biomass within a reaction vessel and, in particular, enhancing biomass growth in reaction vessels which handle effluent and sewage.
2. Discussion of the Prior Art
In recent years, a process for treating industrial effluent and sewage involving the use of biomass support bodies has shown itself as an attractive alternative to the conventional activated sludge treatment process. In the conventional process, sewage or industrial effluent in a reaction vessel is aerated and agitated to stimulate the metabolism of a biological population within the vessel with various impurities in the effluent. The secondary sludge produced by this interaction is removed by sedimentation
In the biomass support body process, the reaction vessel is a vertical structure and it contains a number of free moving biomass support bodies Effluent and air are introduced at the base of the vessel and, as the effluent is oxygenated and propelled upward by the air, the biological population in the biomass support bodies reacts with the oxygenated effluent to produce carbon dioxide and additional biomass. This process is described in detail in U.S. Pat. No. 4,419,243 which also describes a suitable apparatus for accomplishing the process.
The biomass support body process has demonstrated that the capacity of the reaction vessel used in the process for a given through flow of effluent can be approximately one fifth of that of a conventional aeration tank and so the process offers commensurate savings in the cost of an effluent treatment plant. However, even more savings could be achieved if the critical variables of the biomass growth process, such as the pH level, control of recirculated solids and control of biomass populations, could be more precisely controlled. Additionally, it would be desirable to completely control the movement of the biomass support bodies through the vessel independent of the flow of effluent as opposed to relying on the upward flow of the effluent to suspend or fluidize the bodies, as is required in the existing biomass support processes. Furthermore, a wider choice of materials and construction of the support bodies could be available if there were no requirement that biomass support bodies be suspended or fluidized.
SUMMARY OF THE INVENTION
Accordingly, this invention provides a process and an apparatus for optimizing the use of biomass support bodies to treat effluent or sewage in a reaction vessel. A process according to the invention comprises flowing effluent into a media compartment having a number of biomass support bodies, circulating the effluent through a screen into a media-free compartment and re-circulating the effluent back into the media compartment or into successive media compartments. Biomass growth occurs on the biomass support bodies as the effluent passes through the media compartment and contacts the bodies. The means for re-circulating the effluent can comprise means for aerating the effluent as well.
An apparatus according to the invention comprises a media compartment and a media-free compartment, each compartment having an open face and connected along their open faces with a screen interposed at the point of interconnection. A diffuser can be provided at the base of the media-free compartment to aerate and upwardly propel effluent which passes through the media compartment and into the media-free compartment.
It is an object of this invention to provide precise control of the nutrients, environment, biomass equilibrium and optimization of the total treatment of various biological fermentation processes which occur in a reaction vessel.
It is a further object of this invention to provide a reaction vessel to treat higher bio-chemical oxygen demand rates than can be treated by a conventional activated sludge plant.
It is an additional object of this invention to provide a process and an apparatus permitting control of the movement of biomass support bodies within a reaction vessel.
It is yet a further object of this invention to provide a process and an apparatus for treating effluents which avoids hydraulic stratification of biomass support bodies.
It is yet a further object of this invention to provide a process and an apparatus for treating effluents by offering favorable heat conservation features.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cutaway elevational view of a treatment assembly;
FIG. 2 shows a cutaway elevational view of a treatment assembly and including a second media-free compartment;
FIG. 3 shows a cutaway elevational view of a number of treatment assemblies connected in series;
FIG. 4 shows a cutaway elevational view of the apparatus of FIG. 3 and further including an activated sludge zone and a suspended growth zone; and
FIG. 5 shows a top view of the apparatus of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference first to FIG. 1, a reaction vessel 10 comprises a number of treatment assemblies 11 arranged side by side and connected in a manner further described below. The treatment assemblies 11 will be discussed with regard to one such assembly and it is to be understood that the other treatment assemblies 11 are identically configured. Each treatment assembly 11 comprises a media-free compartment 12 having a screen 16 along one vertical side and a media compartment 14 which shares screen 16 as a vertical side. At the base of media-free compartment 12 are a number of aerators or diffusers which provide a selectively variable flow of air into the compartment. A number of supplemental diffusers 28 are provided at the base of media compartment 14. Each media compartment 14 can be provided with a second screen as another vertical side and the second screen is also a vertical side of the media-free compartment of a contiguous treatment assembly 11. Accordingly, a number of treatment assemblies 11 can be arranged in a horizontal series with each media compartment 14 defined by a screen 16 separating the media compartment from the media-free compartment 12 of the assembly and by a second screen separating the media compartment from the media compartment of a contiguous treatment assembly 11. Apart from the screens 16, the vertical sides of each treatment assembly 11 are watertight and are sealed to the base of reaction vessel 10. In one preferred embodiment, the tops of each treatment assembly are uncovered, but in all embodiments an open space 19 is provided along the tops of the vertical sides of treatment assemblies 11.
A number of biomass support bodies 18 are housed in each media compartment 14. The bodies 18 can be constructed of ceramic, rock, porous plastic, sponge or formed plastic as dictated by the nature of the effluent and the treatment objectives.
The treatment of effluent or sewage by handling in reaction vessel 10 is as follows. Effluent (not shown) is pumped into open space 19 above the media compartment 14 of the first treatment unit 11. Under the action of its own weight and, shortly thereafter, the action of recirculated, unreacted effluent as well, the effluent flows downward in the media compartment and contacts the biomass support bodies 18. This contact produces an increase in biomass as nutrient leaves the effluent to produce more biomass. As the unreacted effluent nears the base of media compartment 14, it is drawn through screen 16 into media-free compartment 12. The upward air flow from diffusers 20 oxygenates and propels the unreacted effluent up media-free compartment 12 until the unreacted effluent spills over the top of screen 16 and again into the top of media compartment 14.
While the effluent is being pumped into the media compartment of the first treatment assembly 11, an upward airflow is simultaneously being generated in the media-free compartment 12 of the next, contiguous treatment unit 11. This structure is shown in FIG. 2. As noted, the media compartment 14 shares a common screen with the contiguous media-free compartment 12 of the next treatment assembly 11. Thus, some of the unreacted effluent is drawn into and propelled up the next media-free compartment. The upwardly propelled effluent spills over the top of the media-free compartment and into both the media compartment of the first treatment assembly and the media compartment of the second treatment assembly.
The simultaneous action of the downwardly flowing effluent in the media compartments being fed by the effluent spilling over from the media-free compartments creates an overall net hydraulic flow, from left to right of FIG. 1, through the treatment assemblies 11. As the effluent passes down each successive media compartment 14, nutrients in the effluent react with the biological populations in the biomass support bodies 18.
As can be appreciated, a reaction vessel comprising a number of treatment assemblies 11 can be controlled and modified to precisely tailor the treatment environment. Variables such as the acidity of the treatment environment, the control of recirculated solids, control of biomass density and selective removal or treatment of sludge can be precisely controlled. Media compartments 14 can be partially or completely filled with bodies 18. If media compartments 14 are completely filled with bodies 18 so as to create a packed bed reactor, the biomass will operate in a fixed film mode with the biomass being retained in the bodies 18. On the other hand, a suspended growth mechanism can be achieved by partially filling the media compartments 14 with bodies 18 so that the bodies move with respect to one another and with respect to the screens 16.
Additional oxygenation of the downwardly flowing effluent for superior oxygen transfer efficiency and reduced energy consumption can be provided through operation of supplemental diffusers 28 located at the base of each media compartment 14. Supplemental diffusers 28 can be operated to agitate the bodies 18 in selected media compartments which are completely filled with such bodies so as to cause excess biomass to be shaken loose so it can thereafter be removed. Means for slightly aerating or circulating the effluent can be provided to fluidize the bodies.
Each treatment assembly 11 can be individually stocked with bodies 18 to tailor a biological environment independent of the adjoining treatment assemblies. Additionally, the specific geometry of each treatment assembly 11 can be selected to provide a reaction vessel 10 having media compartments of varying volume.
The process and apparatus of the invention for treating effluent can also be adapted to allow continuous or intermittent removal and reinsertion of biomass support bodies 18 as, for example, the bodies become filled with biomass. Additionally, the process and apparatus of the invention can be adapted to provide an anoxic or an anaerobic environment in which circulation of the effluent is accomplished by mechanical means in lieu of diffusers 20. For example, the process and apparatus of the invention can be adapted to provide an anoxic environment by recirculating off-gases.
It is also contemplated that the process and apparatus of the invention can be structured to provide extremely high rates of recirculation. For example, it may be desirable to provide a false bottom under each of the media compartments 14, solid walls instead of screens between the aeration compartments 12 and the media compartments 14 and to recirculate effluent back along the false bottom to the first treatment assembly 11.
As shown in FIGS. 4 and 5, a further process and apparatus in accordance with the invention may include a conventional activated sludge process to further treat the effluent, such as, for example, by flocculating the effluent. The activated sludge process may, for example, take place after the effluent has circulated through the series of treatment assemblies 11.
In addition to incorporating an activated sludge process into the process of the present invention, the invention may be utilized in conjunction with other processes such as nitrification processes, denitrification processes using anoxic treatment and flocculation processes for phosphorus control.
Also, the process and apparatus of the present invention may be adapted as an independent process or apparatus used to scavenge additional carbonaceous bio-chemical oxygen demand (BOD). For example, a process according to the present invention could be operated following treatment of the effluent in a conventional carbonaceous BOD removal process. Since carbonaceous BOD is responsible for the bulk of cell growth in any biological process, it is contemplated that the full range of biomass support configurations could be used to provide a process which most effectively handles the cell growth.
The invention may also be used in a process or apparatus used to remove nitrogenous or ammonia BOD. The process or apparatus could be designed with the knowledge that the process of removing ammonia by converting it to nitrate compounds typically results in limited cell growth and, correspondingly, no need of filtration to handle excess solids. Of course if the nitrogenous BOD removal process results in limited cell growth, the process or apparatus of the invention can also operate with limited solid accumulation in the biomass support bodies without the need for periodic removal of biomass.
Although the invention has been described with respect to certain embodiments, it is understood that other embodiments and modifications can be made without departing from the scope or spirit of the invention. | A process and an apparatus is provided for growing biomass from a supply of nutrient in a manner which permits precise control of the biomass growth environment. A reaction vessel includes a media-free compartment and a media compartment which retains biomass support bodies. A screen separates the two compartments. Nutrient is circulated through the media compartment, passed through the screen and is oxygenated and/or re-circulated between said compartments. As shown in FIG. 3, additional pairs of media-free and media compartments can be connected in series to provide a single reaction vessel. Suspended or packed biomass support bodies can be used and can be continuously or intermittently removed for cleaning. | 2 |
BACKGROUND
[0001] The present invention generally relates to an apparatus that may be used to hold pet refuse or waste, and more specifically an apparatus of this type that may be connected to a pet leash or that may be a part of a pet leash.
[0002] It is a common requirement that pets in public places, such as parks and walkways, be connected to a leash that is controlled by the person accompanying the pet. There are also many instances where a leash is desired to control the movement of a pet located on private premises. In addition, there is also often a requirement or desire that the person accompanying the pet promptly remove any refuse or waste deposited by the pet on the premises. In these cases, the person often carries a bag, which is used to scoop up and retain the deposited pet refuse. After retrieving the pet refuse in the bag, the person often ties a knot in the bag adjacent to the bag opening so that neither the refuse, nor the odor it produces, escapes from the bag. For obvious reasons, the person typically does not desire to hold the bag with his or her hands or anything closely associated with the person (such as a pocket in the clothing) after retrieving the waste. Thus, there is a need for an apparatus that may be used to carry the bag until the bag may be properly disposed of, in which the person is not required to directly contact the bag after retrieving the pet refuse. There is also the need for the apparatus to be lightweight and unobtrusive so that it does not interfere with the enjoyment of time spent with the pet. Further, the apparatus needs to be easy to use, especially in light of the ongoing need to control the movement of the pet. Further still, the apparatus needs to be inexpensive to manufacture.
SUMMARY
[0003] The present invention is directed to an apparatus that meets the needs discussed above in the Background section. As described in greater detail below, the present invention, when used for its intended purposes, has many advantages over other devices known in the art, as well as novel features that result in a new apparatus and a new method for its use that are not anticipated, rendered obvious, suggested, or even implied by any prior art devices or methods, either alone or in any combination thereof.
[0004] In one version, the present invention is comprised of an apparatus used to hold a pet refuse bag. In this version, the apparatus is comprised of a cord member, cord connecting means to connect the cord member to a pet leash, and slideable clamping means having a passageway therein bounded by two entry points. Both the cord connecting means and the slideable clamping means are described in more detail below. The cord member is positioned in the passageway in a manner so that a leash-connecting loop is formed in the cord member adjacent to the slideable clamping means at one entry point of the passageway. A bag-holding loop is formed in the cord member adjacent to the slideable clamping means at the other entry point of the passageway. The leash-connecting loop is connected to the cord connecting means. A portion of a pet refuse bag is placed within the bag-connecting loop, so that the slideable clamping means may be slid down the cord member along the bag-holding loop until the slideable clamping means is positioned approximately adjacent to the pet refuse bag. The slideable clamping means may then be clamped to the portion of the cord member positioned within the passageway of the slideable clamping means so that the pet refuse bag is held securely within the bag-holding loop. In some embodiments of this version, the cord connecting means may be comprised of an aperture positioned in the pet leash. The leash-connecting loop is connected to the pet leash by a portion of the leash-connecting loop being positioned within the aperture. Alternatively, the cord connecting means may be comprised of a fastener, in which the fastener attaches a portion of the leash-connecting loop to the pet leash. In other embodiments, the slideable clamping means may be a mechanical toggle holding device, a buckle-type clasp, a friction collar, or another type of clamping device. In still other embodiments, the apparatus may further comprise the pet refuse bag, the pet leash, or both.
[0005] In another version of the present invention, the apparatus is comprised of a cord member, a cord connecting member, and a slideable clamping member having a passageway therein bounded by two entry points. In this version, cord connecting means are used to connect the leash-connecting loop of the cord member to the cord connecting member and member connecting means are used to connect the cord connecting member to a pet leash. Both the cord connecting means and the member connecting means are described in more detail below. In this version, and except as described in more detail elsewhere herein, the apparatus has substantially the same structure, features, functions and characteristics as the first version of the present invention described above. In some embodiments, the member connecting means may be comprised of an adhesive positioned on a surface of the cord connecting member. The adhesive may be covered with a peel-off strip that is removed from the adhesive, exposing the adhesive, prior to attachment of the cord connecting member to the pet leash. The cord connecting member is attached to a surface of the pet leash by means of the adhesive. In this version, some embodiments may also further comprise the pet refuse bag, the pet leash, or both.
[0006] The present invention also includes a method of securing and holding a pet refuse bag to a pet leash using the apparatus of the present invention. The method generally comprises the following described actions. A portion of a pet refuse bag is placed within the bag-connecting loop portion of the cord member. Next, the slideable clamping member is slid down the cord member along the bag-holding loop until the slideable clamping member is positioned approximately adjacent to the pet refuse bag. Next, the slideable clamping member is clamped to the portion of the cord member positioned within the passageway of the slideable clamping member so that the pet refuse bag is held securely within the bag-holding loop.
[0007] The apparatus and method of the present invention therefore meet the requirements set forth above in the Background section above. For example, using the disclosed apparatus and method, a pet refuse bag may be removably connected to a pet leash. Thus, the person holding the pet leash is not required to hold the pet refuse bag with his or her hands or anything closely associated with the person (such as a pocket in the clothing) after retrieving the waste. In addition, the apparatus is lightweight and unobtrusive so that it does not interfere with the enjoyment of time spent with the pet. Further, the apparatus is easy to use, especially in light of the ongoing need to control the movement of the pet. Further still, the apparatus is inexpensive to manufacture.
[0008] There has thus been outlined, rather broadly, the more primary features of the present invention. There are additional features that are also included in the various embodiments of the invention that are described hereinafter and that form the subject matter of the claims appended hereto. In this respect, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the following drawings. This invention may be embodied in the form illustrated in the accompanying drawings, but the drawings are illustrative only and changes may be made in the specific construction illustrated and described within the scope of the appended claims. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing summary, as well as the following description, will be better understood when read in conjunction with the following appended drawings:
[0010] FIG. 1 , which is a perspective view of an embodiment of the apparatus of the present invention from above and to the side of the apparatus;
[0011] FIG. 2A , which is a perspective view of another embodiment of the slideable clamping means of the apparatus of FIG. 1 ;
[0012] FIG. 2B , which is a perspective view of yet another embodiment of the slideable clamping means of the apparatus of FIG. 1 ;
[0013] FIG. 3 , which is a perspective view of yet another embodiment of the slideable clamping means of the apparatus of FIG. 1 ;
[0014] FIG. 4 , which is a perspective view of another embodiment of the apparatus of the present invention from above and to the side of the apparatus; and
[0015] FIG. 5 , which is a plan view of the connecting surface of the cord connecting member of the embodiment of the apparatus illustrated in FIG. 4 , as taken along the lines 5 - 5 in FIG. 4 ;
[0016] FIG. 6A , which is a perspective view of another embodiment of the cord connecting member; and
[0017] FIG. 6B , which is a perspective view of a cord connecting member removably attached to a conventional lead, which is also shown in perspective view.
DETAILED DESCRIPTION
[0018] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it is to be noted that the embodiments are not intended to limit the invention to those embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents that may be included within the spirit and scope of the invention as defined by the appended claims.
[0019] An embodiment of the present invention is represented by the apparatus 10 illustrated in FIG. 1 . In this embodiment, the apparatus 10 is generally comprised of a pet leash 20 , a cord member 30 , cord connecting means to connect the cord member 30 to the pet leash 20 , and slideable clamping means. The cord connecting means and slideable clamping means are both described in more detail below. The pet leash 20 illustrated in FIG. 1 is a retractable pet leash 20 generally comprised of a body 21 , a handle 22 , a cord retraction switch 23 , and a retractable cord 24 . Although the handle 22 and the outer shell of the body 21 of the pet leash 20 are usually constructed primarily of a plastic material, other materials may also be used in their construction. The user of the apparatus 10 typically holds the pet leash 20 by the handle 22 . Using the cord retraction switch 23 , the user may cause the retractable cord 24 to be extended from and retrieved to a coil of cord (not illustrated) inside the body 21 . This action allows the pet (not illustrated) connected to the distal end of the retractable cord 24 to move farther from the pet leash 20 (and therefore farther from the user of the apparatus 10 ) or be pulled closer to the pet leash 20 (and therefore closer to the user). This type of pet leash 20 is well known in the relevant art, and the details of its operation are not material to this description of the present invention. It is to be noted that the pet leash 20 of FIG. 1 is illustrative only. In other embodiments, other types of pet leashes may be utilized in lieu of the pet leash 20 . For example, the pet leash 20 may be a conventional lead 420 , such as a cotton web or leather lead, as illustrated in FIG. 6B , or other types of pet leashes or leads currently known in the art or that may be developed in the art in the future. It is also to be noted that in some embodiments, the present invention is comprised of the cord connecting means, the cord member 30 , and the slideable clamping means. In other embodiments, the present invention may be further comprised of the pet leash 20 or the pet refuse bag 40 or both.
[0020] The cord member 30 is generally a continuous cord without ends, as illustrated in FIG. 1 . Preferably, the cord member 30 is seamless, so that there are no knots or other connectors or fasteners present along its length. It is possible, however, that in other embodiments the cord member 30 could be comprised of a cord with ends, in which the ends are tied together, such as by a square knot, or otherwise fastened together to form the cord member 30 . The cord member 30 may be comprised of any materials suitable for use as a cord, as long as the cord member 30 has adequate strength to hold the pet refuse bag 40 in normal operation of the apparatus 10 . For example, the cord member 30 may be comprised of rubber (including neoprene) and other elastomers, homogeneous polymers, twisted or woven polymer fibers, cotton fibers, other fibers, cloth, fabrics, or other suitable materials or combinations of such materials. Such materials may allow the cord member 30 to stretch. Preferably, the cord member 30 is comprised of nylon. In addition, the length of the cord member 30 , when it is positioned in a manner so that it is linear with two strands positioned side-by-side, is preferably in the range from three inches to eight inches long (from linear end point to end point). More preferably, the cord member 30 is approximately five inches long when placed in this orientation. Further, the cord member 30 preferably has a circular cross-section with a diameter in the range from 1/16th inch to ⅛th inch. In other embodiments, however, the cord member 30 may have a different shaped cross-section. For example, the cross-section of the cord member 30 may be elliptical, arcuate, square, rectangular, triangular, pentagonal, hexagonal or another shape or combination of such shapes.
[0021] In the apparatus 10 illustrated in FIG. 1 , the slideable clamping means is a mechanical toggle holding device 50 having a passageway 50 a therein that is bounded by entry points 51 and 52 . A portion of the cord member 30 is positioned in the passageway 50 a in a manner so that a leash-connecting loop 31 is formed in the cord member 30 adjacent to the mechanical toggle holding device 50 at one entry point 51 of the passageway 50 a and a bag-holding loop 32 is formed in the cord member 30 adjacent to the mechanical toggle holding device 50 at the other entry point 52 of the passageway 50 a. When the button 53 of the mechanical toggle holding device 50 is pressed down, the cord member 30 is released so that the mechanical toggle holding device 50 may slide along the cord member 30 . When the button 53 of the mechanical toggle holding device 50 is released, the cord member 30 is held in position in the passageway 50 a so that the mechanical toggle holding device 50 does slide along the cord member 30 . In operation, a portion of a pet refuse bag 40 is placed within the bag-connecting loop 32 . The mechanical toggle holding device 50 is then slid down the cord member 30 along the bag-holding loop 32 until the mechanical toggle holding device 50 is positioned approximately adjacent to the pet refuse bag 40 . The mechanical toggle holding device 50 may then be clamped to the portion of the cord member 30 positioned within the passageway 50 a of the mechanical toggle holding device 50 so that the pet refuse bag 40 is held securely within the bag-holding loop 32 . Preferably, there is a knot 41 tied approximately adjacent to the opening of the pet refuse bag 40 to prevent the refuse and associated odor from escaping from the pet refuse bag 40 and to assist the bag-holding loop 32 in holding the pet refuse bag 40 . To release the pet refuse bag 40 , the mechanical toggle holding device 50 is unclamped from the cord member 30 and slid down the cord member 30 along the leash-connecting loop 31 a distance until the pet refuse bag 40 can be removed from the bag-holding loop 32 .
[0022] It is to be noted that in other embodiments, the slideable clamping means may take another form. For example, as illustrated in FIG. 2A , the slideable clamping means may be in the form of a friction collar 150 having a passageway 150 a therein that is bounded by entry points 151 and 152 . In this embodiment, a portion of the cord member 130 is positioned within the passageway 150 a of the friction collar 150 in a manner so that a leash-connecting loop 131 is formed in the cord member 130 adjacent to the friction collar 150 at one entry point 151 of the passageway 150 a, and a bag-holding loop 132 is formed in the cord member 130 adjacent to the friction collar 150 at the other entry point 152 of the passageway 150 a. The passageway 150 a and the cord member 130 each have a cross-sectional shape and diameter such that the friction collar 150 is held in place relative to the cord member 130 by friction. When an adequate force is applied longitudinally against the friction collar 150 while the cord member 130 is held in place, the friction collar 150 slides along the cord member 130 until the force is removed, at which point the friction collar 150 is once again held in place (clamped) relative to the cord member 130 by friction. Thus, the bag (not illustrated) can be placed in the bag-holding loop 132 , and the friction collar 150 may be slid along the cord member 130 until the friction collar 150 is approximately adjacent to the bag. The friction collar 150 is then held in place by friction (clamped), allowing the bag to be held in the bag-holding loop 132 until a force is applied to the friction collar 150 , moving it away from the bag and thereby releasing the bag. In yet another embodiment, as illustrated in FIG. 2B , the passageway 150 a ′, 150 a ″ of the friction collar 150 ′ may be comprised of two channels 150 a ′, 150 a ″. In this embodiment, the friction collar 150 ′ may have substantially the same type of features, structure and operation as the friction collar 150 described above and illustrated in connection with FIG. 2A , except that the passageway 150 a ′, 150 a ″ is comprised of two separate channels 150 a ′, 150 a ″ and each channel 150 a ′, 150 a ″ has a portion 130 a ′, 130 b ′ of the cord member 130 ′ positioned therein. Each portion 130 a ′, 130 b ′ of the cord member 130 ′ is held in place relative to the friction collar 150 ′ by friction. As yet another example, as illustrated in FIG. 3 , the slideable clamping means may take the form of a buckle-type clasp 250 . In this embodiment, a portion of the cord member 230 is positioned within the “passageway” of the clasp 250 , which is generally comprised of two apertures 251 , 252 that also function as entry points to the clasp 250 for the cord member 230 . Thus, the leash-connecting loop 231 is formed adjacent to aperture 251 and the bag-holding loop 232 is formed adjacent to aperture 252 . The clasp 250 is held against the cord member 230 by friction when the cord member 230 is pulled tightly through the apertures 251 , 252 . The clasp 250 may be slid along the cord member 230 when the cord member 230 has a loop on the side of the apertures 251 , 252 opposite the side of the clasp 250 where the cord member 230 enters the apertures 251 , 252 . In yet other embodiments, the slideable clamping means may be other types of devices, such as cam-type clamps, clips, or other suitable devices or combinations of such devices currently known in the art or that may be developed in the art in the future. It is also to be noted that the “passageway” of the slideable clamping means may take many shapes and forms.
[0023] In the apparatus 10 illustrated in FIG. 1 , the cord connecting means is comprised of a protruding member 25 having an aperture 26 therein. In this embodiment, the leash-connecting loop 31 of the cord member 30 is connected to the protruding member 25 (as the cord connecting means) by positioning the leash-connecting loop 31 of the cord member 30 in the aperture 26 in the manner illustrated in FIG. 1 . The aperture 26 in the protruding member 25 may have any suitable shape. In other embodiments, the cord connecting means may take any suitable form. For example, as is also illustrated in FIG. 1 , the cord connecting means may be comprised of a recess 27 and a pin 28 (both shown in phantom in FIG. 1 ). In this case, the leash-connecting loop 31 a of the cord member 30 a (both shown in phantom in FIG. 1 ) is positioned in the recess 27 in the manner illustrated in FIG. 1 . In yet other embodiments, the cord connecting means used to connect the leash-connecting loop 31 to the pet leash 20 may take the form of another suitable fastener, such as glue, adhesive, adhesive tape, screws, nuts and bolts, pins, dowels, nails, clamps, clasps, brackets, hook and loop fasteners (such as VELCRO), or other means or combinations of such means.
[0024] Another embodiment of the present invention is illustrated in FIG. 4 . In this embodiment, the apparatus 310 has substantially the same structure, features, functions and characteristics as the embodiment of the apparatus 10 described above and illustrated in connection with FIG. 1 , except that the apparatus 310 is comprised of a cord connecting member 360 instead of a pet leash 20 . The embodiment of the apparatus 310 illustrated in FIG. 4 is also comprised of member connecting means, which are described in more detail below, to connect the cord connecting member 360 to a pet leash 320 . In this embodiment, the leash-connecting loop 331 of the cord member 330 is connected to the cord connecting member 360 by cord connecting means. The cord connecting means of the apparatus 310 may have substantially the same structure, features, functions and characteristics as the cord connecting means of the apparatus 10 described above and illustrated in connection with FIG. 1 , except that the cord connecting means of the apparatus 310 is used to connect the leash-connecting loop 331 to the cord connecting member 360 instead of a pet leash 20 . The cord connecting member 360 may have almost any shape as long as at least one surface of the cord connecting member 360 is of a size and shape adapted to be connected to the pet leash 320 using the member connecting means, which are described in more detail below. For example, the cord connecting member 360 may have shapes and surfaces that are wholly or partially spheroidal, ellipsoidal, polygonal, or having other linear or arcuate surfaces, contours or shapes or combinations of such shapes. In addition, the aperture 362 in the cord connecting member 360 may have any suitable shape. Preferably, the cord connecting member 360 has the shape illustrated in FIG. 4 and FIG. 5 . In the embodiment illustrated in FIG. 4 and FIG. 5 , the surface 361 of the cord connecting member 360 is adapted to be attached to the lower surface of the body 321 of the pet leash 320 in the manner illustrated in FIG. 4 . In other embodiments, the cord connecting member 360 may be attached to other portions or surfaces of the pet leash 320 . The cord connecting member 360 may also be constructed of any suitable material. For example, the cord connecting member 360 may be constructed of metal, minerals, cloth, fabric, leather, glass, wood, cork, bone, plastics or other polymers, ceramics, paper, fiberglass, resins, or other artificial and naturally occurring materials, or combinations of such materials. Preferably, the cord connecting member 360 is constructed of a material that allows the surface 361 to flex slightly to accommodate curvatures in the surface of the pet leash 320 to which the cord connecting member 360 is connected. More preferably, the cord connecting member 360 is constructed of a semi-rigid polymer, such as silicone or nylon. The member connecting means may be comprised of any means suitable to connect the cord connecting member 360 to the pet leash 320 . For example, the member connecting means may be comprised of an adhesive (not illustrated) positioned on the surface 361 of the cord connecting member 360 that is to be connected to the pet leash 320 . The adhesive may be covered with a peel-off strip (not illustrated) that is removed from the adhesive, exposing the adhesive, prior to attachment of the cord connecting member 360 to the pet leash 320 . The cord connecting member 360 is attached to a surface of the pet leash 320 by means of the adhesive. Examples of adhesive/peel-off strips that are suitable for this purpose include 3M VHB Tapes and 3M Double Coated Tapes with release liner that are sold by the 3M Company. In other embodiments, the member connecting means may be comprised of hook and loop fasteners, such as VELCRO. For example, the surface 361 of the cord connecting member 360 may have the hook portions (not illustrated) positioned thereon and the portion of the surface of the pet leash 320 to which the cord connecting member 360 is attached may have the loop portions (not illustrated) positioned thereon, so that the cord connecting member 360 may be removably connected to the pet leash 320 using the hook and loop fasteners. Another example of how hook and loop fasteners may be utilized is illustrated in FIG. 6A and FIG. 6B . In this embodiment, the connecting member 460 , 460 ′ is comprised of a cord connecting portion 463 , 463 ′ and a strap portion 464 , 463 ′, respectively. The cord connecting portion 463 may be mounted on the strap portion 464 , as illustrated in FIG. 6A , or the cord connecting member 463 ′ may be incorporated as a part of the strap portion 464 ′, as illustrated in FIG. 6B . It is to be noted that the connecting portion 463 , 463 ′ and the strap portion 464 , 464 ′ may be of almost any shape or size as long as they may be used to connect the cord connecting member 460 , 460 ′ to the pet leash 420 . The surface 465 of the strap portion 464 that faces away from the pet leash 420 has hook portions positioned on one portion 465 a thereof. The surface 466 of the strap portion 464 that faces toward the pet leash 420 has loop portions (not illustrated) positioned on a portion thereof, so that the hook portions and the loop portions removably interconnect when the strap portion 464 of the cord connecting member 460 is wrapped around the pet leash 420 , as described below. In operation, as illustrated in FIG. 6B , the cord connecting member 460 ′ is placed approximately adjacent to a surface of the pet leash 420 and the distal portions of the strap portion 464 ′ are wrapped around the pet leash 420 until the hook and loop fasteners interface to make a removable connection. It is to be noted that in other embodiments the hook portions and loop portions may be positioned on different surfaces of the cord connecting member 460 , 460 ′, which can be wrapped around the pet leash 420 in different ways. It is also to be noted that the cord connecting member 460 , 460 ′ may also be used in conjunction with the pet leash 320 illustrated in FIG. 4 . For example, the cord connecting member 460 , 460 ′ may be connected to the handle 322 of the pet leash 320 in a manner similar to that described above and illustrated in connection with FIG. 6B . Referring again to FIG. 4 and FIG. 5 , in still other embodiments, the member connecting means used to connect the cord connecting member 360 to the pet leash 320 may take other suitable forms of permanent or removable means, such as glue, adhesive, adhesive tape, screws, nuts and bolts, pins, dowels, nails, clamps, clasps, brackets, or other means or combinations of such means. It is to be noted that in yet other embodiments, the apparatus 310 may further comprise the pet leash 320 (or 420 ) or the bag (not illustrated), or both.
[0025] Referring again to the apparatus 10 of FIG. 1 as an example, the present invention also includes a method of securing and holding a pet refuse bag 40 to a pet leash 20 . Generally, the method comprising the following actions. First, a portion of the pet refuse bag 40 is placed within the bag-connecting loop 32 of the cord member 30 . Next, a slideable clamping member (the mechanical toggle holding device 50 in the embodiment of FIG. 1 ) is slid down the cord member 30 along the bag-holding loop 32 until the slideable clamping member 50 is positioned approximately adjacent to the pet refuse bag 40 . The slideable clamping member 50 is then clamped to the portion of the cord member 30 positioned within the passageway of the slideable clamping member 50 so that the pet refuse bag 40 is held securely by the bag-holding loop 32 . | The present invention is an apparatus that is used to hold a bag in which pet refuse or waste is deposited without the need to directly hold the bag with the hands or another item closely associated with the person accompanying the pet, such as the person's clothing. The apparatus is generally comprised of a cord member and a clamping member. A bag-holding loop and a leach-connecting loop are formed in the cord member by the clamping member. The pet refuse bag is held within the bag-holding loop by sliding the clamping member down the cord member until the clamping member is adjacent to the bag. The leash-connecting loop is attached to a pet leash or a cord connecting member, which may be attached to a pet leash. The present invention also includes a method of using the apparatus. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of, and claims the benefit of, the applicants' prior parent regular utility patent application, entitled Safety Apparatus and Method of Use, Ser. No. 11/640,809, filed Dec. 18, 2006, now U.S. Pat. No. ______, which is a continuation of, and claims the benefit of, the applicants' prior parent regular utility patent application, entitled Safety Apparatus and Method of Use, Ser. No. 11/233,675, filed Sep. 22, 2005, now U.S. Pat. No. 7,150,054, issued Dec. 19, 2006, which prior parent regular utility patent application claimed the benefit of the applicants' prior U.S. provisional patent application Ser. No. 60/719,671, filed Sep. 21, 2605, entitled Safety Apparatus and method of Use. The contents of the above-referenced prior patent application are hereby incorporated by reference in their entirety.
FIELD
[0002] The application concerns a device for orienting a body with respect to another object and method of use. In one embodiment, the application concerns a device for relatively securely orienting a human body, such as a sleeping infant for example, with respect to an adjacent blanket or sheet and method of use.
BACKGROUND
[0003] A common problem faced by caregivers and parents of an infant, particularly a young infant, is that the infant typically is unable to keep a blanket over a lower portion of the infant while the infant is asleep. This arises because the infant may move around during sleep or kick off the blanket. This can result in the infant becoming cold during sleep and therefore waking, requiring the attention of an adult to re-cover the infant. In more serious cases, the blanket can be moved up over the face of the infant or the infant may slip down under the blanket thus increasing the risk of overheating and suffocation of the infant.
[0004] A further problem commonly faced by caregivers and parents of infants is that the infant may roll over onto its stomach during sleep thus also increasing the risk of suffocation. Also, the infant may roll over during sleep and wedge their face against the side of a cot in which it sleeps, again increasing the risk of suffocation.
[0005] Yet another problem for caregivers and parents is the possible loss of oxygen and other problems (such as falling out of bed) that may arise for an infant if it moves toward the sides or headboard of bed.
[0006] One solution known in the art is to tuck a blanket tightly around an infant and hope that the infant does not have enough strength to remove the blanket. However, there is a risk that the blanket could be tucked too tight and thus restrict the infant's breathing. A further known solution is to simply not cover the infant during sleep, but provide a very warm room in which the infant can sleep. However, the cost of heating a room to a suitable temperature, and maintaining the same, renders such a solution impractical to most parents. Also, the use of heaters to maintain such a temperature increases the risk of fire thus endangering the infant.
SUMMARY
[0007] Certain embodiments of the present invention address one or more of the above mentioned problems and provide a solution which reduces the risk of suffocation to an infant while also reducing the infant's discomfort.
[0008] Some embodiments provide a safety device for offering increased safety to a sleeping infant comprising cover means operable to cover at least a portion of an infant and securing means operable to secure at least a portion of an infant to the cover means.
[0009] In certain embodiments, the cover means comprise a blanket or sheet. The cover means may be formed of a soft material which may be a fabric material. The cover means may be formed from any natural or synthetic fabric, or any woven or non-woven fabric. Examples of a soft fabric material include brushed cotton and fleece.
[0010] In certain embodiments, the securing means are adjustable. The securing means may comprise a support member that may be adapted to fit between the legs of an infant. The support member may comprise a seat that is preferably adapted to support the seat of an infant. The support member may be attached to a first face of the sheet, such as, for example, toward a first end thereof. The support member may comprise a crotch strap or support.
[0011] In some embodiments, the securing means comprises strapping means, which strapping means may be adapted to strap an infant to the cover means. The strapping means may comprise a strap, a center section of which may be attached toward a second end of the support member. The securing means can generally triangularly or T-shaped. The securing means may comprise a harness that may fit between an infant's legs and around an infant's waist or torso.
[0012] The cover means may comprise at least one aperture. Alternatively, the cover means may comprise at least two apertures. The strapping means may be adapted to pass through the at least one aperture in the cover means. The strapping means can be adapted to pass through the at least two apertures in the cover means.
[0013] In some embodiments, the securing means is operable to secure at least a portion of an infant to a first face of the cover means. The securing means can be operable to be adjusted at a second face of the cover means.
[0014] The safety device may also further comprise strap retaining means operable to secure the strapping means to the cover means. The strap retaining means can be attached to the second face of the cover means.
[0015] In certain embodiments, toward a first end of the strapping means are attachment means operable to removably attach the first end of the strapping means to the strap retaining means. Toward a first end of the strapping means may be strap attachment means operable to removably attach a second end of the strapping means thereto. In additions toward a second end of the strapping means may be attachment means operable to removably attach the second end of the strapping means to the first end of the strapping means.
[0016] In certain embodiments, the safety device is adapted to be attached to or incorporated within a surface, which surface may be substantially planar. In certain embodiments, the surface is a surface upon which an infant sleeps. Alternatively, the safety device may be sized and used with other than infants, in order to more reliably secure a non-infant in position, such as infirm elderly person.
[0017] The safety device may be attached to or incorporated within a bed sheet or mattress such that an infant (or other body) may be held in position relative to the bed sheet or mattress by the safety device. The safety device can be attached to or incorporated within a bed sheet or mattress so as to form a pocket. The pocket can be adapted to receive an infant therein and may be locate to maintain the infant in a desired position with respect to the bed or other structure, including the bed sheet.
[0018] In some embodiments, the support member is attached to an internal face of the cover means when the safety device is attached to or incorporated within a bed sheet or mattress. By internal face of the cover means it is meant a face of the cover means which directly abuts the mattress or bed sheet. The strapping means may be operable to be secured to an external face of the cover means when the safety device is attached to a mattress or bed sheet (and in this application, the term “sheet” includes blankets as well as conventional bed sheets).
[0019] In certain embodiments, a method of securing an infant (or other body) to a surface comprises the steps of: attaching a safety device comprising cover means and securing means to a surface, placing an infant or other body between the safety device and the surface, adjusting the securing means to fit the infant or other body, and securing the infant or other body to the safety device using the securing means. The method may instead or in addition comprise placing a cover on the infant or other body after first placing the infant or other body in the security means, such as a harness, and securing the harness in place. Other methods are disclosed.
[0020] In certain embodiments, the surface is a mattress or bed sheet.
[0021] All of the above aspects may be combined with any of the features disclosed herein in any combination.
[0022] The foregoing is a brief summary of aspects of the various embodiments disclosed in this specification. There are additional aspects that will become apparent as this specification proceeds. In addition, it is to be understood that embodiments of the invention need not include all such aspects or address all issues in the Background above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The preferred and other embodiments are shown in the accompanying drawing in which:
[0024] FIG. 1 shows a perspective view of a front surface of a safety (or securing) device;
[0025] FIG. 2 shows a perspective view of a rear surface of a safety device;
[0026] FIG. 3 shows a perspective view of a safety device attached to a mattress cap;
[0027] FIG. 4 shows a perspective view of a safety device attached to a fitted bed sheet in a predetermined position (for example to secure an infant adjacent the foot of a bed or at least away from the head or head board of a bed);
[0028] FIG. 5 shows a partial cross-sectional view from the top of a safety device attached to a bed sheet, the bed sheet being fitted to a mattress;
[0029] FIG. 6 shows a perspective view of a rear surface of a second embodiment of a safety device;
[0030] FIG. 7 shows a perspective view of a safety device secured to a fitted mattress with straps penetrating passages in the fitted sheet;
[0031] FIG. 8 shows a bottom view of the fitted sheet with the safety device mounted to the fitted sheet as in FIG. 7 ;
[0032] FIG. 9 shows a perspective view of an alternative arrangement for securing a safety device to a fitted mattress at the sides of the mattress;
[0033] FIG. 10 is a side view showing a method in which a blanket is slid over the bottom end of a mattress with a cover sheet;
[0034] FIG. 11 is a perspective view showing insertion of a harness on top of the mattress, in the method of FIG. 10 ;
[0035] FIG. 12 is a perspective view showing insertion of an infant between the harness and upper blanket, in the method of FIG. 10 ;
[0036] FIG. 13 is a perspective view showing the opposing securing straps of the harness pulled through mating strap passages in the blanket providing for strap locations on opposing sides of the infant's torso, in the method of FIG. 10 ;
[0037] FIG. 14 is a perspective view showing a first securing strap secured to a mating hook and pile fastener section on the upper surface of the blanket above the infant's torso, in the method of FIG. 10 ; and
[0038] FIG. 15 is a perspective view showing a second securing strap secured to a mating hook and pile fastener section on the upper surface of the first secured strap above the infant's torso, completing the method of FIG. 10 .
[0039] In the following Detailed Description section various spatially orienting terms are used such as “upper” and “lower.” It is to be understood that such terms are used for convenience in association with the drawings but are not be themselves limiting or requiring of any absolute orientation in space.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] Referring to FIGS. 1 and 2 , a safety device 102 comprises cover means in the form of a rectangular sheet 104 , and a harness 106 . The sheet 104 and the harness 106 are formed of a flexible, soft, and breathable material, such as fleece. It should be appreciated that the sheet 104 and the harness 106 may be made from any suitable material. Factors to consider when choosing a suitable material include the softness of the material, possible irritation to the infant's skin, climate in which the device will be used (i.e., cooling fabrics for warmer climates, etc.) fabrics which will not react to an infant's bodily excretions such as saliva, vomit and urine, etc.
[0041] The harness 106 comprises a gusset strap 108 as displayed in FIG. 2 and a securing strap 110 extending perpendicularly away from each side of a first end thereof. The gusset strap 108 of the harness 106 is attached at a second end thereof to a rear face 112 of the sheet 104 . The attachment may be accomplished in a wide variety of ways, such as by stitching or with buttons in mating button holes in the harness, or via other fastening techniques.
[0042] The opposing ends of the securing strap 110 pass from the rear face 112 of the sheet 104 to a front face 114 of the sheet 104 via two laterally spaced elongate apertures 116 in the sheet 104 . Therefore, as shown in FIG. 2 , the harness 106 forms a T shape, but other shapes may be utilized.
[0043] An alternative embodiment of a harness 206 is shown in FIG. 6 . In this embodiment, the harness 206 has a seat 208 of a shape that an infant can sit in, for example, in the shape of a seat of a pair of briefs. A bottom edge 210 of the seat 208 is secured to the rear face 112 of the sheet 104 . Attached at opposing sides toward the top of the seat 208 are securing straps (not shown) which extend through the apertures 116 and function in the same manner as will be described below. The front face 114 of the sheet 104 fitted with the preferred harness 206 is as described with reference to FIG. 1 below.
[0044] The front face 114 of the sheet 104 (as shown in FIG. 1 ) has a securing pad 118 approximately centrally disposed between the two apertures 116 . The securing pad 118 is attached to the sheet 104 by stitching and has female hook and pile fastener on its outer surface, e.g., the pile portion of the hook and pile fastener.
[0045] Toward a first end 120 of the securing strap 110 there is attached a portion of hook and pile fastener on each face thereof (not shown), one portion being male hook and pile fastener, the other portion being female hook and pile fastener. Toward a second end 122 of the securing strap there is attached a portion of male hook and pile fastener (not shown).
[0046] It is preferred that the male hook and pile fastener (i.e., the hook portion) be attached on the surfaces which are least likely to come into contact with an infant, in use. This is because the texture of the male hook and pile fastener is coarse and may irritate an infant, whereas the female hook and pile fastener (the pile) has a softer texture. This is exemplified by providing the female hock and pile fastener on the securing pad 118 which faces upwards, away from the infant, in use.
[0047] The device 102 may be attached to or form part of a mattress or cushion upon which an infant sleeps.
[0048] Alternatively, as shown in FIGS. 4 and 5 , the device 102 may be attached to or form part of a fitted bed sheet 126 . In this embodiment, a fitted bed sheet has an upper face 128 and side faces 130 of an appropriate size to fit an infant's mattress 132 . The device 102 may be attached to the upper face 128 of the fitted bed sheet 126 .
[0049] The attachment or incorporation of the device 202 onto or into a bed sheet, mattress, cushion etc. should incorporate a pocket 124 as shown in FIGS. 3 , 4 and 5 into which an infant may be placed.
[0050] A further alternative (shown in FIG. 3 ) is to form the sheet 104 into a pocket which may be fitted over one end of a mattress already fitted with a bed sheet. The device 102 would therefore be held in place by the weight of the mattress.
[0051] The sheet. 104 is shown in a preferred rectangular shape, however it should be appreciated that many shapes of sheet could perform the same function in a similar manner.
[0052] In use, an infant (not shown) is placed under the sheet 104 such that the gusset strap 108 of the harness 106 sits between the infant's legs and the securing strap 110 around the infant's waist or torso. The ends of the securing strap 110 are then pulled through the apertures 116 so that the infant is pulled toward the rear face 112 of the sheet 104 . The first end 120 of the securing strap 110 is then attached to the securing pad 118 by the hook and pile fastener thereon. The second end 122 of the securing strap 110 is then attached to the first end 120 of the securing strap 110 by the hook and pile fastener between them.
[0053] As shown in FIG. 7 , yet another embodiment of the safety or securing device has a harness 200 that is mountable to fitted or other sheet 202 , which is in turn mounted to a bed mattress (not shown). In this embodiment, the harness 200 has a generally semi-triangular or T-shape with three securing straps 204 , 206 , 208 extending from the central body 210 of the harness 200 . Two collinear but opposing securing straps 206 , 208 penetrate mating securing strap passages, 212 , 214 respectively, in the sheet 202 . The mating securing strap passages 212 , 214 are equidistant from the axial center A of the bed mattress, in order to center a body secured by the harness 200 in the axial center of the bed mattress and equally spaced from the opposing lateral sides 216 , 218 and top and bottom sides 220 , 222 of the sheet on the bed mattress.
[0054] A center, axially extending securing strap 204 extends from the central body 210 transverse to the opposing securing straps 206 , 208 toward the bottom or foot of the bed 222 . The remote end 224 of the axially extending strap 204 is secured to the bed sheet 220 such as by stitching or other fastening means.
[0055] Each of the opposing securing straps, e.g., 204 , extends from its mating securing strap passage, e.g., 212 , between the sheet 202 and underlying mattress (not shown) to then protrude outwardly from mating side strap passage, e.g., 226 , in the associated side 216 of the sheet 202 and underlying bed mattress. The distal, protruding end 228 of the securing strap 204 is then secured to side 216 of the sheet 202 such as by a hook and pile fastener sections matingly mounted between the protruding end 228 and the side 216 of the sheet 202 . Other types of fasteners may also be used. Alternatively, the protruding end 228 may be lengthened and tied to adjacent structure (not shown) such a as a crib gate.
[0056] As shown in a somewhat alternative construction in FIG. 8 , the axially extending strap 204 may be adjustable and/or removable rather than fixed to the bed sheet 202 as in FIG. 7 and, for example, extend through a mating strap passage 230 in the bed sheet 202 . The fastening end 232 of the axially extending strap 204 may similarly be secured to the bed sheet 202 by hook and pile or other fasteners (not shown). Alternatively, the axially extending strap 204 may extend through yet an additional passage (not shown), such as in the bottom side 222 of the bed sheet 202 to be secured in the fashion of the opposing securing straps 206 , 208 as shown in FIG. 7 . Numerous other harness securing structures and techniques may be utilized.
[0057] For example, in yet another embodiment, the mating side strap passage 226 of FIG. 7 may be enlarged 240 as shown in FIG. 8 . Further, the hook and pile fastener portion 242 secured to the bed sheet 202 may be widened to cover a greater lateral area on the side 216 of the bed sheet 202 . This configuration can allow for lateral adjustment of the mounting or fastening position of the associated opposing or sidewardly extending securing strap 244 . In this manner, the securing strap 244 may be mounted in various locations along the side 216 of the bed 202 and avoid interfering structure such as a crib gate or side bed post (not shown).
[0058] The securing harnesses shown in FIGS. 8 and 9 may thus be relatively easily removed from the associated bed sheet and replaced, washed, or repaired as desired. Further, they can be secured in position, to maintain an associated body in position, in a fashion that can be difficult or impossible for an infant, or perhaps other body, to undo the orientation of the harness when secured to the associated bed street or other structure.
[0059] In the embodiments of FIGS. 7-9 , the harness is shown unattached to a sheet or blanket. A sheet (meaning herein any other desired cover, such as a blanket as noted above) may be either attached to the harness before or after installation of the harness and in any number of ways. For example, a sheet might be secured in position with respect the harness and associated infant or other body by securing corners of the sheet to a crib gate or other structure. The corners of the sheet may have any number of fastening devices attached to such or other locations. Examples can include straps secured to the sheet location, mating hook and pile fasteners mounted on the straps of mating structures, or button and mating passage fastening structures.
[0060] The sheet can be further secured in position in many other ways. One example is to secure the sheet to the harness above the infant or other body by means of mating hook and pile fastener sections mounted to the harness and the mating section of the sheet.
[0061] Alternatively, the sheet can include included pocket structure with the harness of FIGS. 7-9 mounted within the pocket to secure an infant or other body within the pocket. The pocket may be created by slip-over sheeting on a mattress, or it may be formed of a section of sheet stitched or otherwise fastened to another sheet.
[0062] With reference now to FIGS. 10-15 , one method of utilizing a harness and associated sheet with an infant comprises:
A. sliding a pre-constructed or arranged pocket sheet 300 (such as, as one example, a stretchable fleece blanket in the embodiment of FIGS. 10-15 ) over the bottom or lower end 302 of a mattress pre-covered with an underlying fitted sheet 304 ; B. inserting a somewhat triangularly shaped securing harness 306 between the fitted sheet 304 and mating upper section 308 of the pocket sheet 300 ; C. placing an infant 310 on the upper face 312 of the harness 306 and below the mating upper section 308 of the pocket sheet 300 , with the upper edge 314 of the mating upper section 308 of the pocket sheet 300 extending across the infant's torso 316 spaced from the infant's head 318 and, in this particular embodiment, shoulders 320 ; D. pulling the two opposing securing straps 322 , 324 of the harness 306 through mating strap passages, e.g., 326 , in the sheet 300 providing for strap passage locations on opposing sides 328 , 330 of the infant's torso 316 ; E. securing a first securing strap 322 to a mating hook and pile fastener section 332 on the upper surface 334 of the sheet 300 above the infant's torso; and F. securing the opposing second securing strap 324 to a mating hook and pile fastener section 336 on the upper surface 338 of the first secured strap 322 above the infant's torso 316 .
[0069] The infant 310 is thereby secured safely in position on the lower end 302 of the bed mattress generally equidistant from the opposing lateral sides 340 , 342 of the bed mattress.
[0070] It can thus be seen that the applicants have provided body orienting device that may, depending on the embodiment utilized, relatively comfortably orient a body, such as a human body, with respect to other objects, particularly when the body is intended to be at rest. In this regard, the embodiments shown herein have shown particular structures for a harness. As noted above, other harness structures or configurations may be used to secure a body in position. For example, the harness may be enlarged to secure larger bodies, such as older children, infirm adults, or certain animals undergoing care.
[0071] In the embodiments such as those in which the securing element or harness is used in conjunction with a flexible, relatively thin, fleece sheet secured to a fitted or otherwise relatively secured bed sheet, such as in FIGS. 4 , 5 , and 10 - 15 for example:
reduces the risk of being kicked off or over the infant's head, thereby also reducing the risk of suffocation or breathing of oxygen reduced or depleted air; reduces the risk that the baby may slip down under the blanket, further reducing the risk of overheating or suffocation; reduces the need for excessive heating in the baby's room and further reducing the chance of overheating the baby; allows comforting airflow around the baby as it kicks to maintain a desired body temperature; positions the baby at the foot of the bed and away from the sides, thereby reducing danger of suffocation or breathing of oxygen reduced or depleted air; maintains the baby in the correct sleeping position, comfortably, while reducing the danger sudden infant death syndrome; maintains swaddling of the baby in the a soft harness, promoting increased sleep duration.
[0079] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
[0080] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0081] For example, the harness may be configured to consist of a central body with three corners, and each corner may have extending sections that may wrap around a separate mounting strap and secure to the strap or to themselves by mating hook and pile fastening sections or other fastener devices. In turn, the harness may be mounted to one or more separate, removable, and adjustable mounting straps secured around or to a mounting structure, such as a bed. For example, two corners of the harness might be mounted to one strap extending across a bed, and another corner mounted to another strap extending across the bed.
[0082] It is to be understood that the foregoing is a detailed description of preferred and alternative embodiments. It would be apparent to those skilled in the art that many more modifications than mentioned above are possible without departing from the invention or while implementing it. The disclosure, therefore, is not to be restricted by the foregoing detailed descriptions, and the scope of the invention is to be determined by reference to the claims as issued. | Body orienting harnesses and associated structures are disclosed, along with methods of use. The body orienting harness can position a body, such an infant, with respect to the associated structure, such as a bed, bed frame or crib, a sheet, or a blanket for example. The harness may be integrated with a sheet or blanket in order to secure not only a body in position but also secure the sheet or blanket in position with respect to the body. The sheet, blanket, or other cover, can provide a slip cover for an underlying support surface, such as a mattress for example. Alternatively, the cover can be secured in other ways to form a pocket in association with other structure, such as a bed sheet for example. The harness can be mounted in association with the pocket to secure a body in position with the respect to the pocket and associated structure, such as a mattress, crib, etc. When used to secure an infant during sleep, certain embodiments of the harness and associated structure can help significantly reduce the chance of overheating, suffocating, or otherwise harming the infant. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of application Ser. No. 09/470,284, filed on Dec. 22, 1999 now U.S. Pat. No. 7,133,076, which is incorporated herein by reference. This application claims benefit of the priority of U.S. Provisional Application Ser. No. 60/113,850, filed Dec. 24, 1998 and entitled “Contoured Surface of Image Plan Array Cover Plate.”
BACKGROUND
The present specification generally relates to image sensor arrays, and particularly to a contoured-surface cover plate for such image sensor arrays.
When a sensor array is mounted on an image sensor assembly such as a digital camera system, the sensor array is sealed for protection by bonding a cover plate on the assembly over the sensor array. Often, the cover plate is a flat piece of transparent material, such as glass, plastic or plexiglass, which provides protection only from the environment. The cover plate offers little in terms of optical enhancement.
On the other hand, competition for cheap camera systems is driving demand for high quality optics at a low price. However, such high quality optics are difficult to design and fabricate without the use of multiple lensing elements. Therefore, the use of multiple lensing elements often drives the price up. In addition, the lensing elements, once fabricated, must be mounted and aligned to the camera system at fairly tight tolerances in positioning, focus, and attitude. This also adds to the overall cost of the camera system.
SUMMARY
The techniques described herein obviate, the above described difficulties by deterministically contouring the optically-flat cover plate. The contouring allows for the use of the cover plate as an additional lensing element. The placement of the contoured cover plate in the optical path of an incident light converts a singlet lens system into a doublet system, a doublet system into a triplet system, and so on.
The contouring of the cover plate also allows using the plate as mounting structures for the lensing elements, such as lenses, filters, and polarizers. The mounting structures can have alignment marks which are used to automatically align and secure the lensing elements. Furthermore, the contouring of the cover plate enhances the ability of the lensing element to correct the aberration of Petzval field curvature. The aberration is the natural tendency for a lens to produce its image on a curved rather than a flat focal plane. Therefore, the placement of the contoured cover plate close to the image sensor often reduces this aberration.
A lensing structure may include lensing elements, mounting structures, and alignment marks.
In one aspect, the present specification involves a cover for an image sensor array. The cover includes a plate formed of substantially transparent material and placed adjacent to the image sensor array. The plate has a plurality of surfaces and forms a lensing structure. At least one of the plurality of surfaces is contoured into a lensing surface capable of performing an imaging improvement or enhancement function.
In another aspect, an image sensor camera system for converting optical data into digital image data is described. The camera system includes a lens system, an image sensor array, and sensor electronics.
The lens system carries and focuses the optical data onto the image sensor array. The lens system includes a plurality of lenses and a cover plate. The cover plate is contoured into a lensing structure for imaging improvement and enhancement function.
The image sensor array has a plurality of sensors. The sensors receive the optical data and integrate the data into electrical charge proportional to the amount of optical data collected within a particular period of time. The sensor electronics receive the electrical charge and converts the electrical charge received by the plurality of sensors into digital image data.
The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other embodiments and advantages will become apparent from the following description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects will be described in reference to the accompanying drawings wherein:
FIG. 1A is an exploded view of a cover plate;
FIG. 1B is a side view of the cover plate cut along the plane 1 - 1 indicated in FIG. 1A ;
FIG. 1C is another embodiment of the cover plate contoured into a positive lens with convex protuberance;
FIG. 2A is one embodiment of an existing three-element lens system;
FIG. 2B is the lens system of FIG. 2A inserted into the cover plate;
FIG. 3A is a diffraction grating blazed onto the surface of the cover plate;
FIG. 3B is a diffraction grating blazed on a concave depression;
FIG. 3C is a diffraction grating blazed on a convex protuberance;
FIG. 4A is an injection molded cover plate having a post and a convex lensing surface;
FIG. 4B is an injection molded cover plate having a post and a concave lensing surface;
FIGS. 5A and 5B show top views of the cover plates including mounting structures;
FIGS. 5C through 5H show different embodiments of the mounting structure from the side;
FIGS. 6A through 6C show different embodiments of the cover plate having a combination of lensing elements and mounting structures;
FIG. 7A is a cut-away side perspective view of an image sensor camera system; and
FIG. 7B is a block diagram of the image sensor camera system.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
A detailed description of the contoured surface of an image sensor array cover plate is herein provided with respect to the figures.
FIG. 1A shows an exploded view of a cover plate 100 placed in front of an image sensor array 102 . The image sensor array can be an array of active pixel sensors. Each active pixel sensor includes a photoreceptor, e.g., a photodiode or photogate, an in-pixel follower transistor, and an in-pixel selector transistor. The cover plate 100 is contoured to act as an additional lensing element 104 . The lensing element 104 operates to enhance the focusing of light onto the image sensor array 102 .
FIG. 1B shows a side view of the cover plate 100 cut along the plane 1 - 1 indicated in FIG. 1A . The cover plate 100 is contoured into a negative lens with concave depression 106 and is placed in front of the image sensor array 102 to focus the light falling onto the sensor array 102 .
FIG. 1C shows another embodiment of the cover plate 108 contoured into a positive lens with convex protuberance 110 . The cover plate 108 is placed in front of the sensor array 102 .
FIG. 2A shows one embodiment of an existing three-element lens system 200 . The lens system 200 includes a first convex lens 202 , a second plano-concave lens 204 , and a third plano-convex lens 206 . The lens system 200 also includes a lens mount 208 , a threaded retaining ring 210 , and a guide tab 212 . Light enters the lens system 200 from the direction indicated as 214 .
FIG. 2B illustrates the lens system 200 inserted into a cover plate 214 . The cover plate 214 can have a mounting structure 218 attached to the front surface 222 . In another embodiment, the cover plate 214 can be a single-piece injection molded structure that includes the mounting structure 218 .
The lens system 200 can be inserted into the cover plate 214 by threading it into the mounting structure 218 . The threaded retaining ring 210 on the lens mount 208 is guided into a threaded ring 220 on the mounting structure 218 to lock the lens system 200 onto the cover plate 214 . In an alternative embodiment, the lens system 200 can be secured onto the cover plate 214 by locking the guide tab 212 on the lens mount 208 onto the cover plate 214 using an alignment mark 216 .
Once the three-element lens system 200 is firmly secured to the cover plate 214 , the combination effectively forms a four-element lens system comprising the three lenses 202 , 204 , 206 in the lens system 200 and a contoured surface 226 of the lens 224 formed by the cover plate 214 . Furthermore, the contoured lens 224 enhances the ability of the four-element lens system to correct the aberration of Petzval field curvature. The aberration is the natural tendency for a lens to produce its image on a curved rather than a flat focal plane. Therefore, the placement of the contoured cover plate 214 close to the image sensor 102 often reduces this aberration inherent in flat cover plates.
FIG. 3A shows a diffraction grating 302 blazed onto the surface of a cover plate 300 . The diffraction grating 302 performs similar imaging improvement function to the refractive lens system in FIG. 2B . Therefore, the cover plate 300 with the diffraction grating 302 formed on its surface acts as a diffractive lensing element 316 .
In another embodiment, hybridization of refractive and diffractive profiles is formed on a cover plate 304 . FIG. 3B shows a diffraction grating 306 blazed on a concave depression 308 formed on the cover plate 304 . The concave grating 306 can be manufactured using ruling and holographic techniques. The concave grating forms a hybrid refractive-diffractive lensing element 318 .
In a further embodiment, shown in FIG. 3C , a diffraction grating 312 is formed on a convex surface 314 of a cover plate 310 . The convex grating 312 can be manufactured using a similar is technique used for the concave grating 306 shown in FIG. 3B . The convex grating forms a hybrid refractive-diffractive lensing element 320 .
FIG. 4A shows an injection-molded cover plate 400 having a post 402 and a convex lensing surface 404 . The post 402 and the lensing surface 404 form a complete lens system and thereby eliminate the need for additional lenses. The post 402 and the lensing surface 404 are formed over the sensor array region 406 to direct the light onto the sensor array 102 . The post 402 and the lensing surface 404 form a lensing element 408 .
In an alternative embodiment, shown in FIG. 4B , the lensing surface 410 can be contoured as a concave depression forming a lensing element 412 .
FIGS. 5A through 5H show several different embodiments of a mounting structure 500 , 502 . The mounting structure 500 , 502 is formed over the sensor array. The mounting structure 500 , 502 is configured to allow the lens system to be easily and quickly mounted onto the cover plate 504 .
FIG. 5A shows a top view of the cover plate 504 including the mounting structure 500 formed on the top surface 506 of the cover plate 504 . In this embodiment, the mounting structure 500 forms a square pattern, which allows a square-shaped lens mount to be mounted securely to the mounting structure 500 . FIG. 5B shows a circular-shaped mounting structure 502 formed on the surface 506 of the cover plate 504 .
FIGS. 5C through 5H show several different embodiments of the mounting structure 500 from the side. The side views are formed by slicing the cover plate 504 along the line 5 - 5 .
FIG. 5C shows a mounting structure formed with a mesa-like protrusion 508 on the surface 510 of the cover plate 504 . The protrusion 508 can be a clear material attached to the front surface of the cover plate 504 or injection molded into a single-piece cover plate 504 . The protrusion 508 can have a threaded retaining ring on the outside wall for easy insertion, focus and removal of the lens system.
FIG. 5D shows a variation of the mounting structure shown in FIG. 5C . The mounting structure in FIG. 5D can be formed with a hollowed-out mesa-like protrusion or a ringed-wall structure attached to the cover plate 504 .
FIGS. 5E and 5F show two variations of the ringed mounting structure 512 shown in FIG. 5D . FIG. 5E shows a threaded retaining ring 514 on the outside wall of the ringed structure 512 . FIG. 5F shows the threaded retaining ring 514 on the inside wall of the ringed structure 512 . The threaded retaining ring 514 is used to mount and securely attach the lens mount to the mounting structure 512 .
FIGS. 5G and 5H show a mounting structure formed with a well-like depression 516 in the cover plate 504 . The depression 516 can be used to lock the lens mount onto the cover plate 504 . FIG. 5H also shows a threaded retaining ring 518 on the side wall of the well-like depression 516 for locking the lens mount.
FIGS. 6A through 6C show different embodiments of the cover plate having a combination of lensing elements and mounting structures.
FIG. 6A shows a cover plate 600 having a lensing element 608 and a mounting structure 604 . The lensing element 608 is formed with a concave lensing surface 602 . The mounting structure 604 can have a threaded retaining ring 606 on the inside or outside wall of the mounting structure 604 .
FIG. 6B shows another combination of a lensing element 616 and a mounting structure 612 . The lensing element 616 is formed with a post 618 and a convex lensing surface 614 at the top of the post 618 .
FIG. 6C shows a combination of a ringed mounting structure 622 and a lensing element 620 in the middle. The lensing element 620 is formed with a post 624 and a convex lensing surface 626 .
FIG. 7A shows a cut-away side perspective view of an image sensor camera system 700 . The camera system can be an active pixel sensor (APS) system or a charge-coupled device (CCD) system. The camera system 700 includes a lens system 708 , a cover plate 702 , an image sensor array 704 , and sensor electronics 706 .
The lens system 708 includes a plurality of lenses 714 mounted on a lens mount 710 . The lens system 708 may also include other lensing elements, such as a filter or a polarizer 712 . The contoured cover plate 702 acts as an additional lensing element.
FIG. 7B shows a block diagram of the image sensor camera system 700 . The camera system 700 receives optical image data 716 . The optical data 716 are focused by the lens system 708 and the contoured cover plate 702 onto the image sensor array 704 . The sensor electronics 706 converts electrical charge falling on the sensor array 704 to digital image data 718 .
Although only a few embodiments have been described in detail above, those of ordinary skill in the art certainly understand that modifications are possible. For example, a contouring can be done on both surfaces of the cover plate. Also, while the preferred aspect shows only a square and a circular mounting structures, mounting structures of other shapes are possible, such as a hexagonal- or octogonal-shaped mounting structure. In addition, other alignment marks or lens locking mechanisms can be used on the cover plate to securely attach the lens system to the cover plate. All such modifications are intended to be encompassed within the following claims, in which: | A cover for an image sensor array is disclosed. The cover includes a plate formed of substantially transparent material and placed adjacent to the image sensor array. The plate has a plurality of surfaces and forms a lensing structure. At least one of the plurality of surfaces is contoured into a lensing surface capable of performing an imaging improvement or enhancement function. | 7 |
TECHNICAL BACKGROUND
[0001] The present invention relates to a flashing suitable for flashing, for example, parts of the envelope of a building.
[0002] Many forms of flashing are known. Traditionally flashings were formed from sheets of lead and were conformed on site to shapes required. Lead is both heavy and expensive and requires a lot of labour. It is also difficult to have it satisfactorily retain a painted surface.
BACKGROUND ART
[0003] The present invention recognises the prospect of providing lightweight flashings (preferably tile trim flashings) that are versatile as to their use (even though they may be pre-shaped for convenience) and demand little in the way of skill in their use. It is to this that the present invention is directed.
[0004] I have determined that an effective conformable region of a flashing structure can be prepared by associating a conformable yet shape retaining layer having a mesh, perforate or other “open” character (eg; expanded sheet aluminium of a “mesh” character) using an appropriate adhesive bonding with a flexible weathering layer and thereafter relying on a tack retaining adhesive surface (whether simply “show through” adhesive or adhesive in addition) for associating such a conformable region to a surface of a region to be flashed.
[0005] There are instances however where it is desirable to have part of a flashing underlying a cladding panel or member. An example may include a transition from a wall into a roofline. With such an arrangement it is not necessary for that region to be overlayed by a cladding panel or member (or indeed even plaster) to be conformable yet shape retaining since it is held in place not by its own inherent shape retention but rather by the overlaying panel or other cladding. Nevertheless there is a need, since it is the transition that is to be flashed, for there to be continuity in the weathering surface. There are other instances where such an arrangement is applicable which may not involve rooves and therefore the term “flashing” and its variations should not be so restricted.
[0006] As used herein the term “weathering layer” includes any single material or multiple materials, whether laminated, mixed or otherwise, to provide a layer (not necessarily planar nor of constant thickness) of which an outer surface is to act as the weathering surface and another surface of which can act as a surface to be bonded by said adhesive matrix to said conformable layer.
[0007] As used herein the term “conformable yet shape retaining layer” includes metal (eg; aluminium) expanded sheet into a perforate “mesh-like” form but is not confined thereto. It can include perforated or non perforated metal (eg; lead or aluminium) or other sheeting (eg; steel wire mesh or zinc) and irrespective, if perforate, whether sheet-wise expandable or not.
DISCLOSURE OF THE INVENTION
[0008] In a first aspect the invention is a three dimensional flashing comprising or including
[0009] a substantially three dimensional region in use to be exposed to the weather, and
[0010] a less three dimensional region adapted in use to underlie and/or attach to at least in part a cladding material or cladding materials of a building,
[0011] wherein said three dimensional region and said less three dimensional region can articulate relative to each other at an articulation zone,
[0012] and wherein said three dimensional region has at least one flexible material providing an exterior flexible weathering surface therefor that extends at least as part of said less three dimensional region,
[0013] and wherein said three dimensional region is at least in part held in its three dimensional form by a conformable yet shape retaining three dimensionally conformed material,
[0014] and wherein there is sufficient tack retaining adhesive available on the non weathering side of said three dimensional region to associate such three dimensional region to a substrate to be flashed thereby.
[0015] Preferably said less three dimensional region is substantially planar.
[0016] Preferably said three dimensionally conformed material is a metal.
[0017] Preferably said metal is sheet aluminium.
[0018] Preferably said three dimensional region is configured so as to exhibit a substantially sinusoidal section when being viewed in section towards said articulation zone.
[0019] Preferably a suitable natural or synthetic rubber material or plastics material provides said exterior flexible weathering surface (eg; a UV resistant EDPM, TPO (thermoplastic polyolefin), TPU (thermoplastic urethane) or FPVC (flexible PVC)).
[0020] Preferably, in some embodiments, said three dimensionally conformed material is mould embedded at least in part in another material, said another material (eg; a cheaper rubber or plastics material to UV resistant EDPM) being flexible but not necessarily being said flexible material(s) (eg; EDPM) providing the exterior weathering surface.
[0021] Preferably a release sheet (eg; siliconised paper) is associated with said tack retaining adhesive.
[0022] Said three dimensionally conformed material is preferably a sheet metal (eg; aluminium, galvanised steel or COLOURSTEEL™). It is either bonded or mechanically attached. For example a piece of steel may or not be any particular profile that extends in part into the less three dimensional region.
[0023] Preferably said three dimensionally conformed material is a perforate or expanded sheet of a suitable metal.
[0024] Preferably said less three dimensional region includes a plurality of weather seal ridges, flanges, or the like.
[0025] Preferably said less three dimensional region includes a number of openings therethrough to allow penetrative fixers (eg; nails or screws) to affix the same for subsequent overlying by a cladding material or cladding materials (eg; wallboards).
[0026] Preferably said articulation zone is a defined region between what is almost exclusively a three dimensional region and what is almost exclusively a substantially planar region save for sealing and/or other contoured features thereof.
[0027] Preferably said flashing is of a form and/or structure substantially as hereinbefore described with reference to any one or more of the accompany drawings.
[0028] In another aspect the invention consists in a three dimensional flashing (preferably being a ridge capping or other preshaped flashing) (hereafter “flashing form”) which extends into at least one flanking conformable yet shape retaining three dimensionally conformed region
[0029] wherein said three dimensionally conformed region has at least one flexible material providing an exterior flexible weathering surface therefor that extends at least as part of said flashing form,
[0030] and wherein the or each such conformed region has sufficient tack retaining adhesive available on the non-weathering side thereof to associate that region by adhesion to a suitable roofing material where said less three dimensional region is substantially planar.
[0031] Preferably said three dimensionally conformed material is a metal.
[0032] Preferably said metal is sheet aluminium.
[0033] Preferably said flashing form is flanked to either side with a said three dimensionally conformed region.
[0034] Preferably the (or both) three dimensional region(s) is (are) configured so as to exhibit a substantially sinusoidal section when being viewed in section towards said flashing form.
[0035] Preferably a suitable natural or synthetic rubber material provides said exterior flexible weathering surface.
[0036] Preferably said three dimensionally conformed material is mould embedded at least in part in another material, said another material being flexible but not necessarily said flexible material providing the exterior weathering surface.
[0037] Preferably a release sheet is associated with said tack retaining adhesive.
[0038] Preferably said three dimensionally conformed material is a perforate or expanded sheet of a suitable metal.
[0039] Preferably said flashing form is a capping form which steps its weathering surface orthogonally of said flanking three dimensionally conformed regions. In other forms it does not step (eg; is straight).
[0040] Preferably said flashing is of a form and/or structure substantially as herein described with reference to any one or more of the accompany drawings.
[0041] In another aspect the present invention consists in a flashing comprising or including
[0042] a flexible weathering layer having one part adapted to flash from underneath cladding (eg; wall panel) of a structure and another region to flash over part of cladding (eg; roofing) of the same structure, said flashing being characterised in that said flexible weathering layer has at least part of said region to overlie part of the cladding rendered conformable yet shape retaining by the association to at least part of its underside of a conformable shape retaining layer of a mesh, perforate or other “open” sheet material using an appropriate adhesive.
[0043] Preferably a tack retaining adhesive surface is provided whereby at least one of the following becomes possible,
[0044] (a) at least part of the region of said flexible weathering layer underlaid by said conformable yet shape retaining member has sufficient adhesive to enable its adhesive association with a substrate forming part of the structure to be flashed,
[0045] (b) at least part of the flexible weathering layer not underlaid by said conformable yet shape retaining member but nonetheless being part of the underside (i.e. not to be directly weathered) is provided with sufficient tack retaining adhesive to allow its association to a substrate to be flashed thereby, and
[0046] (c) both (a) and (b).
[0047] Preferably said flashing includes a release sheet detachably associated with the tack retaining adhesive surface to allow (upon its removal) at least part of said flashing to be associated with a substrate to be flashed.
[0048] Preferably said flashing is provided in a form whereby the conformable yet shape retaining region or at least part thereof is provided other than in a flat condition.
[0049] Part of the flashing which includes said conformable yet shape retaining region can be provided in a substantially sinusoidal form which ensures a sufficient amount of the conformable region being available for a flashing like association with a complex underlying three dimensional surface without any need for stretching of the conformable yet shape retaining layer.
[0050] Preferably said conformable yet shape retaining member including region is provided in a three dimensional form that facilitates its being matched to a likely profile to be encountered during its flashing use or from which it can be easily deformed.
[0051] To this end see FIG. 9A with its distal edge 13 (if notionally flattened) being substantially longer than it is when in its 3D form.
[0052] In some forms of the present invention, when viewed if plan, preferably said flashing is substantially of a rectangular or square form with an apparent straight fold line separating said regions which (usually) in use are to extend in different planes, the region on one side of said fold line which includes said conformable yet shape retaining member having a three dimensional form whereby, were it along with the other region (if necessary) to be notionally flattened down into the plane of the plan view, would mean that the area of said three dimensional form region thereof significantly increases.
[0053] Preferably the arrangement is of a kind contemplated by enclosed FIGS. 9A, 9B and 9 C hereof.
[0054] In still a further aspect the present invention consists in a flashing of a kind substantially as hereinafter described in whole or in part but substantially having the characteristics described with reference to any one o more of the accompanying drawings.
[0055] In yet a further aspect the present invention consists in the use or methods of use of a flashing of any of the aforementioned kinds.
[0056] In a further aspect the present invention consists in a structure flashed by a flashing of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0057] Preferred forms of the present invention will now be described with reference to the accompanying drawings in which;
[0058] [0058]FIG. 1 is a view of a flashing in accordance with the present invention having one region upwardly disposed as it may be when it is attached to a wall to be clad that is make a transition down on to a roof line and showing in a three dimensional view relative thereto a corrugated region held in its three dimensional form by an underlying conformable yet shape retaining layer which underlies part thereof,
[0059] [0059]FIG. 2 is a view from below of the arrangement shown in FIG. 1,
[0060] [0060]FIG. 3 is a view of the arrangement shown in FIG. 1 looking along the flutes of the corrugated region,
[0061] [0061]FIG. 4 is a side elevation view of the arrangement of FIG. 1,
[0062] [0062]FIG. 5 is a view of a preferred sheet of flexible material as it may be moulded for the purpose of manufacture of a product as shown in FIGS. 1 through 4, there be shown the underside prior to the association thereof of any of the conformable yet shape retaining material, eg; expanded aluminium sheet in to a mesh-like form,
[0063] [0063]FIG. 6 is the same moulded sheet as in FIG. 5 showing how the same is adapted to be folded for use in the particular application for which the particular flexible member has bee designed,
[0064] [0064]FIG. 7 is a similar view to that of FIG. 5 but showing the conformable yet shape retaining member associated therewith,
[0065] [0065]FIG. 8 is a similar view to that of FIG. 6 but again with the conformable yet shape retaining layer associated with part thereof,
[0066] [0066]FIGS. 9A to 9 C show a simplified plan view of the flashing of FIG. 7, with 9 B showing the flashing as it is in FIG. 7 from above, the three dimensional at in part conformable yet shape retaining region being designated by the letter “A” and the fold line being depicted by the line that separates region “A” from the other region “B”, FIG. 9A showing the same product from above in the same form but after the flattening out into the plane of the region “B” of the region “A”,
[0067] [0067]FIG. 10 shows a variant of a flashing as FIG. 4 but where a (perforate or non perforate) sheet (not shown) of a conformable material (e.g. aluminium) is embedded or is to be retainably received in flexible material,
[0068] [0068]FIG. 11 shows the flashing of FIG. 10 from another view showing an articulation zone between the near substantially planar or less three dimensional region and the conformable and three dimensionally conformed three dimensional region, the metal sheet not being shown,
[0069] [0069]FIG. 12 shows a ridge capping flashing in accordance with the present invention having a stepped ridge or like capping form which extends to either flank to a conformable yet shape retaining three dimensional conformed region, such three dimensionally conformed region being of a kind as previously defined, and
[0070] [0070]FIG. 13 is a plan view of the flashing of FIG. 12.
[0071] As an example of a preferred form of the present invention, a simple form of flashing useful, for example, for providing a flashed transition from under cladding of a wall on to a roof line (whether tiled or covered with corrugated iron) referred to in the drawings.
[0072] A moulded component 1 of an appropriate weathering material that is flexible (eg; EPDM) is provided. As shown in FIG. 5 this component is preferably moulded to provide the two zones of the product viz that which at least in part is to be conformable 2 and to be at least in part shape retaining and that part 3 which is preferably to underlie cladding or the like of the structure to be clad. As shown there is provision at 4 for a fold line between what is essentially preferably a fully flexible part 3 (albeit with optional ceiling ridges 5 and optional nailing holes 6 ) and an at least in part reinforced part which renders the whole or region 2 conformable yet shape retaining.
[0073] The moulding of the component 1 can have the shape of the region 2 (as depicted in FIG. 5) assumed from the outset or it can alternatively be moulded in a substantially planar form and thereafter configured either before or after its association with the conformable yet shape retaining layer to be associated therewith. Of course intermediate conformations are also possible.
[0074] In the preferred form of the present invention the arrangement as depicted in FIG. 5 is associated with a mesh like, perforate or other “open” character malleable material 7 . Whilst such a shape retaining conformable layer could be of another metal such as lead or zinc preferably it is expanded aluminium sheet, eg; METEX™ of IPSCO, NZ.
[0075] Preferably a region only as depicted in the accompanying drawings is reinforced by the layer 7 but sufficient so as to hold at the distal edge 8 the desired confirmation after its transition out from the region 9 .
[0076] A number of different ways of associating the conformable yet shape retaining layer to part of the underside of the zone 2 of the component 1 can be provided.
[0077] As can be seen preferably the moulded member shown in FIG. 5 includes ridges 10 to facilitate location of the layer 7 but these are simply optional.
[0078] The preferred material of the flexible weathering layer can be any appropriate material. A preferred material is a UV resistant EPDM (eg; ROYLENE of Uniroyal, USA or ESPRENE™ of Cymatium Corp of Japan) although other options for that component include at least UV resistant silicone rubber (eg; SILPLUS™ of General Electric, USA), flexible PVC, SANTOPRENE™, NEOPRENE™, and similar materials (eg; TPO or TPU).
[0079] Such materials can be readily precoloured, eg; to terracotta and other tile or the like matching colours.
[0080] Preferably the region “B” is to be less prone to flexible bending and to this end can be either a modified or different material to the rest of the flexible layer “A”, eg; two different but compatible feed streams could be provided into the mould to produce the flexible layer. Alternatively the region “B” can be thicker to the same end. Region “B” can even be a metal.
[0081] At least the material 7 is associated with the underside of the region 2 at zone 11 in the embodiment depicted. In this respect it can be associated therewith by a butyl adhesive matrix that will provide a show through of the openings 12 (preferably both visual as well as physical show through) which not only associates the material 7 to the zone II but also confers at least some adhesive tack to a level to enable the distal region of the zone 2 to be adhesively affixed to a substrate. A suitable adhesive matrix is one of butyl adhesive such adhesive can be provided simply as a viscous butyl adhesive mass layer from one of several ways of butyl adhesive layers whether tape (eg; PVC) or re-informant (eg; P.P. or nylon) carried are possible, eg; double sided tapes or sheets of butyl adhesive of Bostik or 3M.
[0082] One option simply is to interpose a layer of butyl adhesive between 11 and 7 and to rely on a consolidation process to provide the desired show through. In such an arrangement double sided tapes, each carrying a sufficient quantity of butyl adhesive can be provided with that side to be directed downwardly having a sufficient depth to provide the requisite show through Alternatively an over layer of butyl adhesive can be applied over the exposed mesh 7 shown in FIG. 8.
[0083] In some preferred forms of the present invention the whole underside or substantially all of the underside of the zone 2 can have a substrate attachment surface of an appropriate adhesive (preferably the same butyl adhesive). Moreover even the zone 3 can be provided with an undersurface carrying such an adhesive. All such tack retaining adhesive surfaces to facilitate fixing are preferably covered with an appropriate release sheet, eg; of siliconised paper or plastics (eg; SCOTCHCAL SCW-33™ of 3M, USA).
[0084] With the arrangement as depicted in the drawings the FIGS. 9B and 9C show the device substantially as depicted in the earlier drawings but in a simplified form designating two zones as either “A” or “B”. Zone “A” corresponds to that of zone 2 whilst zone “B” corresponds to that of zone 3 .
[0085] [0085]FIG. 9A demonstrates that were the three dimensional formation of the zone “A” to be notionally flattened out into the plan of zone “B” a significant increase in the area thereof in plan view occurs as well as some curvature at 13 .
[0086] In some preferred forms of the present invention the weathering layer can be defined by a variety of materials particularly where some of the weathering area is to be less exposed to the effects of the weather. For example, a UV resistance EDPM can be used to define a top weathering surface for some or all of the flashing and that can be supported by a flexible material of lesser cost which does not have the same weathering characteristics. For example, separate masses of a suitable plastics or rubber material can be provided one of which is to associate either by a sliding capture, adhesive attachment or moulded capture to the preferred shape retaining conformable material such as, for example, solid aluminium sheet or perforate or expanded aluminium sheet.
[0087] With such a structure if desired the articulation axis could be provided by the EDPM material alone rather than any underlying support material but most preferably there is a significant degree of integrity to the flashing structure through the articulation zone.
[0088] [0088]FIG. 10 and 11 shows a flashing that has been moulded from a suitable mouldable flexible material (eg; EDPM) which defines on either side of an articulation zone 14 (eg; an integral moulded hinge) first a region that is to be three dimensional or is moulded three dimensional. Such region 15 has provision for being moulded around or having engaged after the moulding procedure a metal strip (eg; of aluminium or zinc—perforate or non-perforate) into the region 16 where it is captured by the lips 17 .
[0089] Also shown in FIG. 11 is the less three dimensional or substantially planar region 18 which preferably includes (preferably parallel to the articulation zone 14 ) sealing ribs or ridges 19 which are to act as seals against overlying cladding on the weathering side of the flashing to prevent rising water access to beyond the flashing.
[0090] A suitable material for the moulded component shown in FIGS. 10 and 11 is any of those previously described and if desired it can be a mixture of materials (or hardness of the same material) such that one or both of the regions 15 and 18 may comprise or include a weathering layer of, for example, a suitable EDPM over a lesser weatherable and cheaper yet more easily moulded plastics material. For example, EDPM could extend over all of the weathering side of a component as shown in FIG. 10 yet not necessarily run the full extent up the ribbed or ridged side of the member 18 since there is not expected to be the extreme of weathering (eg; UV exposure) at that region.
[0091] As can be seen the region 18 includes a plurality of openings 20 adapted to facilitate penetrative fixing.
[0092] The arrangement as shown in FIGS. 12 and 14 is such that a ridge cap flashing is stepped with regions 21 , 22 and 23 yet, orthogonally to such stepping from 21 through 23 , there is a flanking three dimensional region on either side. This three dimensional region 24 preferably has the characteristics of the three dimensional regions previously described.
[0093] In the form as depicted in FIGS. 12 and 13 however it can be that the whole of the moulded article depicted has a weathering surface of a suitable material such as EDPM even if all of that material is itself supported by an underlying other material which is not itself necessarily shape retaining and conformable, ie; is simply flexible. Ideally the stepped (or unstepped) capping is shape retaining.
[0094] Persons skilled in the art will appreciated the options that abound in order to take advantage of the three dimensional conformable yet shape retaining already three dimensional conformed regions of a flashing or any of the kinds defined.
[0095] Persons skilled in the art will appreciate that the present invention provides an alternative to existing flashing systems. | Three dimensional flashings suitable for association with buildings where at least part of the flashing is a shape retaining three dimensional form to render its association with an underlying three dimensional substrate of the building easier even should it not initially match the conformation thereof. Such a flashing in such three dimensional region is adhesively associable with the substrate and includes for shape retention purposes below a suitable flexible weather resistant layer (e.g.; EDPM) an underlying conformable three dimensionally conformed material such as aluminium sheeting (optionally in a mesh form). | 4 |
FIELD OF THE INVENTION
The present invention relates to a method for converting a two-channel audio system into a multichannel audio system and to an audio processor thereof, and more particularly to a method of processing the phase of the original audio signal to achieve the object.
BACKGROUND OF THE INVENTION
Multichannel Dolby system and the like are very popular in current audio systems. Those systems emphasize that the original multichannel audios are first encoded into two-channel audios for transmitting, and then returned to the original multichannel audios by a specially designed decoder for playing.
However, if a system has audios of only two channels, using the aforementioned multichannel systems for processing will cause misleading operation and distortion.
Therefore, if a system is to convert a two-channel audio system into a multichannel audio system, a special design is required.
OBJECT OF THE INVENTION
It is therefore an object of the present invention to provide a method to convert a two-channel audio system into multichannel audio system and an audio processor thereof. The original two-channel audios are not coded and decoded, but just the phase of the original audio signals is processed to achieve the object.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically the surrounding distribution of converting a two-channel audio system into multichannel audio system according to the present invention.
FIG. 2 shows schematically a circuit diagram of the audio processor according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , which shows schematically the surrounding distribution of converting a two-channel audio system into multichannel audio system according to the present invention. An audience 1 is in the center, 9 audio equipments are distributed surroundingly as CT, L, CRL, RL, RCT, RR, CRR, R and SUB respectively.
The conventional two-channel audios L in (left channel audio) and R in (right channel audio) are inputted into each of the 9 audio equipments, and are processed by a specially designed audio processor 2 (see FIG. 2 ) for outputting special outputs.
The special outputs of the 9 audio equipments are as below:
1. CT: L in +R in 2. L: L in 3. CRL: 2L in −(½)R in 4. RL: 2L in −R in 5. RCT: L in +R in 6. RR: 2R in −L in 7. CRR: 2R in −(½)L in 8. R: R in 9. SUB: (L in +R in )×LPF
L in represents left channel audio, while R in represents right channel audio, and LPF is a low-pass filter. The audio effects in the spaces between each two of the 9 audio equipments are 2L in +R in , 3L in −(½)R in , 4L in −(1+½)R in , 3L in , 3R in , 4R in −(1+½)L in , 3R in −(½)L in , 2R in +L in and 2L in +2R in respectively as shown.
Referring to FIG. 2 , which shows schematically a circuit diagram of the audio processor according to the present invention, in which the left channel audio L in and the right channel audio R in are inputted respectively into operational amplifiers OP 1 and OP 2 through some resistors. A control signal CTRL in the center of the circuit diagram is used to control four switches SW 1 , SW 2 , SW 3 and SW 4 . An inverter IN is also included as shown.
When the control signal CTRL is low, SW 1 will open and SW 2 will close, the right channel audio R in can't be inputted into OP 1 , so OP 1 is only influenced by the left channel audio L in . According to the principle of the operational amplifier, the voltage level of L out at B must be the voltage level at A×(R 3 +R 4 )/R 3 , while the voltage level at A is L in ×R 2 /(R 1 +R 2 ) according to the circuit diagram, thus L out =L in ×R 2 /(R 1 +R 2 )×(R 3 +R 4 )/R 3 =L in ∘
When the control signal CTRL is high, SW 1 will close and SW 2 will open, the right channel audio R in will be inputted into the “−” terminal of OP 1 through resistor R 3 . According to the principle of the operational amplifier, the right channel audio R in will generate an output of R in ×(−)R 4 /R 3 =−½R in at B, while the left channel audio L in will generate an output of L in at B (as described above), thus the composition voltage of L out at B is L in −½R in ∘
In the circuit of the audio processor stated above, since it is designed by letting R 1 =R 4 and R 2 =R 3 , the left channel audio L in can be reproduced at L out . If we need to demonstrate the influence of the right channel audio R in , it is only necessary to change the voltage level of the control signal CTRL, and the user can clearly distinguish the effect of adding the right channel audio R in ∘
In the circuit of the audio processor stated above, L out =L in , but if we change the ratio between R 1 and R 2 , the coefficient before L in in L out can be changed; and if we change the ratio between R 3 and R 4 , the coefficient before R in in L out can be changed.
Similarly, when the control signal CTRL is low, SW 3 will open and SW 4 will close, the left channel audio L in can't be inputted into OP 2 , so OP 2 is only influenced by the right channel audio R in . According to the principle of the operational amplifier, the voltage level of R out at D must be the voltage level at C×(R 7 +R 8 )/R 7 , while the voltage level at C is R in ×R 6 /(R 5 +R 6 ) according to the circuit diagram, thus R out =R in ×R 6 /(R 5 +R 6 )×(R 7 +R 8 )/R 7 =R in .
When the control signal CTRL is high, SW 3 will close and SW 4 will open, the left channel audio L in will be inputted into the “−” terminal of OP 2 through resistor R 7 . According to the principle of the operational amplifier, the left channel audio L in will generate an output of L in ×(−)R 8 /R 7 =−½L in at D, while the right channel audio R in will generate an output of R in at D (as described above), thus the composition voltage of R out at D is R in −½L in .
In the circuit of the audio processor stated above, since it is designed by letting R 5 =R 8 and R 6 =R 7 , the right channel audio R in can be reproduced at R out . If we need to demonstrate the influence of the left channel audio L in , it is only necessary to change the voltage level of the control signal CTRL, and the user can clearly distinguish the effect of adding the left channel audio L in .
In the circuit of the audio processor stated above, R out =R in , but if we change the ratio between R 5 and R 6 , the coefficient before R in in R out can be changed, and if we change the ratio between R 7 and R 8 , the coefficient before L in in R out can be changed.
Referring to FIG. 1 again, it is found that each of the outputs of the 9 audio processors has different coefficients before L in and R in , this is because we change the ratio between related resistors.
The operational amplifiers, the voltage dividers, the switches, the resistors and the inverter in the audio processor of the present invention can be implemented by the digital simulation techniques of computer software.
The spirit and scope of the present invention depends only upon the following Claims, and is not limited by the above embodiment. | The present invention provides a method to convert the conventional two-channel uncoded audio system into multichannel system. There is no coding/decoding procedure in the invention, but just process the phases of the original two audio channels to provide different audio sources for surrounding distribution and achieve the best effect of reproducing the original audios. The present invention also provides an audio processor for implementing the method. | 7 |
FIELD OF THE INVENTION
The present invention generally relates to workflows and in particular to state transitions of a workflow.
BACKGROUND OF THE INVENTION
Enterprise Content Management (ECM) system refers to a system organizing and storing organization's electronic documents and other business-related objects and/or content. ECM system may comprise content management systems (CMS), document management systems (DMS) and data management systems. Such systems comprise various features for managing electronic documents, e.g. storing, versioning, indexing, searching for and retrieval of documents. It is appreciated that there are both dynamic and static content management systems. The difference between dynamic and static systems is the way they store files. In the static systems files are stored e.g. in a constant treelike hierarchy that defines relationships for folders and documents stored in the tree. In the dynamic systems the files may be given identifications that define their existence in the system. The location of the files is not constant, but may vary in a virtual space depending on the situation.
In the enterprise content management system, electronic objects, such as documents, proceed through a workflow having certain action states for the electronic object. The action states are appointed with certain users who have right to perform the action in question. The right can be given to individual user or a user group defined by a role. Such a role is determined at system-level so that when a user group is defined, also users belonging to such groups are statically defined.
SUMMARY OF THE INVENTION
Now there has been invented an improved method and technical equipment implementing the method, by which workflows, and especially state transitions, in an ECM system can be controlled in more delicate way. Various aspects of the invention include a method, an apparatus and a computer readable medium comprising a computer program stored therein, which are characterized by what is stated in the independent claims. Various embodiments of the invention are disclosed in the dependent claims.
According to a first aspect, the method for controlling state transition of an electronic object in a workflow, comprises receiving a request for a state transition for an electronic object from a user; determining the current state of the object from a metadata of the electronic object; determining the next state after the state transition from the request; determining one or more pseudo-users that are allowed to perform a state transition from the current state to the next state; retrieving at least one person identity by utilizing at least one property in a metadata of the electronic object, which person identity is retrieved from a value of a property corresponding to the determined one or more pseudo-users; comparing the identity of the requesting user to the retrieved person identity, and if they match; performing a state transition according to the request.
According to a second aspect, the apparatus for controlling state transition of an electronic object in a workflow, comprises a processor, memory including computer program code, the memory and the computer program code configured to, with the processor, cause the apparatus to perform at least the following: receiving a request for a state transition for an electronic object from a user; determining the current state of the object from a metadata of the electronic object; determining the next state after the state transition from the request; determining one or more pseudo-users that are allowed to perform a state transition from the current state to the next state; retrieving at least one person identity by utilizing at least one property in a metadata of the electronic object, which person identity is retrieved from a value of a property corresponding to the determined one or more pseudo-users; comparing the identity of the requesting user to the retrieved person identity, and if they match; performing a state transition according to the request.
According to a third aspect, the computer program product comprises a computer-readable medium bearing computer program code embodied therein for use with a computer, wherein the computer program code comprises code for receiving a request for a state transition for an electronic object from a user; code for determining the current state of the object from a metadata of the electronic object; code for determining the next state after the state transition from the request; code for determining one or more pseudo-users that are allowed to perform a state transition from the current state to the next state; code for retrieving at least one person identity by utilizing at least one property in a metadata of the electronic object, which person identity is retrieved from a value of a property corresponding to the determined one or more pseudo-users; code for comparing the identity of the requesting user to the retrieved person identity, and if they match; code for performing a state transition according to the request.
According to an embodiment, one or more pseudo-users allowed to perform a state transition are determined from an access control list for the state transition.
According to an embodiment, at least one person identity is retrieved directly from at least one property of the electronic object, said at least one property being indicated by at least one determined pseudo-user.
According to an embodiment, said at least one property is used as a reference to another electronic object, wherein a property of said another electronic object, which property is indicated by at least one determined pseudo-user, defines said at least one person identity.
DESCRIPTION OF THE DRAWINGS
In the following, various embodiments of the invention will be described in more detail with reference to the appended drawings, in which
FIG. 1 shows an example of a document management system;
FIG. 2 shows an example of a metadata structure for a document and for a project,
FIG. 3 shows an example of a user interface view for state-transition permissions; and
FIG. 4 shows an example of a user interface view for defining permissions for a certain state transition.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the following, several embodiments of the invention will be described in the context of enterprise content management system. It is to be noted, however, that the invention is not limited to enterprise content management system. In fact, the different embodiments have applications widely in any environment in which workflows are used for tasks, electronic objects and/or documents.
In the present disclosure “workflow” relates to business process, but especially defines rules for delivering an electronic object, e.g. a document, from a state to another. The workflow can be considered, in this application, to define a life cycle for an electronic object. In related technology, term workflow usually relates to tasks being performed during the workflow, wherein the state transitions are made according to the states and/or tasks. Various users are identified and given rights to perform a state transition.
An example of an electronic content management (ECM) system is shown in FIG. 1 in a simplified manner. The ECM system comprises at least one server 100 for storing electronic objects such as documents. One or more client devices 101 , 102 , 103 can access said at least one server 100 in order to work with the stored electronic objects. In FIG. 1 's example, the client device 101 retrieves a document D 1 , whereas the client device 103 stores a document D 2 to the server 100 .
The ECM system makes it possible to generate electronic workflows for electronic objects (such as documents) according to business process(es). There can be several workflows relating to one document, and each workflow may comprise various states (i.e. working status) that relate to certain actions of an electronic object (e.g. document). The electronic object can be processed by a person to whom the electronic object is assigned via the workflow state. Such a person can make a state transition to a next state after s/he has finished working with the electronic object.
A document may have workflows for defining different processes for the document. The workflow comprises states for defining the state where the document is in the workflow in question. As an example, the workflow is “Processing incoming mail”. Relating to workflow “Processing incoming mail”, the states can be “New message arrived”, “Message assigned to assistant”, “Message returned to sender”, “Message processed”. Workflows are controlled by rules that define persons being allowed to perform a state transition for an electronic object.
In the following example, workflow “Operating Procedure Approval” comprises states
1. Draft 2. Waiting for content approval 3. Content approved 4. Authorized for use 5. Retired
Please note that the numbers in the previous example are only reference numbers that are utilized in the following description of the embodiment.
When an electronic object (e.g. a document) is transferred from a state “Draft” to a state “Waiting for content approval”, the state transition is defined as 1→2. It is appreciated that a state transition 2→1 is a different state transition, as well as 1→3, 1−4 etc. are also different state transitions.
One of the functionalities of a document management system is to control who can perform a state transition for an electronic object, and which state transition is permitted for that person. The controlling can be based on an access control list (ACL) that is defined for each state transition, which access control list defines users who can perform the state transition.
Traditionally an access control entry (ACE) in the access control list of a state transition defines the rights statically by a notation <user or user group><allowed/denied>. Below is an example of the traditional way for defining rights for a state transition:
ACL for state transition 1→2: John: Allowed Mike: Denied Managers: Allowed
In this example, John and any user belonging to group “Managers” are given permission to perform the state transition 1→2, whereas Mike is denied. In addition, any user not specified in the access control list is implicitly not allowed to perform the state transition.
The permission can also be defined with an implicit allowance flag, whereby an “allow”/“deny” option needs not to be used. In such a simplified approach, if a user is specified in the access control list, then such a user has the right to perform a state transition, and if a user is not specified in the access control list, then such a user does not have a right to perform a state transition.
“Managers” is a user group (“a role”) that has been statically defined in the system. In order to utilize such a user group in the ACL for a state transition, it also needs to be defined who belongs to such a group, for example:
Managers: Susan Peter Tom
A user group may also include other user groups as its members (nested groups).
Now, the right to perform the state transition 1→2 is statically appointed to Susan, Peter and Tom according to the access control entry for Managers in “ACL for state transition 1→2”. Considering all the access control entries in “ACL for state transition 1→2”, the users “John”, “Susan”, “Peter” and “Tom” can perform state transition 1→2 for any object in a system having a state “1”, whereas other users cannot.
Many systems of the related technology use the term “role” to describe a method of identifying a set of users. For example, user “Susan” may be assigned the role “Manager”. It is appreciated that this is merely another point of view of how user groups are formed, since all users who have been assigned the role “Manager” can be seen to implicitly form the user group “Managers”. Thus, the terms “user group” and “role” can often be used interchangeably.
Some of the traditional systems define access control entries on the basis of “users” and “user groups”, while some other systems refer to “users” and “roles”. It is to be noted that both of these essentially similar methods, i.e., the definition for “roles” for users and the definition of “user groups” with member users, are system-wide or workflow-wide by their nature. As a result, the approach of specifying “users” and “roles” in access control lists, which is well known in the art, does not provide enough flexibility and fine-grained control for controlling the rights for performing a specific state transition for a specific document or electronic object in a workflow, because the traditional approach does not utilize the direct and/or indirect metadata of the electronic object.
For example, the traditional methods for controlling state-transition permissions may enable defining that users with the role “Approver” can move an electronic object to the state “Approved”. However, since the users having the “Approver” role are defined on the system level or on the workflow level, the traditional method does not provide means to determine the right for performing a specific state transition such as 1→2 in a dynamic manner.
In the present solution, the definition for ACL for state transition is diversified to take into account—not only the ACL for state transition—but also by utilizing the direct and/or indirect metadata of the electronic object, e.g., by determining the [Document].[ContentApprover] user from the electronic document's direct metadata, or the [Document].[Project].[ProjectManager] user from the electronic document's indirect metadata.
The electronic objects comprise metadata (i.e. data about the data), wherein the metadata refers to information on a document's properties. A creator of a file, a creation date, a project, a responsible are examples of properties of an electronic object. Metadata is composed of two parts—a definition part and a content part. The definition part defines generally the type of property; client, project, customer, creator, date, etc. The content part on the other hand specifies the value of the metadata, i.e. which client (“Earth Image Ltd”), which project (“The World”), which customer (“PhotoShoot Inc.”) which creator (“Martha Stelline”), which date (“20120601”). For further example, specified values for a creator of the file or a creation date represent content of the metadata. In addition, a project which the document belongs to; a client who owns the document; a type of the document (letter, assignment, publication, order etc.); name of the document are examples of the properties of the metadata. Despite the plural form of metadata, in this disclosure, the term metadata may also refer to a singular form. Therefore, an object being defined by “metadata” may in practice be defined by one or more pieces of metadata. In the present disclosure, term “property-properties” is used as a synonym for metadata.
Direct metadata is a list on properties that define the electronic object directly. Direct metadata is therefore the properties of the object. Indirect metadata is a list of properties for a property of the electronic object. Therefore, indirect metadata does not define the electronic object, but the property of the electronic object. The indirect metadata is thus reachable via object's property. FIG. 2 illustrates examples of metadata structures 200 , 210 . A document's metadata structure 200 comprises properties such as “name”, “creator”, “created”, “project”, “state”, “content approver”, “sent”, and “last modified”. A project's metadata structure 210 comprises properties such as “manager”, “created”, “participant”, “state”, “HR” and “last modified”. Document's properties listed in structure 200 are document's direct metadata. Project's properties listed in structure 210 are project's direct metadata. However, project's properties listed in structure 210 are document's indirect metadata. This is because the document “contract.doc” has a property “Project” having a value “Web site testing” which refers to a project object “Web site testing” having its own properties.
For defining an ACL for state transition 2→3 of a workflow according to an embodiment of the present solution, the notation can be the following:
[Document].[ContentApprover]: Allowed
Such a notation does not give system-wide permission to users of a group “Content Approvers”, but the definition dynamically takes into account the document's (or electronic object's) metadata, which document (or electronic object) is in the workflow.
Now, if the document has a property “ContentApprover”, the value of which is “Susan”, the ACL for state transition 2→3 defining “[Document].[ContentApprover]: Allowed” will be interpreted as a definition
“Susan: Allowed”. Therefore user “Susan” can make the state transition 2→3 for this document. However, user “Susan” cannot necessarily make state transition 2→3 for other documents, if those documents have a different value than “Susan” in document's “ContentApprover” property.
The previous was an example of utilizing direct metadata for defining rights to perform a state transition. In the following, an example of using indirect metadata for the same purpose will be described.
For defining an ACL for a state transition 2→3 of a workflow according to another embodiment of the solution, the notation can be the following:
[Document].[Project].[ProjectManager]: Allowed
In this notation, there is one level (“Project”) of indirectness. However, there can be more than one level of indirectness via which the specified user can be reached.
The indirect notation gives rights to perform a state transition 2→3 for a document to a user that has been defined in the property “ProjectManager” of certain project's metadata, which project is defined in the “Project” property in the metadata of the document in question.
Another example of the use of indirect metadata for defining rights for state transition is described next. A document “Instructions” goes through a workflow so that at first it is assigned to state “Content approved” and after that it is assigned to state “Authorized for use”.
An ACL for a state transition “Waiting for content approval→Content approved” defines “[Document].[ContentApprover]: Allowed”. Therefore a user that has been defined as the value of “ContentApprover” property for the document can perform the state transition from a state “Waiting for content approval” to “Content approved”.
An ACL for a state transition “Content approved→Authorized for use” defines “[Document].[ContentApprover].[Supervisor]: Allowed”. By this, a supervisor of the “ContentApprover” may perform the state transition from “Content approved” to “Authorized for use”. The value for the “Supervisor” can be retrieved from metadata of the person being defined in document's “ContentApprover” property.
The permissions for state transitions can be defined as illustrated in a user interface view shown in FIG. 3 . The state-transition permission view 300 may list all the states from which the transition may be performed and all the states to which the transition may be targeted 302 , and who is allowed to perform such a transition. By ticking a state transition option and selecting a button “Permissions” 305 , the user may define the permissions to perform the selected state transition. Other means of displaying the state transitions can be used as well. For example, a visual diagram of all states may be displayed, and connectors or other indicators between the states in the diagram may represent state transitions between the states, and the user may define the permissions for each relevant state transition.
A user interface view 400 shown in FIG. 4 allows a user to define permissions for the selected state transition (being selected from a user interface shown in FIG. 3 ). In this example, the state transition is from “2. Waiting for content approval” to “3. Content approved”. It is appreciated that in this example, rights for performing the state transition have been appointed in three different ways: directly to a group “Managers” 405 , directly to a user “Bill Henkel” 407 and to a user who is defined as a “ContentApprover” in document's metadata 409 .
It is appreciated that nearly any property in the metadata of the electronic object may have more than one value. This means that a property “Content approver” may define one or more users (“Susan” or “Susan”, “Peter”) as content approvers, one or more user groups (“Project ABS Team Members”) or any combination of them (“Susan”, “Peter”, “Project ABS Team Members”). Therefore also the permission to perform a state transition will be appointed to one or more users, one or more user groups or any combination of those, depending on the value(s) of the property “ContentApprover”.
In the previous embodiments, the permitted users are defined as dynamic (i.e. metadata based) roles of the document management system, the true character of which is defined from a direct or indirect metadata of the electronic object. Such a role without a defined person is called as a pseudo-user. An example of notation for defining a pseudo-user based on direct metadata is “[Document].[ContentApprover]”. In addition, an example of notation for defining a pseudo-user based on indirect metadata is “[Document].[Project].[ProjectManager]”. Often the pseudo-users are defined based on metadata of electronic objects. However, in some situations, the pseudo-users can be defined as a user who has performed a certain state transition. In such a case the pseudo-user definition may be “User who moved this object to state X”, where X stands for a name of a state. This can be utilized in such a manner that a permission to perform state transition “Approved→Approval Revoked” is given to only such user who made the state transition to a state “Approved” for the particular electronic object.
The present embodiments are yet described by means of an example, where an invoice is a document that goes through the workflow. The metadata of the invoice comprises properties for “Reviewer” and “Cost unit”. A state transition from “Waiting for reviewing” to “Reviewed” can be performed by a pseudo-user “Reviewer”, the value of which can be obtained from the metadata of the invoice. A permission to perform the next state transition from “Reviewed” to “Accepted for paying” is indirectly defined by “[Document].[Cost unit].[Director]: Allowed”, which give rights for the cost unit director, which is a property of the cost unit. Depending on which cost unit is defined to be the cost unit of the invoice, the state transition to “Accepted for paying” can be performed by such a director.
In the previous embodiments the workflow state transition can be performed by a user that is defined through direct or indirect metadata. In a traditional example the permission to perform a state transition is defined by an ACL for a state transition, defining e.g. “Carl Hillberg: Allowed” and/or “Managers: Allowed”. In the present embodiments the permission can be defined by an ACL for a state transition, defining “[Document].[Responsible]: Allowed” or “[Document].[Project].[Cost unit].[Admin]: Allowed” wherein the metadata of the document (or electronic object) defines the value for the permitted user.
The present embodiments enable using pseudo-users as permitted users for performing the state transition for a workflow. Pseudo-user is a user that is defined according to metadata/properties. Pseudo-user defines a role of a user, e.g., “Creator”, “Postmaster”, “Assistant”, “Responsible”—instead of person identities, and the identities for the pseudo-users are obtained from the metadata of a document in question. The term “pseudo-user” is an attribute that refers to a metadata item (i.e. property) representing a user or a user group. This attribute is called “pseudo-user” as long as the user item lacks a value.
As said, the present embodiments give rights to pseudo-users to perform state transition. It is appreciated that Delete/Read/Write/Access rights for a document are directly appointed to the document. However, in the present embodiments a right to perform a state transition represents different point of view. The right to perform a state transition is targeted directly to the workflow instead of the document. A certain state transition can be performed by different users depending on the document and its metadata.
The various embodiments of the invention can be implemented with the help of computer program code that resides in a memory and causes the relevant apparatuses to carry out the invention. For example, a client device may comprise circuitry and electronics for handling, receiving and transmitting data, computer program code in a memory, and a processor that, when running the computer program code, causes the client device to carry out the features of an embodiment. Yet further, a server device may comprise circuitry and electronics for handling, receiving and transmitting data, computer program code in a memory, and a processor that, when running the computer program code, causes the server device to carry out the features of an embodiment.
It is obvious that the present invention is not limited solely to the above-presented embodiments, which are given for understanding purposes, but it can be modified within the scope of the appended claims. | The invention relates to a method for controlling state transition of an electronic object in a workflow. The method comprises receiving a request for a state transition for an electronic object from a user; determining the current state of the object from a metadata of the electronic object; determining the next state after the state transition from the request; determining one or more pseudo-users that are allowed to perform a state transition from the current state to the next state; retrieving at least one person identity by utilizing at least one property in a metadata of the electronic object, which person identity is retrieved from a value of a property corresponding to the determined one or more pseudo-users; comparing the identity of the requesting user to the retrieved person identity, and if they match; performing a state transition according to the request. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a Divisional Application of U.S. patent application Ser. No. 11/833,802, filed Aug. 3, 2007 and published as US 2009/032255 A1, and entitled “Method and Apparatus for Isolating a Jet Forming Aperture in a Well Bore Servicing Tool,” which is hereby incorporated by reference herein in its entirety.
BACKGROUND
[0002] Hydrocarbon-producing wells often are stimulated by hydraulic fracturing operations, wherein a fracturing fluid may be introduced into a portion of a subterranean formation penetrated by a well bore at a hydraulic pressure sufficient to create or enhance at least one fracture therein. Stimulating or treating the well in such ways increases hydrocarbon production from the well.
[0003] In some wells, it may be desirable to individually and selectively create multiple fractures along a well bore at a distance apart from each other. The multiple fractures should have adequate conductivity, so that the greatest possible quantity of hydrocarbons in an oil and gas reservoir can be drained/produced into the well bore. When stimulating a reservoir from a well bore, especially those well bores that are highly deviated or horizontal, it may be difficult to control the creation of multi-zone fractures along the well bore without cementing a casing or liner to the well bore and mechanically isolating the subterranean formation being fractured from previously-fractured formations, or formations that have not yet been fractured.
[0004] To avoid explosive perforating steps and other undesirable actions associated with fracturing, certain tools may be placed in the well bore to place fracturing fluids under high pressure and direct the fluids into the formation. In some tools, high pressure fluids may be “jetted” into the formation. For example, a tool having jet forming nozzles, also called a “hydrojetting” or “hydrajetting” tool, may be placed in the well bore near the formation. Hydrojetting may also be referred to as a process of controlling high pressure fluid jets with surgical accuracy. The jet forming nozzles create a high pressure fluid flow path directed at the formation of interest. In another tool, which may be called a casing window, a stimulation sleeve, or a stimulation valve, a section of casing includes holes or apertures pre-formed in the casing. The casing window may also include an actuatable window assembly for selectively exposing the casing holes to a high pressure fluid inside the casing. The casing holes may include jet forming nozzles to provide a fluid jet into the formation, causing tunnels and fractures therein.
SUMMARY OF THE INVENTION
[0005] An embodiment of a well bore servicing apparatus includes a housing having a through bore and at least one high pressure fluid aperture in the housing, the fluid aperture being in fluid communication with the through bore to provide a high pressure fluid stream to the well bore, and a removable member coupled to the housing and disposed adjacent the fluid jet forming aperture and isolating the fluid jet forming aperture from an exterior of the housing. In other embodiments, the removable member is a degradable sleeve removed by degradation. Still other embodiments include a jet forming nozzle in the high pressure fluid aperture.
[0006] An embodiment of a method of servicing a well bore includes applying a removable member to an exterior of a well bore servicing tool, wherein the removable member covers at least one high pressure fluid aperture disposed in the tool, lowering the tool into a well bore, exposing the tool to a well bore material, wherein the removable cover prevents the well bore material from entering the fluid aperture, removing the removable member to expose a fluid flow path adjacent an outlet of the high pressure fluid aperture, and flowing a well bore servicing fluid through the fluid aperture outlet and flow path. In other embodiments, removing the removable member includes degrading a protective sleeve. In yet other embodiments, flowing the well bore servicing fluid further expands the fluid flow path adjacent the tool, into the surrounding formation, or both.
[0007] Another embodiment of a method of servicing a well bore includes disposing a fluid jetting tool in the well bore, the fluid jetting tool having a fluid jetting aperture and a removable member adjacent the fluid jetting aperture, cementing the fluid jetting tool into the well bore, wherein the removable member prevents cement from entering the fluid jetting aperture, and removing the removable member to expose a fluid flow path adjacent an outlet of the fluid jetting aperture. Other embodiments include pumping a well bore servicing fluid into the fluid jetting tool and through the fluid jetting aperture, and perforating the cement to further expand the fluid flow path. Still other embodiments include continuing to pump the servicing fluid into a formation adjacent the perforated cement to fracture the formation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more detailed description of the embodiments, reference will now be made to the following accompanying drawings:
[0009] FIG. 1 is a schematic, partial cross-section view of a fluid stimulation tool in an operating environment;
[0010] FIG. 2 is a cross-section view of a hydrojetting tool assembly;
[0011] FIG. 3 is a cross-section view of a fluid pressurizing well completion assembly;
[0012] FIG. 4A is a partial cross-section view of a hydrojetting casing window assembly;
[0013] FIG. 4B is a partial cross-section view of the casing window assembly of FIG. 4A in a shifted position;
[0014] FIG. 5 is a partial cross-section view of a well completing assembly including embodiments of FIGS. 4A and 4B ;
[0015] FIG. 6A is a partial cross-section view of an exemplary fluid jetting window assembly in an open position;
[0016] FIG. 6B is a partial cross-section view of an embodiment of the assembly of FIG. 6A in a closed position;
[0017] FIG. 6C is a partial cross-section view of an embodiment of the assembly of FIG. 6B showing removal of a removable member;
[0018] FIG. 6D is a partial cross-section view of an embodiment of the assembly of FIG. 6C showing fracturing;
[0019] FIG. 6E is a partial cross-section view of an embodiment of the assembly of FIG. 6D moved to a closed position; and
[0020] FIG. 7 is a partial cross-section view of an alternative embodiment of the fluid jetting window assembly of FIG. 6A .
DETAILED DESCRIPTION
[0021] In the drawings and description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Unless otherwise specified, any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Reference to up or down will be made for purposes of description with “up”, “upper”, “upwardly” or “upstream” meaning toward the surface of the well and with “down”, “lower”, “downwardly” or “downstream” meaning toward the terminal end of the well, regardless of the well bore orientation. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
[0022] Disclosed herein are several embodiments of fracturing or stimulation tools wherein pressurized fluid is directed or jetted through fluid apertures into an earth formation to create and extend fractures in the earth formation, or otherwise extend a flow path from the tool to the formation. Also disclosed are several embodiments of a removable member disposed over the fluid apertures, particularly jet forming nozzles, for example, to isolate the fluid apertures from an exterior environment of the tool. The exterior environment of the tool may include cement or other viscous, aperture-plugging materials that negatively effect the pressurizing or jetting nature of the apertures. As disclosed herein, exemplary embodiments of the removable member include a degradable sleeve wrapped around a portion of the tool housing having the fluid apertures. A degradable sleeve can comprise a variety of materials, as disclosed below. Also disclosed herein are operations of a fluid pressurizing or jetting tool including the removable member disposed over the fluid apertures to isolate such apertures from materials that may encumber or obstruct the fluid apertures. As disclosed, the operations of the fluid pressurizing or jetting tools may include a complete well servicing or treatment process to adequately fracture the earth formation.
[0023] FIG. 1 schematically depicts an exemplary operating environment for a fluid pressurizing or hydrojetting tool 100 for fracturing an earth formation F. As disclosed below, there are many embodiments of the fluid pressurizing or hydrojetting tool 100 , but for reference purposes, the schematic tool 100 will be called the “fluid stimulation tool 100 .” As depicted, a drilling rig 110 is positioned on the earth's surface 105 and extends over and around a well bore 120 that penetrates a subterranean formation F for the purpose of recovering hydrocarbons. The well bore 120 may drilled into the subterranean formation F using conventional (or future) drilling techniques and may extend substantially vertically away from the surface 105 or may deviate at any angle from the surface 105 . In some instances, all or portions of the well bore 120 may be vertical, deviated, horizontal, and/or curved.
[0024] At least the upper portion of the well bore 120 may be lined with casing 125 that is cemented 127 into position against the formation F in a conventional manner. Alternatively, the operating environment for the fluid stimulation tool 100 includes an uncased well bore 120 . The drilling rig 110 includes a derrick 112 with a rig floor 114 through which a work string 118 , such as a cable, wireline, E-line, Z-line, jointed pipe, coiled tubing, or casing or liner string (should the well bore 120 be uncased), for example, extends downwardly from the drilling rig 110 into the well bore 120 . The work string 118 suspends a representative downhole fluid stimulation tool 100 to a predetermined depth within the well bore 120 to perform a specific operation, such as perforating the casing 125 , expanding a fluid path therethrough, or fracturing the formation F. The drilling rig 110 is conventional and therefore includes a motor driven winch and other associated equipment for extending the work string 118 into the well bore 120 to position the fluid stimulation tool 100 at the desired depth.
[0025] While the exemplary operating environment depicted in FIG. 1 refers to a stationary drilling rig 110 for lowering and setting the fluid stimulation tool 100 within a land-based well bore 120 , one of ordinary skill in the art will readily appreciate that mobile workover rigs, well servicing units, such as slick lines and e-lines, and the like, could also be used to lower the tool 100 into the well bore 120 . It should be understood that the fluid stimulation tool 100 may also be used in other operational environments, such as within an offshore well bore or a deviated or horizontal well bore.
[0026] The fluid stimulation tool 100 may take a variety of different forms. In an embodiment, the tool 100 comprises a hydrojetting tool assembly 150 , which in certain embodiments may comprise a tubular hydrojetting tool 140 and a tubular, ball-activated, flow control device 160 , as shown in FIG. 2 . The tubular hydrojetting tool 140 generally includes an axial fluid flow passageway 180 extending therethrough and communicating with at least one angularly spaced lateral port 142 disposed through the sides of the tubular hydrojetting tubular hydrojetting tool 140 . In certain embodiments, the axial fluid flow passageway 180 communicates with as many angularly spaced lateral ports 142 as may be feasible, (e.g., a plurality of ports). A fluid jet forming nozzle 170 generally is connected within each of the lateral ports 142 . As used herein, the term “fluid jet forming nozzle” refers to any fixture that may be coupled to an aperture so as to allow the communication of a fluid therethrough such that the fluid velocity exiting the jet is higher than the fluid velocity at the entrance of the jet. In certain embodiments, the fluid jet forming nozzles 170 may be disposed in a single plane that may be positioned at a predetermined orientation with respect to the longitudinal axis of the tubular hydrojetting tool 140 . Such orientation of the plane of the fluid jet forming nozzles 170 may coincide with the orientation of the plane of maximum principal stress in the formation to be fractured relative to the longitudinal axis of the well bore penetrating the formation.
[0027] The tubular, ball-activated, flow control device 160 generally includes a longitudinal flow passageway 162 extending therethrough, and may be threadedly connected to the end of the tubular hydrojetting tool 140 opposite from the work string 118 . The longitudinal flow passageway 162 may comprise a relatively small diameter longitudinal bore 164 through an exterior end portion of the tubular, ball-activated, flow control device 160 and a larger diameter counter bore 166 through the forward portion of the tubular, ball-activated, flow control device 160 , which may form an annular seating surface 168 in the tubular, ball-activated, flow control device 160 for receiving a ball 172 . Before ball 172 is seated on the annular seating surface 168 in the tubular, ball-activated, flow control device 160 , fluid may freely flow through the tubular hydrojetting tool 140 and the tubular, ball-activated, flow control device 160 . After ball 172 is seated on the annular seating surface 168 in the tubular, ball-activated, flow control device 160 as illustrated in FIG. 2 , flow through the tubular, ball-activated, flow control device 160 may be terminated, which may cause fluid pumped into the work string 118 and into the tubular hydrojetting tool 140 to exit the tubular hydrojetting tool 140 by way of the fluid jet forming nozzles 170 thereof. When an operator desires to reverse-circulate fluids through the tubular, ball-activated, flow control device 160 , the tubular hydrojetting tool 140 and the work string 118 , the fluid pressure exerted within the work string 118 may be reduced, whereby higher pressure fluid surrounding the tubular hydrojetting tool 140 and tubular, ball-activated, flow control device 160 may flow freely through the tubular, ball-activated, flow control device 160 , causing the ball 172 to disengage from annular seating surface 168 , and through the fluid jet forming nozzles 170 into and through the work string 118 .
[0028] The hydrojetting tool assembly 150 , schematically represented at 100 in FIG. 1 , may be moved to different locations in the well bore 120 by using work string 118 . Work string 118 also carries the fluid to be jetted through jet forming nozzles 170 . During use, the hydrojetting tool assembly 150 may be exposed to a variety of hindrances or nozzle plugging materials. Therefore, it is desirable to maintain unhindered jet forming nozzles 170 such that successful fluid jets are created each time the tool assembly 150 is used.
[0029] Referring now to FIG. 3 , in another embodiment, the schematic fluid jetting tool 100 comprises an exemplary well completion assembly 200 . The well completion assembly 200 is disposed in the well bore 120 coupled to the surface 105 and extending down through the subterranean formation F. The completion assembly 200 includes a conduit 208 extending through at least a portion of the well bore 120 . The conduit 208 may or may not be cemented to the subterranean formation F. In some embodiments, the conduit 208 is a portion of a casing string coupled to the surface 105 by an upper casing string, represented schematically by work string 118 in FIG. 1 . Cement is flowed through an annulus 222 to attach the casing string to the well bore 120 . In some embodiments, the conduit 208 may be a liner that is coupled to a previous casing string. When uncemented, the conduit 208 may contain one or more permeable liners, or it may be a solid liner. As used herein, the term “permeable liner” includes, but is not limited to, screens, slots and preperforations. Those of ordinary skill in the art, with the benefit of this disclosure, will recognize whether the conduit 208 should be cemented or uncemented and whether conduit 208 should contain one or more permeable liners.
[0030] The conduit 208 includes one or more pressurized fluid apertures 210 . Fluid apertures 210 may be any size, for example, 0.75 inches in diameter. In some embodiments, the fluid apertures 210 are jet forming nozzles, wherein the diameter of the jet forming nozzles are reduced, for example, to 0.25 inches. The inclusion of jet forming nozzles 210 in the well completion assembly 200 adapts the assembly 200 for use in hydrojetting. In some embodiments, the fluid jet forming nozzles 210 may be longitudinally spaced along the conduit 208 such that when the conduit 208 is inserted into the well bore 120 , the fluid jet forming nozzles 210 will be adjacent to a local area of interest, e.g., zones 212 in the subterranean formation F. As used herein, the term “zone” simply refers to a portion of the formation and does not imply a particular geological strata or composition. Conduit 208 may have any number of fluid jet forming nozzles, configured in a variety of combinations along and around the conduit 208 .
[0031] Once the well bore 120 has been drilled and, if deemed necessary, cased, a fluid 214 may be pumped into the conduit 208 and through the fluid jet forming nozzles 210 to form fluid jets 216 . In one embodiment, the fluid 214 is pumped through the fluid jet forming nozzles 210 at a velocity sufficient for the fluid jets 216 to form perforation tunnels 218 . In one embodiment, after the perforation tunnels 218 are formed, the fluid 214 is pumped into the conduit 208 and through the fluid jet forming nozzles 210 at a pressure sufficient to form cracks or fractures 220 along the perforation tunnels 218 .
[0032] The composition of fluid 214 may be changed to enhance properties desirous for a given function, i.e., the composition of fluid 214 used during fracturing may be different than that used during perforating. In certain embodiments, an acidizing fluid may be injected into the formation F through the conduit 208 after the perforation tunnels 218 have been created, and shortly before (or during) the initiation of the cracks or fractures 220 . The acidizing fluid may etch the formation F along the cracks or fractures 220 , thereby widening them. In certain embodiments, the acidizing fluid may dissolve fines, which further may facilitate flow into the cracks or fractures 220 . In another embodiment, a proppant may be included in the fluid 214 being flowed into the cracks or fractures 220 , which proppant may prevent subsequent closure of the cracks or fractures 220 . The proppant may be fine or coarse. In yet another embodiment, the fluid 214 includes other erosive substances, such as sand, to form a slurry. Complete well treatment processes including a variety of fluids and fluid particulates may be understood with reference to Halliburton Energy Service's SURGIFRAC® and COBRAMAX®. The fluid component embodiments described above may be used in various combinations with each other and with the other embodiments disclosed herein.
[0033] Referring now to FIGS. 4A and 4B , an exemplary casing window assembly 300 is shown as adapted for use in the well completion assembly 200 . As used herein, the term “casing window” refers to a section of casing configured to enable selective access to one or more specified zones of an adjacent subterranean formation. A casing window has a window that may be selectively opened and closed by an operator, for example, movable sleeve member 304 . The casing window assembly 300 can have numerous configurations and can employ a variety of mechanisms to selectively access one or more specified zones of an adjacent subterranean formation.
[0034] The casing window 300 includes a substantially cylindrical outer casing 302 that receives a movable sleeve member 304 . The outer casing 302 includes one or more apertures 306 to allow the communication of a fluid from the interior of the outer casing 302 into an adjacent subterranean formation. The apertures 306 are configured such that fluid jet forming nozzles 308 may be coupled thereto. In some embodiments, the fluid jet forming nozzles 308 may be threadably inserted into the apertures 306 . The fluid jet forming nozzles 308 may be isolated from the annulus 310 (formed between the outer casing 302 and the movable sleeve member 304 ) by coupling seals or pressure barriers 312 to the outer casing 302 .
[0035] The movable sleeve member 304 includes one or more apertures 314 configured such that, as shown in FIG. 4A , the apertures 314 may be selectively misaligned with the apertures 306 so as to prevent the communication of a fluid from the interior of the movable sleeve member 304 into an adjacent subterranean formation. The movable sleeve member 304 may be shifted axially, rotatably, or by a combination thereof such that, as shown in FIG. 4B , the apertures 314 selectively align with the apertures 306 so as to allow the communication of a fluid from the interior of the movable sleeve member 304 into an adjacent subterranean formation. The movable sleeve member 304 may be shifted via the use of a shifting tool, a hydraulic activated mechanism, or a ball drop mechanism.
[0036] Referring now to FIG. 5 , an exemplary well completion assembly 400 includes open casing window 402 and closed casing window 404 formed in a conduit 406 . Alternatively, the well completion assembly 400 may be selectively configured such that the casing window 404 is open and the casing window 402 is closed, such that the casing windows 402 and 404 are both open, or such the that casing windows 402 and 404 are both closed.
[0037] A fluid 408 may be pumped down the conduit 406 and communicated through the fluid jet forming nozzles 410 of the open casing window 402 against the surface of the well bore 120 in the zone 414 of the subterranean formation F. The fluid 408 would not be communicated through the fluid jet forming nozzles 418 of the closed casing window 404 , thereby isolating the zone 420 of the subterranean formation F from any well completion operations being conducted through the open casing window 402 involving the zone 414 . The fluid 408 may include any of the embodiments disclosed elsewhere herein.
[0038] In one embodiment, the fluid 408 is pumped through the fluid jet forming nozzles 410 at a velocity sufficient for fluid jets 422 to form perforation tunnels 424 . In one embodiment, after the perforation tunnels 424 are formed, the fluid 408 is pumped into the conduit 406 and through the fluid jet forming nozzles 410 at a pressure sufficient to form cracks or fractures 426 along the perforation tunnels 424 .
[0039] The embodiments disclosed above including hydrojetting are especially useful in deviated or horizontal well bores. In deviated or horizontal well bores, fractures induced in the formation tend to extend longitudinally, or parallel, relative to the well bore. Such fractures limit production. Hydrojetting causes fractures to extend radially outward, transverse, or perpendicular relative to the well bore. Such transverse fractures increase the area of the fractured zone, thereby increasing production of hydrocarbons from the formation. Including more hydrojetting apertures along the tool also increases the length of the fractured zone.
[0040] The embodiments described above are illustrative of various fluid jetting tools and conveyances to which embodiments described below may be applied. Other conveyances for fluid jetting apertures or nozzles are contemplated by the present disclosure as indicated below and elsewhere herein.
[0041] Referring now to FIG. 6A , a partial cross-section view of a fluid jetting window assembly 500 is shown, wherein the lower half of the assembly 500 is shown in cross-section for viewing certain internal components of the assembly 500 . The fluid jetting window assembly 500 includes an outer housing 502 having a flow bore 512 and apertures 504 , which will be described as jet forming apertures 504 but may also be pressurizing apertures or ports for directing fracturing fluids from the tool into the formation. The outer housing 502 may be coupled to casing string portions 506 , 508 to form a casing string cementable within a well bore as previously shown and described herein. As noted previously, the well bore may be vertical, horizontal, or various angles in between, and thus it is to be understood that the horizontal depiction of assembly 500 in FIGS. 6A-E and 7 may apply to any such well bore orientation. The outer housing 502 retains a movable window sleeve 510 , the window sleeve 510 being reciprocally disposed within the flowbore 512 of the outer housing 502 . The window sleeve 510 includes apertures 514 for communicating with a fluid flowing through the flow bore 512 . A removable member 516 is disposed over a portion of the outer surface of the outer housing 502 having the jet forming apertures 504 .
[0042] In the embodiment shown in FIG. 6A , the removable member 516 is a sleeve disposed around the outer housing 502 and over the jet forming apertures 504 . Retaining rings 518 are positioned above and below the removable sleeve 516 to couple the sleeve 516 to the outer housing 502 and retain the sleeve 516 in place over the jet forming apertures 504 (sleeve 516 and rings 518 being shown in cross-section). In some embodiments, the retaining rings 518 protect the removable sleeve 516 as the assembly 500 moves through the well bore 120 . The removable sleeve 516 is configured to cover the jet forming apertures 504 and isolate them from materials, fluid, and other obstructions that may be applied to the exterior of the outer housing 502 in the well bore environment. For the sake of clarity, the embodiments of FIGS. 6A through 7 are described with the removable member 516 being a sleeve, and the jetting tool assembly 500 being a jetting window conveyed as part of a casing string. Further, the casing string and assembly 500 are cemented in the well bore with cement 520 as one example of a plugging material that may obstruct the fluid jet forming apertures. However, as is recognized throughout the present disclosure, other combinations of fluid pressurizing or jetting tools (e.g., tools such as those shown in FIGS. 1 to 5 ), removable members, and obstructions are contemplated as part of the present disclosure.
[0043] In some embodiments, the sleeve 516 is removable by degradation. The degradable sleeve 516 may comprise a variety of materials. For example, the degradable sleeve may comprise water-soluble materials such that the sleeve degrades as it absorbs water. In an embodiment, the degradable sleeve 516 comprises a biodegradable material such as polylactic acid (PLA). In some embodiments, the degradable sleeve 516 comprises metals that degrade when exposed to an acid, also known as “acidizing.” Other embodiments for degradable sleeve 516 are also disclosed herein.
[0044] For example, the sleeve 516 comprises consumable materials that burn away and/or lose structural integrity when exposed to heat. Such consumable components may be formed of any consumable material that is suitable for service in a downhole environment and that provides adequate strength to enable proper operation of the degradable sleeve 516 . In embodiments, the consumable materials comprise thermally degradable materials such as magnesium metal, a thermoplastic material, composite material, a phenolic material or combinations thereof.
[0045] In an embodiment, the degradable materials comprise a thermoplastic material. Herein a thermoplastic material is a material that is plastic or deformable, melts to a liquid when heated and freezes to a brittle, glassy state when cooled sufficiently. Thermoplastic materials are known to one of ordinary skill in the art and include for example and without limitation polyalphaolefins, polyaryletherketones, polybutenes, nylons or polyamides, polycarbonates, thermoplastic polyesters such as those comprising polybutylene terephthalate and polyethylene terephthalate; polyphenylene sulphide; polyvinyl chloride; styrenic copolymers such as acrylonitrile butadiene styrene, styrene acrylonitrile and acrylonitrile styrene acrylate; polypropylene; thermoplastic elastomers; aromatic polyamides; cellulosics; ethylene vinyl acetate; fluoroplastics; polyacetals; polyethylenes such as high-density polyethylene, low-density polyethylene and linear low-density polyethylene; polymethylpentene; polyphenylene oxide, polystyrene such as general purpose polystyrene and high impact polystyrene; or combinations thereof.
[0046] In an embodiment, the degradable materials comprise a phenolic resin. Herein a phenolic resin refers to a category of thermosetting resins obtained by the reaction of phenols with simple aldehydes such as for example formaldehyde. The component comprising a phenolic resin may have the ability to withstand high temperature, along with mechanical load with minimal deformation or creep thus provides the rigidity necessary to maintain structural integrity and dimensional stability even under downhole conditions. In some embodiments, the phenolic resin is a single stage resin. Such phenolic resins are produced using an alkaline catalyst under reaction conditions having an excess of aldehyde to phenol and are commonly referred to as resoles. In some embodiments, the phenolic resin is a two stage resin. Such phenolic resins are produced using an acid catalyst under reaction conditions having a substochiometric amount of aldehyde to phenol and are commonly referred to as novalacs. Examples of phenolic resins suitable for use in this disclosure include without limitation MILEX and DUREZ 23570 black phenolic which are phenolic resins commercially available from Mitsui Company and Durez Corporation respectively.
[0047] In an embodiment, the degradable material comprises a composite material. Herein a composite material refers to engineered materials made from two or more constituent materials with significantly different physical or chemical properties and which remain separate and distinct within the finished structure. Composite materials are well known to one of ordinary skill in the art and may include for example and without limitation a reinforcement material such as fiberglass, quartz, kevlar, Dyneema or carbon fiber combined with a matrix resin such as polyester, vinyl ester, epoxy, polyimides, polyamides, thermoplastics, phenolics, or combinations thereof. In an embodiment, the composite is a fiber reinforced polymer.
[0048] The degradable sleeve 516 is used for description purposes herein, but the removable member is not to be limited by same. In some embodiments, the removable member is removable by other means. For example, in some embodiments, the removable member is a sleeve movable by actuation or shifting, as with the movable sleeve member 304 . In other embodiments, the removable member may be removed by breakage.
[0049] Referring now to FIGS. 6A through 6E , the fluid jetting window assembly 500 is illustrated in operation, wherein the embodiment shown includes a degradable sleeve 516 . Referring first to FIG. 6A , a closed position of the fluid jetting window assembly 500 is shown, wherein the window sleeve 510 is positioned such that the apertures 514 communicating with the fluid in the flowbore 512 are misaligned with the jet forming apertures 504 . The degradable sleeve 516 is disposed about the outer housing 502 adjacent the jet forming apertures 504 , and retained by retaining rings 518 . The window assembly 500 , in this “run-in” position, may be coupled to casing string portions 506 , 508 and conveyed together into a well bore, such as well bore 120 . Cement 520 may then be applied to the outer portions of the window assembly 500 and casing string portions 506 , 508 to attach them to the well bore (not shown). The sleeve 516 prevents cement from entering the jet forming apertures 504 and plugging them or otherwise obstructing the apertures.
[0050] In some embodiments of the cemented, closed position shown in FIG. 6A , the degradable sleeve 516 begins to degrade immediately or soon after the assembly 500 is cemented into position. For example, if the degradable sleeve 516 is a PLA sleeve, water from the environment exterior of the housing 502 will contact the PLA sleeve and begin to degrade it. Water may come from screens in the back side of the casing, for example, or from the cement slurry. The degradable sleeve 516 may experience varying degrees of degradation, from little to entire sleeve consumption, for example, while the assembly 500 is closed. Alternatively, the sleeve 516 may have begun to degrade from exposure to other fluids or materials present in the well bore during other operations involving the jetting window assembly 500 .
[0051] Referring now to FIG. 6B , fluid jetting window assembly 500 is shown in the open position. The window sleeve 510 has been selectively actuated, mechanically, hydraulically, or by other means for actuating movable sleeves, to a position where the window apertures 514 are aligned with the jet forming apertures 504 . The alignment of the window apertures 514 and the jet forming apertures 504 provides a fluid jet flow path 530 between the interior flow bore 512 and the exterior of the outer housing 502 . At this time, in embodiments including a biodegradable sleeve 516 , the sleeve 516 is in varying stages of degradation. In alternative embodiments, the sleeve 516 is moved, broken, or otherwise removed from covering the jet forming apertures 504 just before or after the assembly is opened as just described. It may be desirable to degrade or remove the sleeve 516 before the assembly 500 is opened such that the apertures 504 are uncovered, or partially uncovered, while pressure integrity is maintained within the assembly 500 .
[0052] In some embodiments wherein a degradable sleeve is present, while the assembly 500 is in the open position, a fluid is communicated from the flow bore 512 , through the jet flow path 530 , and to the degradable sleeve 516 to begin or assist in the degradation process. In embodiments where the sleeve is made of PLA or other biodegradable materials, it may take, for example, a day to several days for substantial degradation of the sleeve to occur while only exposed to the well bore environment. In one embodiment, an acid may be “spotted” through the jet flow path 530 to assist with degradation of the sleeve 516 . This provides a more selective degradation of the degradable sleeve 516 . Spotting acid at this point and location may also focus the process of extending the jet flow path from the jet forming apertures 504 radially outward from the housing 502 at least to a distance equal to the width W of the sleeve 516 . In a further embodiment wherein the sleeve 516 is made of metal, such as aluminum, or another more robust material, an acid may be flowed into the jet flow path 530 to melt or otherwise degrade the sleeve while the assembly 500 is in the open position.
[0053] In additional embodiments wherein the sleeve 516 is degradable, the degradation of the sleeve 516 may create an acid, such as lactic acid, or other erosive material which then begins to degrade the cement. Degradation of the cement beyond the sleeve 516 assists in further extending the jet flow path generally in the area 522 of the cement formation 520 (which is created from a cement slurry applied in the usual manner).
[0054] In still further embodiments, the jet forming apertures 504 may be filled with a degradable substance or removable member. In one embodiment, the apertures 504 are filled with a plug made of the same material as the degradable sleeve 516 , such as PLA. A PLA plug may simply be a portion of PLA in the shape of a plug that is adapted to be inserted into an aperture 504 . In another embodiment, the apertures 504 are filled with a gel that can be degraded as disclosed herein, or may be pushed out of the apertures 504 with fluid pressure. It yet another embodiment, the apertures 504 can be filled with removable members, for example, rupture disks that are selectively ruptured for removal. In the embodiments just described, the aperture-fillers may be used in conjunction with the sleeve 516 , or, alternatively, in place of the sleeve. If the sleeve 516 is not present, the aperture-fillers just described may be removed consistent with those embodiments disclosed herein. In such an embodiment, certain benefits may be achieved, such as the presence of less PLA material; however, certain features are compromised, such as the cavity created by a sleeve beyond the outer tool surface to increase jetting, and the increased acidization provided by a sleeve.
[0055] Referring now to FIG. 6C , degradation of the sleeve 516 has weakened the sleeve 516 and, in some embodiments, the adjacent cement or other surrounding degradable materials. A fluid, such as a perforating or fracturing fluid, is pumped through the flow bore 512 and into the first jet flow path 530 formed by the aligned window apertures 504 and jet forming apertures 504 . The fluid jet from the jet forming apertures 504 creates a perforation 524 , or second jet flow path, extending from the jet forming apertures 504 , through the degraded sleeve 516 (or possibly a completely eliminated sleeve depending on the degree of degradation), and into the cement formation 520 .
[0056] Despite the high pressure in flow bore 512 , the perforation 524 or other extension of the jet fluid flow path beyond the jet forming apertures 504 is significantly hindered without the sleeve 516 . As used herein, high pressure, for example, is generally greater than about 3,500 p.s.i., alternatively greater than about 10,000 p.s.i., and alternatively greater than about 15,000 p.s.i. If sleeve 516 is not present, the cement 520 abuts the outer housing 502 and is flush with the jet forming apertures 504 , thereby obstructing them and resisting fluid flow. Cement may also enter the jet forming apertures 504 and plug them, thereby further increasing resistance to fluid flow therethrough. Under these circumstances, the area of the cement, or other viscous material applied to the outer housing 502 , to which the high pressure fluid in the flow bore 512 is applied is very small, i.e., the size of the jet forming aperture, which is intended to be small to provide the fluid jetting function. If, for example, the jet forming aperture has a diameter of 0.25 inches, the area of the aperture is 0.049 inches squared. Even at 5,000 p.s.i. in flow bore 512 , the force applied to the cement 520 is approximately 250 pounds. A force of this size is typically not efficient to crack or perforate the cement 520 .
[0057] Removal of the sleeve 516 , however, increases the force applied to the cement 520 by creating distance between the jet forming apertures 504 and the cement 520 and widening the area upon which the high pressure jet is applied. For example, as shown in FIGS. 6A and 6B , the area of applied pressure may be increased, in one dimension, from the diameter of the aperture 504 to the length L of the sleeve 516 . Furthermore, the distance between the apertures 504 and the cement 520 also allows the high pressure fluid to flow along an extended fluid jet flow path. For example, as also shown in FIGS. 6A and 6B , the distance W may be used to extend the high pressure fluid jet flow path.
[0058] Referring next to FIG. 6D , the fluid in flow bore 512 continues to be pumped at a high pressure such that the fluid continues to flow along the first jet fluid flow path 530 at apertures 514 , 504 , along the second jet fluid flow path extending from the jet forming apertures 504 and along the perforations 524 , and further extends the jet fluid flow path at the fractures 526 . The fractures 526 increase production of hydrocarbons from the formation F. In one embodiment, hydrocarbons may be produced through the assembly 500 by pumping fluids in the flow bore 512 in the opposite direction, thereby drawing hydrocarbons from the formation F along the jet fluid flow path at the fracture 526 , the perforations 524 , and finally in through the aligned apertures 514 , 504 . In another embodiment, as shown in FIG. 6E , the jetting window assembly 500 may be closed. The window sleeve 510 is moved or actuated back to its original closed position, thereby misaligning the apertures 514 and the jet forming apertures 504 and preventing fluid flow therebetween.
[0059] Referring to FIG. 7 , an alternative embodiment of the jetting window assembly is shown. Jetting window assembly 600 includes a larger degradable sleeve 616 (which may also be any of the various sleeves or removable members disclosed herein) bounded by larger retaining and protection rings 618 . In this embodiment, the area of isolation about the jet forming apertures 604 is increased, as partially shown by the dimensional length L 2 . As previously disclosed, increasing the length to L 2 increases the available area for fluid jetting onto the cement formation (not shown), and thereby increasing the perforating and fracturing forces on the cement. Furthermore, the length L 2 , as opposed to the length L of FIGS. 6A and 6B , for example, provides more flow space for creating longitudinal fractures. A sleeve with length L may be used for creating transverse fractures.
[0060] The various embodiment described herein provide a system for isolating apertures in a high pressure fluid stimulation tool from the exterior of the tool and preventing the apertures from becoming plugged or otherwise obstructed. In some embodiments, the apertures include jet forming nozzles that are susceptible to plugging when the tool in which the jet forming nozzles are placed is cemented onto a well bore. In addition to cementing, other downhole operations or conditions may also introduce plugging materials or hindrances at the nozzles in a jetting tool. A plugged or hindered jetting nozzle then cannot perform its fluid jetting function properly. Thus, maintaining unplugged and unobstructed high pressure fluid apertures and/or jet forming nozzles in high precision fluid stimulation tools is very beneficial. In addition, while some embodiments disclosed herein include acidizing a degradable sleeve, the embodiments of the system disclosed herein avoid the difficult and expensive step of attempting to acidize cement or other obstruction present inside the relatively small fluid apertures and/or jet forming nozzles.
[0061] While specific embodiments have been shown and described, modifications can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments as described are exemplary only and are not limiting. Many variations and modifications are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | An embodiment of a well bore servicing apparatus includes a housing having a through bore and at least one high pressure fluid aperture in the housing, the fluid aperture being in fluid communication with the through bore to provide a high pressure fluid stream to the well bore, and a removable member coupled to the housing and disposed adjacent the fluid jet forming aperture and isolating the fluid jet forming aperture from an exterior of the housing. An embodiment of a method of servicing a well bore includes applying a removable member to an exterior of a well bore servicing tool, wherein the removable member covers at least one high pressure fluid aperture disposed in the tool, lowering the tool into a well bore, exposing the tool to a well bore material, wherein the removable cover prevents the well bore material from entering the fluid aperture, removing the removable member to expose a fluid flow path adjacent an outlet of the high pressure fluid aperture, and flowing a well bore servicing fluid through the fluid aperture outlet and flow path. | 4 |
BACKGROUND OF THE INVENTION
This invention is directed to a Dual Automatic Dryer and Washing Machine Protective Basin, which protects both dryer and washing machine and the underlying surface on which they are supported from drippage, and is effective with both front and top loaders installed side-by-side.
Drippage has historically been handled in differing ways. Appliance drip pans and specifically washing machine and dishwasher drip pans are well known in the prior art. An example of a dishwasher drip pan is U.S. Pat. No. 3,096,781 to Roidt. The Roidt device is used to collect drippage from a built-in dishwasher, and redirect the drippage to the exterior of the building. The Roidt drip pan is comprised of a flat bottom with four vertical walls, i.e., front, rear and side walls. Each corner of the flat bottom is fitted with a foot which supports the drip pan in a level position slightly elevated above the floor. The bottom of the drip pan has openings through which lag screws pass and secure the drip pan into the floor. A drainage opening is provided in either the bottom or rear wall. The drip pan is first installed on the underlying surface, and the dishwasher is then placed within the walls of the device. When installed, a drainage tube is attached to the drainage opening which serves to conduct any leakage through an outside wall to the exterior of the building. The drip pan operates by intercepting any drainage before it reaches the floor, confining the drainage to the area beneath the dishwasher, and conducting the drainage through an opening to the exterior of the building.
The Roidt drip pan is not suitable as a protective drip pan for an automatic front loading dryer and washing machine unit for several reasons. First, it is not designed for a dual, side-by-side automatic dryer and washing machine unit. Second, the Roidt drip pan has a number of structural features which require a complex molding process and assembly of separate components into the final product. The features include small feet for elevating the bottom of the pan above the floor, openings for drainage and attachment of the drip pan to the floor, collars for the attachment openings and the means for attaching the drainage tubing to the drainage opening. These structural features increase the cost of the Roidt drip pan, and the screw openings in the bottom of the pan pose the danger of the failure of any seal between the openings and the lag screws, with the attendant danger of leakage at that point.
Third, the Roidt drip pan requires modification of the building for installation of an attached drain tube which conducts the drainage to the exterior of the building. Installation also requires tubing connections and installation of lag screws and support blocks. These installation requirements add cost and complexity to what is at first glance a rather simple invention.
Fourth, the Roidt drip pan fails to provide any protection for the front or top loading automatic dryer and washing machine units by failing to alert the occupant of the building that leakage is occurring. Small amounts of leakage can indicate impending serious failure of the washing machine unit or possibly lead to serious failure if unchecked (e.g. seal failure contributing to bearing failure, thermostat or blower failure). Since the building occupant is not alerted to take corrective action, the condition is likely to worsen, possibly leading to greater damage than if the drip pan were not used.
Fifth, the Roidt drip pan could lead to greater damage to the building than if no drip pan were used at all, since continual, undetected drainage to the immediate vicinity of a building exterior has the potential to cause damage to the foundation or sub floors of the building.
Finally, the Roidt pan poses another potential hazard to the building: the open drainage tube leading directly to the exterior of the building provides a direct route for pests from the exterior to the interior of the building.
A washing machine water catcher is described in U.S. Pat. No. 3,304,950 to Hubert. The Hubert water catcher is comprised of a bottom wall attached to vertical rear inside walls, and a removable front wall. The bottom wall of the water catcher is fitted with runner plates over which the base of the washing machine slides during installation. A separate drain valve is provided in the front wall for drainage of collected water. The inside area of the water catcher is larger than the base of the washing machine to allow the base of the washing machine to fit completely within the water catcher. The Hubert water catcher is installed by removing the washer, placing the water catcher on the floor, removing the front wall of the water catcher, sliding the washing machine into the water catcher, and replacing the front wall.
The Hubert water catcher is not suitable for use as a dual automatic dryer and washing machine protective basin for a number of reasons. First, the Hubert water catcher allows drainage to accumulate beneath a single appliance that would be unseen and otherwise unnoticed by the occupant of the building. The accumulation of drainage beneath a dual side-by-side dryer and washer unit can lead to mildew and mold, and may provide breeding sites and sustenance for insects or other pests in a room of the house where cleanliness is of great importance. The Hubert invention thus fails to prevent or cure some of the major damaging effects of drainage from an automatic dual dryer and washing machine unit. In addition, the spigot protruding from the front wall would be a tripping hazard for the buildings occupants.
The Hubert water catcher also has structural features which require a complex molding process in the assembly of separate components, adding to the cost of the final product. The features include cleats molded into the bottom and side walls to hold the runner plates, the hole and spigot assembly in the front wall, and precisely sized channels in the side walls to receive and seal the edges of the removable front wall.
A refrigerator drip pan is disclosed in U.S. Pat. No. 1,584,175 to Irons. The Irons refrigerator drip pan is a container for collecting and containing condensation and drip from the waste pipe of the ice chamber of the refrigerator. It is comprised of a rectangular box with a recessed lid. The lid has two recessed channels to guide the drips from their point of impingement near the center of the lid to holes at the front corners of the lid, where the drips fall into the box. A roller is fitted near the rear of the bottom of the pan to aid in removing the pan from beneath the refrigerator. The drip pan is installed completely beneath the refrigerator, and is hidden from view by the lower front panel of the appliance. Periodically, the box must be removed and emptied. The pan is fitted with an overflow hole in the front wall to remind the forgetful building occupant to remove and empty the filled pan. The overflow discharges to the area beneath the refrigerator behind the front cover.
The Irons refrigerator drip pan is unsuitable for use as a protective drip pan for a dual side-by-side automatic dryer and washing machine unit. First, the Irons pan is too tall to fit beneath a standard automatic, dryer and washing machine. Next, the Irons pan is designed to accumulate drainage in an enclosed area beneath the appliance, unseen and otherwise unnoticed by the occupant of the building. The accumulation of drainage beneath a dual automatic dryer and washing machine can lead to mildew and mold, and may provide breeding sites and sustenance for insects or other pests. The Irons invention thus fails to prevent or cure some of the major damaging effects of drainage from a washing machine or dryer.
The Irons drip pan has a number of structural features which require complex forming steps and assembly of separate components into the final product. These features include recessed channels in the lid, an internal baffle, an overflow hole in the front wall, a roller on the bottom of the pan, and a handle on the front of the pan. These structural features increase the cost of the Irons pan. When filled, the Irons pan discharges through the overflow hole in the front wall to the closed area beneath the refrigerator. If used with a washer and dryer, the user would not be alerted to the presence of drainage from the appliance until the pan fills, overflows, and the drainage spreads from beneath the front covers of both appliances. The building occupant is not alerted that the machine is malfunctioning for a potentially long time. The delay could lead to damage to both the automatic dryer and washing machine and the floor beneath.
Another drip pan for refrigerators is also disclosed in U.S. Pat. No. 1,057,654 to Menzl. The Menzl drip pan is a pan mounted on a tiltable support in such a way as to automatically tilt and slide forward from beneath the refrigerator when a predetermined amount of water has accumulated in the pan. The Menzl drip pan was designed for refrigerators which were “ice boxes”, and which had a slow continuous discharge of water from the ice box drain pipe as ice in the ice storage chamber slowly melted. It was therefore convenient and useful for an ice box drip pan to accumulate a quantity of water from the melted ice for the convenience of the user.
Other prior art patents exist which relate to drip pans. U.S. Pat. No. 2,479,000 to Buczkowski is directed to a drip pan for a toilet flush tank. U.S. Pat. No. 4,527,707 to Heymann et al. describes a tray for use inside an automatic dishwasher to catch debris from the glass tray. U.S. Pat. No. 3,662,912 to Calle describes a drip tray for use inside a refrigerator, beneath the freezer compartment. These inventions are not suitable for use as a protective drip pan for a dual front or top loading automatic dryer and washing machine unit for reasons previously cited with respect to the Roidt, Hubert, and Irons patents. Therefore, a need exists for a dryer and washing machine system which protects both the dryer and washing machine and the underlying surface on which it is supported, from leakage liquid emitted from both units.
Dual Automatic Dryer and Washing Machine Protective Basin
The Dual Automatic Dryer and Washing Machine Protective Basin is different from the Bates, Jr. protective automatic dishwashing system for an automatic dishwasher, U.S. Pat. No. 5,224,508. The Bates, Jr. protective automatic dishwashing system is for an automatic dishwasher for the kitchen and not for a dual automatic dryer and washing machine. Secondly it does not catch all of the water that the dual combination washer and dryer basin will accommodate and hold. A standard dishwasher only uses 20 gallons, and the Bates, Jr. system is designed to hold only that amount. Therefore, the Bates, Jr. system is not designed to hold the capacity of a normal 38-gallon washing machine should a leak develop. In addition, if the water evaporative system on a dryer failed at the same time, this would only add more water to the already overflowing Bates Jr. system, again causing damage to the floors and sub floors while also creating a potential hazardous living area for the homeowner due to toxic mold development.
The Dual Automatic Dryer and Washing Machine Protective Basin system, on the other hand, will not overflow even if both the automatic washer and dryer systems fail at the same time and leak all of their capacity into the pan, as it is designed with a capacity sufficient to absorb so great a discharge. This offers a worry-free situation for the homeowner. The new, water- and energy-efficient front-loading automatic washing machines are, unfortunately, notorious for water leakage. As they age, door seals can become less effective, and water churned up against the door can work its way past hardened seals.
As mentioned in the prior invention of Hubert, U.S. Pat. No. 3,304,950, water catcher apparatus, the Dual Automatic Dryer and Washing Machine Protective Basin system is different from Hubert's apparatus because the present invention catches drips and leaks from both the front loading dryer and washing machine, which means it is apparent by the prior art that the Hubert invention is made only for a washing machine by itself and not an automatic dryer and washing machine side-by-side. The present invention, the Dual Automatic Dryer and Washing Machine Protective Basin system holds the water capacity of both if both appliances were to leak or fail at different times or even at the same time, catching all the water from both appliances and not just one appliance.
Different from the prior invention, the present invention is thicker and made of a more durable material which is applied in the manufacturing process. The aforementioned prior drip pan apparatus for the washing machine is not thick enough to provide adequate durability, causing the product to crack or break sometimes within months of being installed in the new house by housing developers or building contractors. The lack of using the proper material therefore can cause a safety hazard for the new homeowner and the building contractor alike. The new homeowner could step on the product by accident while loading the washing machine, cracking it and making it susceptible to leakage. The prior drip pan apparatus, in addition to the material drying out from the UV rays from natural light or perhaps the UV from a light bulb, could cause a potential insurance liability to the contractor as well as a new homeowner if the washing machine should leak or overflow spilling water to a cracked, broke or damaged pan, in turn causing damage to the flooring and sub flooring of the house and or building.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the invention as it is being installed
FIG. 2 is a three-quarter overhead view of one embodiment of the invention which includes the built-in Easy-Slide Wedges™ and the Anti-Vibe Damping Pads™.
FIG. 3 is a three-quarter side view of yet another embodiment of the invention
FIG. 4 is a three-quarter view of yet another embodiment of the invention showing that capability of either the dryer or washing machine pedestal drawer and the invention low enough and yet large enough to accommodate these features of both appliances or of both automatic dryer and washing machine
FIG. 5 is a detailed view of the Safety No-Stub Corners™, showing the thickness and durability of the product and also the Anti-Vibe Diffusion Bumps™.
FIG. 6 is a side view of the service and repair strip safety device in use, adding strength to the front sidewall
FIG. 7 is a depiction of the invention adapted to a single appliance, or a stackable pair, with front wall low enough to clear a pedestal drawer
FIG. 8 is a three-quarter overhead view of one embodiment of the invention adapted to a single appliance, or a stackable pair, which includes repair strip safety device, the built-in Easy-Slide Wedges™ and the Anti-Vibe Damping Pads™
DETAILED DESCRIPTION OF THE INVENTION
Reference numerals are shown in parentheses, and refer to the Figure most nearly preceding them in the text. This invention is a Dual Automatic Dryer and Washing Machine Protective Basin system (The No-Re-Plumb Dual Automatic Dryer and Washing Machine Protective Basin™) for the new front or top loading side-by-side automatic dryer and washing machines— FIG. 4 ( 6 ) with or without a pedestal drawer ( 8 a ), being capable of catching and retaining or safely diverting leaks from both automatic dryer and washing machine if one or both appliances were to leak from the front door seals FIG. 3 ( 7 ) at the same time while washing and drying clothes or perhaps due to the mechanical failure while the washing machine is filling FIG. 4 ( 11 ) or perhaps the dryer heat evaporative and or steam system FIG. 3 ( 10 ) fails, in addition to having the present invention lower in height ( 4 b ) in order for the pedestal drawer ( 8 b ) to be able to clear the front wall of the basin—it can easily be seen that the height of the front wall (or any other wall, for that matter) can be modified down to any height to clear a pedestal drawer or for any other clearance issue, albeit at the expense of total basin capacity. FIG. 1 ( 6 ) shows how the washer and dryer can be swapped from either side without having to re-plumb the drain. This also allows the customer choice of door openings FIG. 3 ( 7 ) due to different cabinet configurations or if the user has a preference of left or right handed position while still allowing for the protective basin to function as intended.
Still referring to the drawings in which the various features are numbered, the Dual Automatic Dryer and Washing Machine Protective Basin system is a water catching protective basin device with a substantially flat bottom ( 2 ), and three or more raised edges ( 1 ). In its simpler form shown in FIG. 1 , it is simply a pan with a flat bottom and four identical side walls. Optionally, this pan is to fit flush into the floors of a laundry room that will fit both automatic dryer and washing machine side by side in FIG. 4 , while these walls are low enough ( 4 b ) to accommodate the pedestal drawer ( 8 b ) of the frontloading automatic dryer and washing machines/side-by-sides ( 6 ) in the event of a drip or leak or failed system in either the dryer or washing machine or both.
In addition to having the base of the pan and it sides designed to fit both dryer and washer side by side, FIG. 4 , it may optionally be helpful to equip the top edges with Safety No-Stub Corners™ of ¼″ approximate radius FIG. 5 ( 3 ) on one or more raised edges or sidewalls ( 1 ) with a greater thickness in the material formed around the top edges and corners ( 9 ) ( 3 ) for injury prevention measures. Those skilled in the art know that the radius could be greater or smaller. It may also be optionally helpful to equip the top edge FIG. 2 ( 5 ) with a rigid formed material that form-fits around the front of one or more raised edges that is a repair strip safety device that snaps FIG. 6 ( 5 ) or is added to the front of one or more said sidewalls or raised edges FIG. 6 ( 4 a ) ( 4 b ) to better assist service and repair of either appliances if they have to be pulled out and repaired FIG. 6 adding strength to the one or more of the raised edges or sidewalls.
FIGS. 7 and 8 show the invention adapted for use with a single appliance—this same adaptation would serve for a stackable pair of appliances—and are analogous to FIGS. 4 and 2 , respectively.
FIG. 5 ( 14 ) shows the Anti-Vibe Diffusion Bumps™ that prevent vibrations from being transmitted through the subfloors when the washer and dryer are operating. The Anti-Vibe Diffusion Bumps, small hollow or solid bumps of irregular sizes each connected to another by bridge-like ‘transferring strands’ spread over the entire bottom of the pan, are designed to disperse downward vibration from washers or dryers horizontally towards the outer edge of the pan so as to prevent or minimize vibration from going down through the floor. The Anti-Vibe Diffusion Bumps keep the vibrations from moving downward thus preventing noise projected downward through the floor.
FIG. 2 ( 13 ) shows The Anti-Vibe Damping Pads™ which also prevent vibrations from being transmitted through the subfloors and prevent the washer and dryer from shaking, moving and damaging one another. The Anti-Vibe Damping Pads, molded into the pan and positioned where the feet of the washer or dryer are located, are raised, hollow bumps with a flat surface top, that create a hollow air chamber between the feet of the appliance and the floor beneath. This hollow air chamber creates a barrier of air that minimizes or neutralizes the transmission of vibration from the appliance to the floor below. Reducing contact with the floor in this manner disperses the energy across a wide area, resulting in minimal noise and vibration transmission to the floor and through the floor.
To allow the increasingly popular pedestal drawers to clear the front wall of the pan when opening, while also maintaining a large capacity to contain leakage, the Anti-Vibe Damping Pads can be molded to a greater height; this can also be done with simple pads that do not incorporate the Anti-Vibe Damping Pad design.
FIG. 2 ( 15 ) shows the Easy-Slide Wedges™ that allow for easy transition and location of appliances during installation. The Easy-Slide Wedges are molded into the inside front edge of the pan design, providing both a strengthening buttress to the front wall aw well as a place for the appliance's feet to rest on once the machine is picked up and over the front lip of the pan. These wedges make it possible for the installer to set the rear feet of the appliance down on the top of the wedge and take a pause/rest from lifting the machine, and further to use the wedges as a guide as one slides the machine safely down the wedges to the bottom of the pan, preventing strain from lifting the machine while also preventing possible damage to the pan or machine if the machine were to be let down hard.
It can readily be seen that the wedges can be made in a variety of widths and lengths/angles—the latter two qualities clearly interdependent, as shortening the wedges used with a given front wall height will increase the angle, and diminishing the angle will accordingly lengthen the wedge. This interdependency illustrates a tension in design requirements, because it is helpful to have the angle of the wedge be as small as possible, while at the same time having the wedge be as short as possible. Because the feet of the appliance must all sit evenly on the floor of the pan (or the optional pads described above) to avoid having the appliance be tilted, and it is functionally and esthetically undesirable to have the pan extend forward beyond the front of the appliance(s), it is optimal to have the length of the wedges be equal to, or slightly smaller than, the distance from the front of the appliance to the front edge of the front feet. When used in conjunction with the optional pads described earlier, the wedges would angle down only to the level of the pads, rather than continuing all the way to the floor of the pan. With raised pads it would optionally be helpful to include additional wedges toward the rear of the pan that would angle up from the floor of the pan to the rear pads, to aid in sliding the rear feet of the appliance up onto the rear pads; these rear wedges could, it can readily be seen, be made considerably longer than the front wedges, if desired, so as to make to sliding easier.
As aforementioned and in addition to the service and repair strip safety device, it may also be optionally helpful to add a hole for water or liquid drainage if necessary ( 12 ) for the installer and/or service repair person to drain water or liquid if needed. Many laundry areas in homes are equipped with drains, but for a variety of reasons—such as the location of hookups, or the orientation of appliance doors—it may not be desirable to install the washing machine directly over such a drain. In the most common situation, there is space for two appliances, and if the washer is put in the “other” position, with the dryer positioned over the drain, any leakage from the washer would issue onto, and potentially damage, the floor before hopefully making its way to the drain.
Even when the washer is installed over the drain, leakage can issue from the dryer. Overloading and/or use with a clogged lint filter and/or exhaust duct can cause the dryer's evaporator and/or heating coil element to over work them selves and fail or perhaps break, and water or moisture from the wet/damp clothes can seep through the tumbler seal(s) and leak down through the inner tumbler panel wall of the dryer.
Furthermore, even when the leaking appliance is located over the drain, there is no guarantee that leakage from the appliance will drip directly into the drain, so damage to the surrounding floor is still a danger. Equipping the floor of the pan with a hole directly over the drain, by drilling or otherwise, makes sure that any leakage is conducted directly down the drain, with no danger of damage to the surrounding floor regardless of how the appliances are situated.
In one further variation, the basin can be equipped with a particularly tall wall—most handily as a separate piece fitting inside the basin, and on the back of the basin, so that this tall wall extends right up to the water supply pipes. This tall wall can thus protect the plaster or wallboard room wall behind it if the hose fitting at either the hose bib or the washing machine starts to leak and spray, and will guide that spray down to the basin. In a particularly useful variation on this idea, this tall wall could be equipped, at its upper end, with a series of horizontal score lines or other means to permit the easy removal of part of the height of this wall to allow it to fit the particular height of the water supply pipes. Should these water supply pipes not be on the same side of the washing machine as the machine's water intake fittings, the basin could obviously be equipped with more than one particularly tall wall. It can also be understood that it may not be advantageous for such particularly tall wall(s) to extend to the dryer, as well, both because the dryer is unlikely to develop any kind of liquid leak that would spray against a wall, and also because such a wall could interfere with dryer vent pipe, so such particularly tall wall is most likely narrower than the basin as a whole.
Those skilled in the art will understand that there are numerous materials that can be utilized to mold the dual automatic dryer and washing machine protective basin, (in its simplest form, “leak pan”) and the repair strip safety device. The materials and methods disclosed herein are the preferred materials and methods respectively. In addition, this invention can, of course, be practiced to fit stackable appliances or even a single appliance. | The Dual Automatic Dryer and Washing Machine Protective Basin is a drip pan sized to fit both a washer and dryer, and to contain leakage from both appliances. The position of the washer and dryer can safely be swapped, and the pan can optionally be provided with an opening directly over a floor drain, which now need not be located under the washing machine. The front wall of the basin can be sized to clear a door or pedestal drawer; alternatively, the basin can have raised spots supporting the feet of the appliance or pedestal, so as to lift doors or drawers above the front wall. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to possible vehicle running distance indication and more particularly to indication of a possible vehicle running distance available for the remnant fuel in continued running.
2. Description of the Prior Art
In driving a vehicle, the driver looks at a fuel meter and decides from his experience how far he will be able to drive the vehicle. However, driving on a special road such as a highway, a driver occasionally runs short of fuel due to lack of experience.
SUMMARY OF THE INVENTION
This invention is made in consideration of the above problem.
An object of this invention is to provide a method and an apparatus for indicating possible vehicle running distance with remnant fuel (residual running range), and for teaching the driver both how far he can go with the remnant fuel and how to drive economically.
Another object of this invention is to provide a method and an apparatus for indicating possible vehicle running distance by measurement of the remnant fuel and the running conditions at that time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an embodiment of the possible vehicle running distance meter according to this invention.
FIG. 2 is a circuit diagram of the fuel consumption measurement circuit in FIG. 1.
FIG. 3 is a circuit diagram of the remnant fuel measurement circuit in FIG. 1.
FIG. 4 is a circuit diagram of the running distance measurement circuit in FIG. 1.
FIG. 5 is a circuit diagram of the calculation circuit in FIG. 1.
FIG. 6 is a signal waveform chart of waves at the various portions of the calculation circuit of FIG. 5 for illustrating the operation of the circuit.
FIG. 7 is a circuit diagram of another embodiment of the calculation circuit in FIG. 1.
FIG. 8 is a circuit diagram of the indicator circuit in FIG. 1.
FIG. 9 is a circuit diagram of an indicator circuit in FIG. 1.
FIG. 10 is a circuit diagram of another embodiment of the remnant fuel measurement circuit in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A block diagram of the total structure of the possible vehicle running distance meter according to this invention is shown in FIG. 1, in which a fuel consumption measurement circuit 1 measures the fuel consumption of an internal combustion engine equipped in a vehicle and supplies a consumption signal to a remnant fuel measurement circuit 2 and to a calculation circuit 4. For measuring the fuel consumption, such methods can be adopted as the fuel flow amount measuring method, suction pressure and revolution measuring method, fuel injection pulse signal measuring method, etc. The remnant fuel measurement circuit 2 calculates the remnant fuel in a fuel tank on the basis of said fuel consumption signal and supplies a remnant fuel signal to the calculation circuit 4. A running distance measurement circuit 3 measures the running distance of the vehicle and supplies a distance signal to the calculation circuit 4. The calculation circuit 4 calculates the distance which can be covered using the remnant fuel in the fuel tank on the basis of said remnant fuel signal and said distance signal and supplies an output signal and an indicator circuit 5. The indicator circuit 5 is preferably installed in front of the driver's seat of the vehicle. The initiation time of the calculation circuit 4 is determined by a set circuit 6.
Next the respective components of the structure of FIG. 1 will be described in more detail referring to the respective figures.
FIG. 2 shows an electric circuit diagram of the fuel consumption measurement circuit 1. In the circuit 1, a fuel injection valve 10 is actuated by injection signals applied to a terminal 10a from an injection controlling circuit 100 with a time width τ adjusted in correspondence with a required fuel amount in the engine, controlling the fuel supply to the engine. The structure and operation of these parts are well known and the detailed description thereof is dispensed with here. The injection signal is also supplied through a buffer circuit comprising resistors 111, 112 and 113 and an input buffering transistor 114 and a delay circuit for canceling the response time lag of the fuel injection valve 10 with respect to the injection signal comprising NOR gates 121 and 126, an inverter 122, a resistor 124, a diode 123 and a capacitor 125 to a conversion circuit comprising a NAND gate 141 and a binary counter 142 (IC CD4020A manufactured by RCA). The NAND gate 141 also receives a clock signal of a fixed frequency supplied from an oscillation circuit comprising inverters 131 and 132, resistors 133 and 134 and a capacitor 135. The frequency of the oscillation circuit and a terminal Q of the binary counter 142 are so arranged that a "1" level pulse signal (consumption signal) is generated at a terminal la at every consumption of 1 cc. of fuel.
The consumption signal from the circuit of FIG. 2 is supplied to the remnant fuel measurement circuit 2 as shown in FIG. 3. In this figure, presettable reversible counters (CD 4029 manufactured by RCA, referred to simply as reversible counters hereinbelow) 201, 202, 203, 204 and 205 are connected in cascade. The count control terminals (UP/D) of the respective reversible counters 201, 202, 203, 204 and 205 are grounded to perform reverse counting (subtraction). In the present embodiment, the capacity of the fuel tank (not shown), i.e. a predetermined fuel amount, is assumed to be 60 liters (60,000 cc). Among the respective input terminals J 1 , J 2 , J 3 and J 4 of the reversible counters, only the input terminals J 2 and J 3 of the reversible counter 205 are applied with a voltage V ("1" level). The reversible counters 205, 204, 203, 202 and 201 are preset to the binary decimal code (reference signal) of (0110), (0000), (0000), (0000) and (0000) corresponding to 60,000 cc. Further, the CL terminals of the reversible counters 201, 202, 203, 204 and 205 are connected to the terminal la of the fuel consumption measurement circuit 1 for counting the consumption signal. The C o output of the final stage reversible counter 205 is connected to one input of an R-S flip-flop consisting of NAND gates 206 and 207. The output of the R-S flip-flop is connected to the input of the first stage reversible counter 201. The PE terminals of the reversible counters 201, 202, 203, 204 and 205 are connected to the other input terminal of the R-S flip-flop through an inverter 208. With these connections, at the time when a terminal 4a (to be described in more detail referring to FIG. 5) becomes "1" level, the reversible counters 201, 202, 203, 204 and 205 stores the capacity of the fuel tank, 60 liters. The "1" level at the terminal 4a is applied through the inverter 208 and the R-S flip-flop to the C 1 input of the reversible counter 201 as a "0" level. The C o output of the reversible counter 205 is at "1" level. Each time when a pulse arrives at the terminal 1a from the fuel consumption measurement circuit 1, the reversible counters 201, 202, 203, 204 and 205 perform reverse counting (subtraction) and generate a binary decimal code (remnant signal) at their outputs Q 1 , Q 2 , Q 3 , and Q 4 corresponding to the remnant fuel in the fuel tank. For example, when 5679 pulses have arrived at the terminal 1a, the remnant fuel in the fuel tank is 54,321 cc, and the reversible counters 205, 204, 203, 202 and 201 provide a binary decimal code of (1010), (0010), (1100), (0100) and (1000) at the respective (Q 1 Q 2 Q 3 Q 4 ) outputs. When the remnant fuel is null or O cc, the reversible counters 201, 202, 203, 204 and 205 all provide (0000), (0000), (0000), (0000) and (0000) at the (Q 1 Q 2 Q 3 Q 4 ) outputs. At this moment, the C o output of the reversible counter 205 also becomes "0" level. This "0." level is inverted in the R-S flip-flop and appears at the terminal 2a as "1" level.
The running distance (distance covered) of the vehicle is measured in the running distance measurement circuit 3 shown in FIG. 4. A magnet 31 is rotated by the speed meter cable of the vehicle and a reed switch 32 is disposed in the vicinity thereof. The on-off operation of the reed switch 32 is done by the rotation of the magnet 31. Thus, a number of pulses proportional to the wheel revolutions, i.e. the running distance, of the vehicle are generated. The circuit following the reed switch 32 and consisting of a transistor 33, resistors 34, 35, 36 and 37, a capacitor 38, an inverter 39 and an R-S flip-flop 30 is provided for shaping the pulses. In this embodiment, 2548 pulses (distance signal) are supplied to a terminal 3a in a run of 1 kilometer.
FIG. 5 shows a detailed structure of the calculaton circuit 4 and the set circuit 6, and the signal waveforms (A) to (N) in FIG. 6 are those at points A to N in FIG. 5. The set circuit 6 comprises a resistor 61 and a set switch 62. When the set switch 62 is closed automatically or manually upon the filling of the fuel tank, a set signal of "0" level is generated at the point A as shown by the waveform (A) in FIG. 6. The calculation circuit 4 comprises presettable reversible counters 401 and 404 (each of which is formed similar to the reversible counters 201, 202, 203, 204 and 205 of FIG. 3 but is represented by a single reversible counter), binary counters 402, 405 and 406, a memory 403, decade counter/divider (RCA CD4017) 407 and 409, an oscillator 408, and R-S flip-flop 410 consisting of two NAND gates, an R-S flip-flop 411 consisting of two NOR gates, inverters 412, 413, 414, 415, 416 and 417, NAND gates 418, 419 and 420 and NOR gates 421 and 422, and calculates a possible running distance with the remnant fuel upon each consumption of a predetermined amount of fuel. Next, the operation of the calculation circuit 4 will be described.
When the set circuit 6 generates a set signal of "0" level as shown by the waveform (A) in FIG. 6, the NAND gate 420 generates a pulse of "1" level to reset the binary counter 402. At the same time, the NAND gate 418 generates a pulse of "1" level at the terminal 4a of the circuit 4 or the point B as shown by the waveform (B) in FIG. 6 to reset the binary counter 405. The pulses arriving at the terminal 1a from the fuel consumption measurement circuit 1 are frequency-divided by the binary counter 405, for example into 1/1000, to generate a "1" level pulse at the point C at energy fuel consumption of 1000 cc (1 liter) as shown by the waveform (C) in FIG. 6 to reset the counter 407 provided with a decimal divider. Then, when the point C becomes again "0" level, the counter 407 begins counting of the clock pulses of a constant frequency supplied from an oscillator 408, and generates, in sequence, a pulse of "1" level at Q 1 , Q 3 and Q 5 outputs, i.e. at points D, E and F, as shown by the waveforms (D), (E) and (F) in FIG. 6. When Q 7 output i.e. point G, becomes "1" level as shown by the waveform (G) in FIG. 6, this pulse enters terminal E and stops counting of the clock pulses. The Q 7 output is held at "1" level until the point C becomes "1" level again. Thus, when a "1" level signal is generated at the Q 1 output of the counter 407, PE terminal of the reversible counter 401 becomes "1" level. Since the output terminal 2b of the remnant fuel measurement circuit 2 (twenty terminals as shown in FIG. 3 but shown as one terminal for simplification) is connected with J terminal (preset input terminal) of the reversible counter 401, the reversible counter 401 reads in a binary decimal code corresponding to the remnant fuel L as the preset value, and gives a "1" level signal at the C o output as shown in waveform (H) in FIG. 6. The binary counter 402 which is reset by the closure of the set switch 62 of the set circuit 6 or by the generation of a "1" level signal at the Q 3 output of the counter 407 begins counting pulses generated at terminal 3a of the running distance measurement circuit 3, and generates the count value at Q output. When the counter 407 generates a "1" level signal at the Q 1 output, the count is stored by the memory 403. Thus, the stored content in the memory 403 is the distance N covered by the vehicle with the consumption of a unit fuel of 1 liter. The binary code generated by the memory 403 is proportion to the distance N can be read in by the reversible counter 404 as the preset value when the counter 407 generates a "1" level signal at the Q 3 output.
Next, when the counter 407 generates a "1" level signal at the Q 5 output, the C o output of the reversible counter 401, i.e. point H, is at "1" level as described before and the counter 409 provided with a decimal divider have the R terminal (reset terminal) at "0" level and counts the clock pulses from the oscillator 408 to generate "0" level at the Q 1 output. Thus, the output of the R-S flip-flop 411, i.e. point J, inverts to "0" level as shown by waveform (J) in FIG. 6 and the clock pulses from the oscillator 408 appear at the output of the NOR gate 422, i.e. point K, as shown by the waveform (K) of FIG. 6 and are applied to the C p input of the reversible counter 404. The reversible counter 404 performs reverse counting (subtraction) by these clock pulses. When the subtraction result becomes zero, a "0" level is generated at the C o output, i.e. the point L, as shown by the waveform (L) in FIG. 6, and the point M becomes " 1" level for inverting the R-S flip-flop 410. This 3∂1" level is applied through the NOR gate 421 and the inverter 412 to the PE terminal of the reversible counter 404, the reversible counter 404 reads in again the content of the running distance N stored in the memory 403 and supplies a "1" level at the C o output again. Then, the output of the R-S flip-flop 410, i.e. the point H, becomes "0" level again. In this way, the reversible counter 404 repeats the above procedure during the application of the clock pulses at the C p input. Thus, there appear a plurality of "1" level pulses at the point M as shown by the waveform (M) of FIG. 6. Here, the period T 1 of this pulse is proportional to the memory content (running distance N) of the memory 403 and an equation T 1 = K 1 .N (K 1 being a constant) can be held. Here, this pulse signal is a first conversion signal representing the running distance per unit fuel (1 liter). The point H becomes "0" level as shown by the waveform (H) of FIG. 6 when the pulse generated at the point M is applied to the C p input of the reversible counter 401, the reversible counter 401 performs reverse counting, and the memory content of the counter becomes zero. This "0" level signal is inverted through the NAND gate 419 and the inverter 416 to become a "1" signal. After resetting, the counter 409 counts the clock pulses from the oscillator 408 and renders the Q 1 , Q 3 outputs to "1" level successively. Thus, the R-S flip-flop 411 is inverted and the output, the point J, becomes "1" level again as shown by the waveform (J) of FIG. 6. Then, since the clock pulse from the oscillator 408 is cut off by the NOR gate 422, the reversible counter 404 stops the above operation. In short, since a plurality of pulses are generated at the point M and applied to the reversible counter 401 during the time period T when the C o output of the reversible counter 401, i.e. the point H is at "1" level and the period T is proportional to the preset value of the reversible counter 401 (remnant fuel L) and to the period T 1 of the pulse generated at the point M, an equation T = K 2 .L.T 1 = K 1 .K 2 .L.N = L.N (setting K 1 .K 2 = 1) can be derived. In this time interval T 1 the clock pulses of the oscillator 408 are counted by the binary counter 406 and pulses divided at a predetermined ratio are generated at the Q output, the point N, as shown by the waveform (N) of FIG. 6. Since the number of these pulses is proportional to the time interval T 1 , the number of pulses appearing at the terminal 4b for the time interval T represents the possible running distance I to be covered by the vehicle with the remnant fuel L by selecting the frequency dividing ratio, for example K = 1/2548 × 1000. Thus, the calculation circuit 4 having a structure as shown in FIG. 5 estimates the remaining possible running distance I by the multiplication of the remnant fuel L and the running distance per unit fuel consumption (1 liter) N.
Alternatively, the calculation circuit 4 may perform the division I = L/L' at each predetermined running distance (e.g. 1 Km) to provide the possible running distance I by dividing the remnant fuel L by the fuel L' consumed by the running of the unit distance, and the embodiment thereof is shown in FIG. 7. In FIG. 7, when the distance signal arrives at a terminal 3a from the running distance measurement circuit 3, it is frequency-divided to 1/2548 in a binary counter 45, which generates one "1" level pulse at the Q output for each kilometer. A counter 47 provided with a decimal divider is reset by a momentary application of a "1" level pulse and Q 1 Q 3 and Q 5 outputs thereof becomes "1" level successively. When the Q 1 output becomes "1" level, the reversible counter 41 stores the remnant fuel signal generated at a terminal 2b by the remnant fuel measurement circuit 2, and a memory 43 stores the number of fuel signal pulses generated in the running of 1 Km proportional to the fuel consumption arriving at a terminal 1a which are counted by a binary counter 42. Thus, the output signal of the memory 43 is a second conversion signal expressing the fuel consumption per 1 kilometer running. At the same time, a proportionality factor multiplier 44 (MC 14527 made by MOTOROLA), is set also. Then, when the Q 3 output of the binary counter 47 is driven to "1" level, the output of the R-S flip-flop 49 consisting of NOR gates becomes "0" level and the clock pulse from an oscillator 46 arrives at the C p input of the proportionality factor multiplier 44. Since the Q output of the memory 43 is connected with the data inputs A, B and C of the proportionality factor multiplier 44, for example if the memory content of the memory 43 is (3), the E o terminal of the proportionality factor multiplier 44 becomes "1" level each time when the C p input receives 10 pulses and the O terminal thereof generates three pulses of "1" level. Therefore, the reversible counter 41 becomes less by three from the preset value. In this way, the subtraction continues until the content of the reversible counter 41 becomes zero. When the memory content of the reversible counter 41 becomes zero, the C o output thereof become "0" level momentarily and the counter 48 provided with a decimal divider begins counting of the clock pulses after resetting to generate "1" level at the Q 1 , Q 3 and Q 5 outputs successively. Thus, when the Q 1 output of the counter 48 becomes "1" level, the R-S flip-flop 49 is inverted to prevent the arrival of the clock pulses at the C p input of the proportionality factor multiplier 44 and at the same time the generation of the pulse at the terminal 4b. Next, when the Q 3 output becomes "1" level, a memory signal of "1" level is generated at the terminal 4c. This operation is repeated each time when the binary counter 45 generates "1" level at the Q output, i.e. at each run of 1 kilometer. The number of pulses generated at the terminal 4b by this one operation is proportional to the preset value of the reversible counter 41 (remnant fuel amount L), and inversely proportional to the memory content of the memory 43 (fuel consumption per 1 kilometer run L'). Thus, the calculation circuit 4 provides the possible running distance I = L/L'.
The indicator circuit 5 for displaying or indicating the calculated possible running distance I is shown in FIG. 8, in which a 4-digit decimal counter 50 (TC 50010 made by Tokyo Shibaura Electric Co., Ltd.) is connected through buffering non-inverters 501, 502, 503 and 504 and inverters 505, 506 and 507 to electroluminescence (light emitting) diode numerical indicators 51, 52 and 53 (5082-7300 made by Yokogawa Hewlett Packard Co., Ltd.). A resistor 50R, a diode 50D and a capacitor 50C are also connected to the counter 50 for controlling the oscillation frequency.
When a reset signal of "1" level arrives at the terminal 4a from the calculation circuit 4, the counter 50 is reset and then counts the signal arriving at the terminal 4b corresponding to the possible running distance I. When the terminal 4c becomes "1" level, the counter 50 stores the count and generates a binary code at output terminals A, B, C and D corresponding to the count. At the same time, the counter 50 generates signals at digit selection outputs T 1 , T 2 and T 3 in synchronism with the respective digits. Thus, if the count of the counter 50 is 135, the numerical display elements 51, 52 and 53 display (5), (3) and (1) respectively and the driver can know that the possible running distance with remnant fuel is 135 kilometers.
In the above embodiment, the initiation time of calculation is set by the set circuit 6 and hence the driver may misunderstand that display until the first run of the predetermined distance (for example, 1 kilometer) or the predetermined fuel consumption (for example, 1 liter) is achieved. This misunderstanding can be prevented by the employment of an indicator circuit having a structure as shown in FIG. 9. Namely, when the initiation time of calculation is set by the set circuit 6, a pulse of "1" level is generated at a terminal 4a. And when one operation of the calculation circuit 4 is ended and the display circuit 5 begins display operation, a pulse of "1" level is generated at a terminal 4c. Between these moments, the output of the R-S flip-flop consisting of NOR gates 71 and 72 is held at "0" level and an inverter 73 produces "1" level. Thus, a transistor 74 becomes conductive and an electroluminescent diode (light emitting diode) 75 luminesces. By connecting the output of the inverter 73 with the BL (blanking) terminal of the counter 50 shown in FIG. 8, the electroluminescence diode 75 luminesces only during the time from the setting of the initiation time of calculation to the end of one calculation and the display of the display circuit 5 begins at the turn-off of the electroluminescent diode 75 to prevent the misunderstanding of the driver.
Further, although in the above embodiment, the present value of the reversible counters 201, 202, 203, 204 and 205 in the remnant fuel measurement circuit 2 is assumed to be always constant (60,000 cc), the preset value may be arranged to be arbitrarily settable according to necessity. FIG. 10 shows an embodiment in which similar parts to those of FIG. 3, are denoted by similar numerals and 10-position switches 21 and 22 (rotary switch 435005-1 made by AMP Inc.) are connected with J 1 J 2 , J 3 and J 4 terminals of the reversible counters 204 and 205. Further, the remnant fuel may be measured directly from the liquid surface in the fuel tank. Further, the methods of remnant fuel measurement, running distance measurement and calculation are not restricted to those of the above embodiment, and other embodiments of the invention, modifications thereof, and alternative thereto will be obvious to those skilled in the art may be made without departing from the present invention. | Indication of possible vehicle running distance with remnant fuel is accomplished by measuring the fuel amount, the fuel consumption and the running distance and calculating the possible remaining running distance with remnant fuel. The indication is directly based on the current driving condition so that the driver can know the possible running distance with remnant fuel in continued driving under similar conditions. The indication can prevent fuel shortage and also teach a driver economic driving. | 6 |
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 13/802,412, filed Mar. 13, 2013, which claims priority to co-pending U.S. Provisional Patent Application No. 61/719,287, filed Oct. 26, 2012, the entire contents of which are hereby incorporated by reference.
FIELD
[0002] The present invention relates to a dispensing device and a battery for powering the dispensing device.
SUMMARY
[0003] A typical automatic dispensing device includes a sensor, such as a motion sensor, and a solenoid controlled based on a signal from the sensor to dispense a substance, such as a fluid.
[0004] In one independent embodiment, the invention provides a fluid dispensing device. The fluid dispensing device may generally include a housing defining a passage having an outlet, a sensor operable to sense a condition and to send a signal based on the sensed condition, a dispensing mechanism operable to dispense fluid through the passage and out of the outlet, a solenoid controlled, based on the signal from the sensor, to cause the dispensing mechanism to dispense fluid, and a hybrid battery disposed in the housing and operable to power the solenoid.
[0005] In another independent embodiment, the invention provides a battery package for a fluid dispensing device. The dispensing device includes a housing defining a passage having an outlet, fluid being dispensed through the passage and out of the outlet, and a powered component. The battery package may generally include a battery cell and a capacitor operable to power the powered component. The battery cell and the capacitor may be encapsulated as a unitary battery package, and the unitary battery package may be supportable in the housing.
[0006] In yet another independent embodiment, the invention provides a method of manufacturing a fluid dispensing device. The method may generally include providing a housing for the fluid dispensing device, the housing defining a passage having an outlet, fluid being dispensed through the passage and out of the outlet, encapsulating a battery cell and a capacitor as a unitary battery package, and supporting the unitary battery package in the housing.
[0007] In a further independent embodiment, the invention provides a fluid dispensing device. The fluid dispensing device may include a housing defining a passage having an inlet, an inlet chamber communicating with the inlet, an outlet, an outlet chamber communicating with the outlet, a pressure chamber in communication with the inlet chamber, a vent passage in selective communication between the pressure chamber and atmosphere, and an opening between the pressure chamber and the vent passage. The fluid dispensing device may also include a sensor operable to sense a condition and to send a signal based on the sensed condition, and a dispensing mechanism operable to dispense fluid through the passage and out of the outlet, the dispensing mechanism including a piston movably supported in the passage between the inlet chamber and the outlet chamber.
[0008] The fluid dispensing device may also include a solenoid controlled, based on the signal from the sensor, to cause the dispensing mechanism to dispense fluid, the solenoid being operable to selectively place the pressure chamber in communication with the vent passage to thereby cause the dispensing mechanism to dispense fluid. The solenoid may include an armature movable between a first position, in which communication between the pressure chamber and the vent passage is inhibited, and a second position, in which communication between the pressure chamber and the vent passage is allowed, the armature being movable between the first position and the second position. In the first position, a portion of the armature may close the opening. The fluid dispensing device may also include a power source operable to power the solenoid.
[0009] In still another independent embodiment, the invention provides a method of manufacturing a hybrid battery for a fluid dispensing device, the hybrid battery having a battery cell and a capacitor. The method may generally include encapsulating the battery cell and the capacitor as a unitary battery package.
[0010] Other independent aspects of the invention will become apparent by consideration of the detailed description, claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a side view of a battery package.
[0012] FIG. 2 is a perspective exploded view of the battery package shown in FIG. 1 .
[0013] FIG. 3 is a perspective view of the battery package shown in FIG. 1 with the top removed.
[0014] FIG. 4 is a perspective cutout view of a dispensing device, such as a flushometer, including the battery package shown in FIG. 1 .
[0015] FIG. 5 is a side view of the flushometer shown in FIG. 4 .
[0016] FIG. 6 is a front view of the flushometer shown in FIG. 4 .
[0017] FIG. 7 is a top view of the flushometer shown in FIG. 4 .
[0018] FIGS. 8A-8I are cross sectional views of a portion of the flushometer shown in FIG. 4 .
[0019] FIG. 9 is a cutout view of another dispensing device, such as a faucet, including the battery package shown in FIG. 1 .
[0020] FIG. 10 is a perspective view of a faucet.
[0021] FIGS. 11-15 are perspective views of other dispensing devices, such as, for example, a soap or lotion dispenser, a commercial metered shower system, an in-wall flushometer, an in-fixture urinal flushing system, and an in-tank touchless toilet flushing system, respectively, including the battery package shown in FIG. 1 .
DETAILED DESCRIPTION
[0022] Before any independent embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other independent embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Use of “including” and “comprising” and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of “consisting of” and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof. Further, it is to be understood that such terms as “forward”, “rearward”, “left”, “right”, “upward” and “downward”, etc., are words of convenience and are not to be construed as limiting terms.
[0023] FIGS. 1-3 illustrate a battery package 10 including a hybrid battery having a battery cell 12 and a capacitor 14 . The battery cell 12 may include an alkaline battery, a lithium-based battery (e.g., a lithium-ion battery), etc. The capacitor 14 may include a lithium-ion capacitor, or other suitable types of capacitor. For example, the hybrid battery may include a 9 volt high purity lithium battery cell packaged with a lithium-ion capacitor.
[0024] In the illustrated construction, the battery package 10 also includes a cup 16 and resin 18 . The hybrid battery (e.g., the battery cell 12 and the capacitor 14 ) is encapsulated, for example, within the cup 16 which is filled with the resin 18 . The cup 16 may be formed of a polymer in a vacuum forming process, a thermoforming process, thin wall injection molding, etc. The resin 18 may include polyurethane, epoxy, acrylic, silicone, UV curable materials, etc., which either completely harden or form a rubber-like consistency.
[0025] In the illustrated embodiment, the cup 16 is a thin-walled molded cup and the resin 18 includes epoxy. The resin 18 fills the cup 16 and includes a top layer sealing off the top of the cup 16 that is thick enough to cover terminals 15 , 17 and exposed wires or connections 19 between the battery cell 12 and the capacitor 14 . As illustrated in FIG. 3 , the wires 19 include a first portion encapsulated within the resin 18 and a second portion (e.g., insulated wires) passing out of the resin 18 for connection to powered components. In some embodiments, the battery package 10 also includes a cap (not shown) coupled to and sealed with the top of the cup 16 (e.g., by the resin 18 ) for assisting in the mounting or holding of the battery package 10 in the dispensing device 20 , which will be described in greater detail below.
[0026] The cup 16 and resin 18 encapsulate the battery cell 12 and the capacitor 14 to, for example, protect the battery cell 12 and the capacitor 14 from contamination (e.g., by fluid, water, other contaminants, etc.). Encapsulating the battery cell 12 and the capacitor 14 in the cup 16 and resin 18 may also minimize the overall package size, minimize the expense of potting material (e.g., the resin 18 ), and/or allow for full encapsulation of the battery cell 12 . Depending on the material used, for installation, the cup 16 may be retained or peeled away from the resin 18 .
[0027] FIGS. 4-8I illustrate a dispensing device 20 including the battery package 10 . The illustrated dispensing device 20 is a flushometer. In other constructions, the dispensing device 20 may include another type of dispensing device, such as, for example, a faucet (see FIG. 9 and FIG. 10 ), a soap, lotion or other fluid dispenser (see FIG. 11 ), a commercial metered shower system (see FIG. 12 ), an in-wall flushometer (see FIG. 13 ), an in-fixture urinal flushing system (see FIG. 14 ), an in-tank touchless toilet flushing system (see FIG. 15 ), a paper towel (or other item/article) dispenser (not shown), etc.
[0028] The dispensing device 20 includes a housing 22 , a sensor 24 , a solenoid 26 and a dispensing mechanism 28 (e.g., a flushing mechanism, a valve or other dispensing device) for dispensing a substance, material, item, article, etc. As illustrated in FIGS. 4-8I , the battery package 10 , the sensor 24 , the solenoid 26 and the dispensing mechanism 28 are all disposed within the housing 22 of the dispensing device 20 . The sensor 24 may be a touchless sensor such that the illustrated dispensing device 20 is a touchless flushometer. The housing 22 may include a window 42 for a portion of the sensor 24 that senses a condition external to the housing 22 , such as the presence of a user.
[0029] The battery package 10 powers the solenoid 26 . Specifically, the battery cell 12 charges the capacitor 14 , and the capacitor 14 powers the solenoid 26 when activated by the sensor 24 . The solenoid 26 is activated in response to a signal from the sensor 24 . For example, the sensor 24 may be a motion or light sensor, and the solenoid 26 is activated when the sensor 24 signals a flushing condition, such as the presence of a user followed by the non-presence of the user.
[0030] The battery package 10 may also power the sensor 24 . For example, the battery cell 12 may power the sensor 24 . In other constructions (not shown), the sensor 24 may include its own separate power source.
[0031] The dispensing mechanism 28 , e.g., a water flushing mechanism of the illustrated flushometer, is illustrated in FIGS. 8A-8I . The dispensing mechanism 28 may include a piston 30 , a valve seat 48 , a piston bleed hole 50 and, defined by the housing 22 , an inlet chamber 32 , a pressure chamber or pressure envelope 34 , an atmospheric vent 36 , and an outlet chamber 38 . In other embodiments, other dispensing mechanisms 28 may be employed (e.g., a dispensing mechanism including a diaphragm and a diaphragm vent, etc.).
[0032] Arrows in FIGS. 8A-8I illustrate water flow in the dispensing mechanism 20 . With reference to FIGS. 8A-8B , the inlet chamber 32 is fluidly connected to a source of pressurized water (not shown; e.g., utility water), receiving the pressurized water through an inlet 46 ( FIG. 8B ). The piston 30 includes at least one bleed hole 50 ( FIG. 8B ) fluidly connecting the inlet chamber 32 to the pressure envelope 34 , and pressurized water flows from the inlet chamber 32 to the pressure envelope 34 through the bleed hole 50 in the piston 30 . The pressure envelope 34 is connected to an atmospheric vent 36 , which vents to the outlet chamber 38 and, thus, to atmosphere. The outlet chamber 38 feeds water into the flush (e.g., into a urinal) to flush the urinal (or other fixture).
[0033] The solenoid 26 includes an armature 40 movable axially between a first position (e.g., a non-dispensing or non-flush position (see FIGS. 8A-8C )), in which the solenoid 26 inhibits the dispensing device 20 from dispensing, and a second position (e.g., a dispensing or flush position (see FIGS. 8D-8E )). The solenoid 26 is energized by the capacitor 14 , at least momentarily causing the armature 40 to move from the first position to the second position or from the second position to the first position. In the illustrated construction, the armature 40 latches in each of the first and second positions after the charge from the capacitor 14 ceases. Each time the solenoid 26 is energized, the armature 40 moves from one position to the other (from the first position to the second position, and vice versa).
[0034] As illustrated in FIGS. 8A-8B , in the first position, the armature 40 is extended away from the body of the solenoid 26 and fluidly separates the pressure envelope 34 from the atmospheric vent 36 such that the pressure envelope 34 cannot fluidly communicate with the atmospheric vent 36 . The armature 40 includes an armature seal 52 for sealing off a vent opening or vent hole 54 ( FIG. 8I ) to the atmospheric vent 36 .
[0035] FIG. 8C illustrates the dispensing device 20 in the non-dispensing position. With the solenoid 26 de-energized and the armature 40 latched in the first position, the armature seal 52 closes off the atmospheric vent 36 , allowing the water pressure above the piston 30 in the pressure envelope 34 to balance the inlet water pressure in the inlet chamber 32 , which forces the piston 30 against the valve seat 48 shutting off the dispensing mechanism 28 .
[0036] In the second position (see FIGS. 8D-8E ), the solenoid 26 , activated in response to a “flush” signal from the sensor 24 , allows the dispensing device 20 to dispense. In the illustrated construction, the armature 40 retracts toward the body of the solenoid 26 and opens the passage between the pressure envelope 34 and the atmospheric vent 36 , fluidly connecting the pressure envelope 34 to the atmospheric vent 36 . The pressurized water vents from the pressure envelope 34 through the atmospheric vent 36 to the outlet chamber 38 and is dispensed or flushed. With the pressure envelope 34 depressurized (when the solenoid 26 is in the second position), the piston 30 , which is pressurized from below by water pressure in the inlet chamber 32 , displaces axially upwardly (e.g., towards the solenoid 26 in the illustrated construction), initiating the flush to the urinal or other fixture.
[0037] As shown in FIG. 8D , when the solenoid 26 is momentarily energized from the first position, the armature 40 retracts, allowing water above the piston 30 in the pressure envelope 34 to vent out, thereby reducing the water pressure above the piston 30 in the pressure envelope 34 . A magnet or other mechanism (not shown) holds the armature 30 in place (e.g., in the latched position), eliminating the need to continuously power the solenoid 26 .
[0038] As shown in FIG. 8E , the pressure differential between the sides and top of the piston 30 forces the piston 30 up, allowing a primary flow of water to flow through the dispensing mechanism 28 between the piston 30 and valve seat 48 . In addition to the primary flow through the dispensing mechanism 28 , a small trickle flow continues through the piston bleed hole 50 , to the pressure envelope 34 and out the atmospheric vent 36 and joins with the primary flow.
[0039] As shown in FIG. 8F , after a predetermined time period (or after a “stop flush” condition is sensed by the sensor 24 ), the solenoid 26 is momentarily powered in a reverse polarity, freeing the armature 40 from the “latch” (e.g., the magnetic hold) and allowing it to return to the first position (see FIGS. 8A-8C ) thereby resealing the atmospheric vent 36 . Even though the vent 36 is closed, water continues to trickle through the piston bleed hole 50 , allowing the pressure envelope 34 to re-pressurize.
[0040] As shown in FIG. 8G , as the pressure in the pressure envelope 34 builds, the piston 30 moves back down, sealing against the valve seat 48 to terminate the flush. Movement of the piston 30 can be controlled by sizing the bleed hole 50 and determining the mass of the piston 30 . As shown in FIG. 8H , when the piston 30 reseats, the pressure in the pressure envelope 34 equalizes with the inlet pressure in the inlet chamber 32 .
[0041] As shown in FIG. 8I , the speed at which the piston 30 jumps up at the start of the flush determines power at which the flush initiates. The size of the vent hole 54 drives piston speed by controlling the rate at which the pressure envelope 34 above the piston 30 evacuates. A larger vent hole 54 equates to a faster piston 30 . However, a larger vent hole 54 may require a stronger solenoid 26 to overcome internal pressure (pressure =force/area). The force a solenoid can produce is a function of the start position of the armature 40 relative to the overall stroke. By balancing the diameter of the vent hole 54 and the retraction distance (stroke) of the armature 40 against the solenoid power, a diaphragm having a diaphragm vent can be eliminated, which may simplify the assembly, reduce material failures, etc. The illustrated dispensing mechanism 28 may also quickly purge entrapped air for consistent flush volume.
[0042] In an alternative embodiment (not shown), the solenoid uses a diaphragm to amplify the speed of the system. In such an embodiment, the armature retracts from a diaphragm vent, or diaphragm bleed hole. The smaller volume of water above the diaphragm is quickly vented, allowing the diaphragm to retract, exposing a larger portion (e.g., a larger diameter portion) of the diaphragm vent such that the larger volume of water above the piston can evacuate quickly.
[0043] In another alternative embodiment (not shown), a larger diaphragm may be used in place of the piston with a bleed hole to communicate between the inlet chamber 32 and the pressure envelope 34 . The pressure envelope 34 could communicate with a diaphragm vent either by direct solenoid control or by way of a smaller diaphragm/solenoid combination.
[0044] FIG. 9 illustrates another dispensing device 20 ′, such as a faucet, including the battery package 10 . The dispensing device 20 ′ is similar to the dispensing device 20 , described above and illustrated in FIGS. 4-8 , and common elements are identified by the same reference number
[0045] The dispensing device 20 ′ includes a housing 22 ′, a sensor 24 ′, a solenoid 26 ′ and a dispensing mechanism 28 ′ for dispensing water. As illustrated in FIG. 9 , the battery package 10 , the sensor 24 ′, the solenoid 26 ′ and the dispensing mechanism 28 ′ are all disposed within the housing 22 ′ of the dispensing device 20 ′. The sensor 24 ′ may be a touchless sensor such that the illustrated dispensing device 20 ′ is a touchless faucet. The housing 22 ′ may include a window 42 ′ for a portion of the sensor 24 ′ that senses a condition external to the housing 22 ′, such as the presence of a user.
[0046] The battery package 10 powers the solenoid 26 ′, as described above with respect to FIGS. 8A-8I . In the construction illustrated in FIG. 9 , the dispensing mechanism 28 ′ is a water dispensing mechanism for a faucet.
[0047] As illustrated in FIGS. 1-15 , the invention may generally provide, among other things, a dispensing device having a compact and contaminant resistant battery package disposed within the housing of the dispensing device to power the dispensing mechanism. Thus, the need for a separate and remote battery, external from the housing of the dispensing device, may be eliminated. | A fluid dispensing device, a battery package for a fluid dispensing device, and a method of assembling a fluid dispensing device. The dispensing device has a housing defining a passage having an outlet, and fluid being dispensed through the passage and out of the outlet. The dispensing device also has a powered component. The battery package has a battery cell and a capacitor operable to power the powered component. The battery cell and the capacitor are encapsulated as a unitary battery package. The unitary battery package is supportable in the housing. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/709,325, filed Feb. 19, 2013 which claims the benefit of U.S. Provisional Application No. 61/154,711, filed Feb. 23, 2009, the contents of which are hereby expressly incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention resides in the field of electrophoretic transfer of macromolecules, such as proteins and nucleic acids, and relates in particular to the transfer of polypeptide species from a matrix following electrophoresis, during which the polypeptide species were separated, to a second substrate for further detection and characterization.
[0004] 2. Description of Prior Art
[0005] Electrophoresis is a fundamental tool in the modern laboratories of biological research. Typically, macromolecules such as proteins and nucleic acids become separated during electrophoresis as they migrate through a solid matrix in an electrical field. At the conclusion of an electrophoresis procedure, the macromolecules are found in distinct locations of the matrix depending on characteristics of the molecules such as molecular weight and electrical charge. Further studies of such macromolecules often require that the molecules be relocated to a second substrate where better reaction conditions are permitted. Electroblotting is one example of the post-electrophoresis transfer.
[0006] Numerous methods of electroblotting are well known and frequently practiced in the art. The transfer process is usually carried out in a liquid or semi-liquid environment where the macromolecules within an electrophoresis matrix, such as a polyacrylamide gel, is transferred to a second matrix suitable for further analysis, such as a membrane of nitrocellurose, nylon, etc. The movement of the macromolecules from the electrophoretic matrix to the analytical matrix is facilitated by an aqueous transfer buffer, which plays an important role in the efficiency of the transfer.
[0007] Various publications describe transfer buffers useful for the purpose of electroblotting, see, e.g., Towbin et al. (1979) Proc. Natl. Acad. Sci. USA 76:4350-4354; Timmons and Dunbar (1990) Methods in Enzymology 182:679-688. The present inventors provide a new aqueous transfer buffer that offers improved transfer efficiency, especially for polypeptides of relatively low molecular weight range.
BRIEF SUMMARY OF THE INVENTION
[0008] In one aspect, this invention relates to an aqueous buffer that is useful for eletrophoretic transfer of biomolecules, such as proteins and nucleic acids, from a matrix used in eletrophoresis to a second substrate appropriate for additional analysis. In general, the aqueous buffer of this invention contains Tris at a concentration of at least 300 mM and glycine at a concentration of at least 300 mM. In some embodiments, the buffer may further include ethanol or methanol at a concentration of no greater than 20% by weight. Or the buffer may further include a detergent, such as SDS, at a concentration of no greater than 0.1% by weight.
[0009] In some embodiments, the buffer contains Tris at a concentration of about 300 mM; or it may contain glycine at a concentration of about 300 mM. In some cases, the pH of the buffer is about 9.0. In particular example, the buffer has about 300 mM of Tris, about 300 mM of glycine, and a pH of about 9.0. In anther case, the concentration of Tris is about 400 mM, the concentration of glycine is about 400 mM, and the solution has a pH of about 9.0. One further example is a buffer having about 500 mM of Tris, about 500 mM of glycine, and a pH of about 9.0.
[0010] In other embodiments, the buffer of this invention contains at least one of Tris or glycine at a concentration of about 1 M or higher. For example, the buffer may contain Tris at about 1 M, glycine at about 1 M, and its pH is at about 9.0. As another example, the buffer contains about 250 mM of Tris, about 1.92 M of glycine, and has a pH of about 8.3.
[0011] In another aspect, this invention also relates to an electrophoretic transfer device containing the aqueous transfer buffer as described herein. In a further aspect, this invention relates to a method of electrophoretic transfer, which utilizes the aqueous transfer buffer described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A compares the transfer efficiency of nine proteins using six different transfer buffers as measured by SYPRO Ruby intensity. Molecular weights of the proteins are as follows: Myosin—200 kDa; β-galactosidase—116 kDa; Phosphorylase B—97 kDa; Bovine Serum Albumin—66 kDa; Ovalbumin—45 kDa; Carbonic Anhydrase—31 kDa; Trypsin Inhibitor—21.5 kDa; Lysozyme—14.4 kDa; Aprotinin—6.5 kDa. The following buffers were used:
Towbin—25mM Tris, 192 mM Glycine, pH 8.3
Timmons—250 mM Tris, 192 mM Glycine, pH 8.9
300 mM Tris/Gly+M+S—300 mM Tris, 300 mM Glycine, 20% MeOH, 0.05% SDS pH 9.0
300 mM Tris/Gly—300mM Tris, 300 mM Glycine pH 9.0
Tim+SDS+MeOH—250 mM Tris, 192 mM Glycine, 20% MeOH, 0.05% SDS pH 8.9
Towbin+SDS+MeOH—25mM Tris, 192 mM Glycine, 20% MeOH, 0.05% SDS pH 8.3
[0013] FIG. 1B compares the transfer efficiency of nine proteins using three different transfer buffers (containing Tris and glycine) as measured by SYPRO Ruby intensity.
[0014] FIG. 1C compares the transfer efficiency of nine proteins using three different transfer buffers (further containing 20% methanol and 0.05% SDS) as measured by SYPRO Ruby intensity.
[0015] FIG. 2 compares transfer efficiency of nine proteins using six different buffers as measured by SYPRO Ruby staining The following buffers were used:
400 mM Tris/Gly—400 mM Tris, 400 mM Glycine pH 9.0
[0016] 500 mM Tris/Gly—500 mM Tris, 500 mM glycine pH 9.0
1M Tris/Gly—1,000 mM Tris, 1,000 mM glycine pH 9.0
10× Towbin—250 mM Tris, 1,920 mM glycine pH 8.3
300 mM Tris/Gly—300 mM Tris, 300 mM glycine pH 9.0
iBlot—proprietary consumables used, exact buffer composition unknown.
[0017] FIG. 3 shows the blots used for quantification depicted in FIG. 2 .
[0018] FIG. 4 shows the voltage curve during transfer using six different transfer buffers.
DETAILED DESCRIPTION OF THE INVENTION
[0019] This invention relates to an aqueous transfer buffer with improved performance in eletrophoretic transfer of macromolecules, including proteins and nucleic acids, especially proteins of relatively low molecular weight.
Ingredients of the Transfer Solution
[0020] The transfer buffer of this invention is an aqueous solution that contains at least two ingredients: Tris and glycine. Each of the two ingredients is present in the transfer solution at a concentration of at least 300 mM. In one example, a transfer buffer of this invention has a pH of 9.0 and contains 300 mM Tris and 300 mM glycine. Compared to the buffers in the art, this buffer has demonstrated a surprisingly high efficiency in transferring proteins across of a broad range of molecular weight (e.g., from about 200 kDa to about 6.5 kDa) from an electrophoretic gel to a blotting membrane, especially in the transfer of proteins of less than about 20 kDa. The concentrations of Tris and glycine can be higher in the solution (such as at least about 400 mM, 500 mM, or 1 M each), and may be as high as their respective solubility: 4 M for Tris and 3.3 M for glycine. In general, however, when the Tris and glycine concentrations in a transfer solution become increasingly higher than 300 mM each, the solution tends to retain its high transfer efficiency with regard to smaller proteins (e.g., about 20 kDa or less, about 15 kDa or less, about 20 kDa to about 6.5 kDa, or about 15 kDa to about 6.5 kDa), but may exhibit gradually diminished transfer efficiency of larger proteins (e.g., more than about 20 kDa or about 50 kDa).
[0021] Optionally, additional ingredients can be included in the transfer buffer as well. SDS, ethanol, and methanol are examples of such optional ingredients. In some examples, the concentration of SDS in the solution can range from 0.025% to 0.1% by weight, e.g., no more than 0.1% by weight, such as 0.05% by weight. In other examples, the concentration of ethanol or methanol in the solution can range from 5% to 20%, e.g., no more than 20% in weight, such as 10% by weight.
pH of the Transfer Solution
[0022] The transfer butter of this invention has a pH range of from about 8.0 to about 9.5, such as about 8.8 to about 9.2. In an exemplary embodiment, the transfer solution has a pH of about 9.0. As it is well known in the art, the solution's pH may be adjusted by diluted HCl or NaOH water solution as needed. As used in this application, the word “about” denotes a range of +/− 10% of the value indicated immediately after “about.”
Method and Device Using the Transfer Solution
[0023] The transfer buffer of this invention can replace various transfer buffers currently used in the electrophoretic blotting methods known in the art and/or in combination with the devices currently available for electrophoretic blotting. In general, the process of electrophoretic blotting involves placing the matrix that was used in electrophoresis and contains the separated proteins in immediate contact with a second substrate to which the proteins are to be transferred for further testing. The matrix used in electrophoresis may be a polyacrylamide gel such as an SDS gel, and the second substrate may be a membrane made of nitrocellulose, nylon, polyvinyl difluoride, or similar material. The assembly of the matrix and substrate is submerged or saturated in the transfer buffer and then placed in an electrical field that directs the movement of proteins towards the second substrate. The voltage, current, and run time in a transfer system may be empirically determined. In some cases, it may be desirable to maintain the entire transfer assembly in a temperature-controlled environment to prevent overheating and possible protein denaturation.
EXAMPLES
[0024] The following examples are provided by way of illustration only and not by way of limitation. Those of skill in the art will readily recognize a variety of non-critical parameters that could be changed or modified to yield essentially the same or similar results.
Example 1
Effects of Tris/Glycine Concentrations on Protein Transfer Efficiency
Methods
[0025] A dilution series of SDS-PAGE Broad Range standards were separated by eletrophoresis on a Criterion 4-20% gel. Gels were blotted to 0.2 μM nitrocellulose membranes. To accommodate the low resistance values inherent in high ionic strength buffers, a custom power supply built by Acopian Technical Company was used. Current was set at 2.5 A and voltage data were recorded every minute. The blots were stained with SYPRO Ruby and imaged on a VersaDoc 4000.
[0026] In each case, blotting was performed for 10 minutes using EcoCloth pads (described in U.S. Ser. No. 11/955,955, “Polymeric Sorbent Sheets as Ion Reservoirs for Electroblotting”). For the experiment comparing Towbin Buffer, Timmons Buffer, and the buffer of this invention, voltage was held constant at 25V with a 2.5 A limit so that the transfer using Towbin Buffer would not overheat. For Timmons Buffer and the buffer of this invention, however, the 2.5 A limit was reached after less than 2 minutes and remained essentially the constant value for the remainder of the transfer. For the experiment comparing increasing concentrations of Tris/Glycine, current was held constant at 2.5 A.
Buffers Tested
[0027] 1. 400 mM Tris, 400 mM Glycine, pH 9.0
[0028] 2. 500 mM Tris, 500 mM Glycine, pH 9.0
[0029] 3. 1 M Tris, 1 M Glycine, pH 9.0
[0030] 4. 10× Towbin Buffer (250 mM Tris, 1.92 M Glycine), pH 8.3
[0031] 5. 300 mM Tris, 300 mM Glycine, pH 9.0
[0032] Additional buffers are provided in the section of Brief Description of the Drawings.
RESULTS
Blot Transfer Efficiency
[0033] FIGS. 1-4 compare SYPRO Ruby signal intensity from blots using various different buffer formulations. Overall, the concentration of Tris and Glycine in the buffer has a significant effect on transfer efficiency. Tris/Glycine concentrations above 300 mM decrease overall transfer efficiency for proteins larger than 14 kDa. In addition, the 1 M Tris/Glycine blot reveals an uneven transfer across the membrane ( FIG. 5 ). For the two smallest proteins in the sample, lysozyme (14.4 kDa) and aprotinin (6.5 kDa), the two highest Tris/Glycine concentrations (1M and 10× Towbin, which contains 250 mM Tris and 1.92 M Glycine) display a significant increase in transfer efficiency. This suggests that a high ionic strength could help prevent migration of low molecular weight proteins through the membrane. However, the 500 mM Tris/Glycine buffer displays a low molecular weight transfer efficiency similar to that of 300 mM Tris/Glycine and 400 mM Tris/Glycine buffer have the poorest transfer efficiency.
Transfer Voltage
[0034] As expected, buffer concentration did have a large effect on the voltage profile generated during testing. In general, as the concentrations of Tris and Glycine increase, the voltage generated during the transfer decreases when current is held constant. Interestingly, the 1M Tris/Glycine held a significantly lower run voltage than the 10× Towbin (250 mM and 1.92 M Glycine), suggesting that Tris may have a more significant effect than Glycine on run voltage.
CONCLUSIONS
[0035] Increasing the Tris/Glycine concentration in the transfer buffer increases transfer efficiency for proteins of relatively small molecular weight, such as 20 kDa or smaller (e.g., 14 kDa or smaller). 1 M Tris/Glycine and 10× Towbin Buffer provide enhancement in small protein transfer efficiency, whereas the larger proteins tend to have relatively lower blotting quality and transfer efficiency.
[0036] All patents, patent applications, and other publications cited in this application are incorporated by reference in the entirety for all purposes. | The present invention relates to an aqueous transfer buffer that provides superior efficiency in transferring polypeptides of a broad range of molecular weight from a matrix used in electrophoresis to another immobilized surface. Also disclosed are electrophoretic methods and devices in which the aqueous transfer solution of this invention is used. | 2 |
FIELD OF THE INVENTION
This invention relates to the recovery of crude oil from crude oil-bearing subterranean reservoirs. Particularly, this invention relates to a process for the formation of carbon dioxide-hydrocarbon mixtures which will mix in all proportions with crude oil from a subterranean reservoir at the ambient temperature and pressure of the reservoir. In another aspect, this invention relates to forming a carbon dioxide-hydrocarbon mixture from carbon dioxide and crude oil.
BACKGROUND OF THE INVENTION
In the recovery of the crude oil from underground reservoirs, one known method includes the injection of a solvent into the reservoir to displace the crude oil through the reservoir. When solvents are employed that will mix in all proportions with crude oil at the ambient temperature and pressure of the reservoir from which the crude oil is produced, the term "miscible flooding" is applied to the process. The process of miscible flooding can be extremely effective in stripping and displacing oil through the reservoir. Miscible fluids which have been used include light hydrocarbons and mixtures thereof, such as paraffins in the C 2 -C 6 range, and in particular, liquid petroleum gas (LPG). However, miscible flooding with LPG has not become widespread because of the ready market and high value of LPG, making miscible LPG projects uneconomic.
In another process for the recovery of crude oil from underground reservoirs, a crude oil displacing fluid which is not miscible with the crude oil at the ambient temperature and pressure of the reservoir but which will develop miscibility with the crude oil is injected into the reservoir to displace the crude oil contained in the reservoir. The term "miscible flooding" is also applied to this process. This sort of miscible flooding is termed "developed miscibility," or "multiple-contact miscibility," wherein it is thought that the intermediates (C 2 -C 6 ) of crude oil transfer into the crude oil displacing fluid over a sustained period of exposure, as opposed to "first-contact miscibility," wherein a zone of contiguously miscible fluids will result.
A mixture of crude oil and a crude oil displacing fluid that will develop miscibility with the crude oil have been observed to form three phase systems when maintained at the temperature and pressure of the reservoir from which the crude oil was produced. The three-phase system comprises an upper vapor phase rich in the miscibility-generating solvent, a middle-phase liquid also rich in the miscibility-generating solvent, and an oil-rich liquid lower phase. A solid asphaltene phase which coexists with the vapor and liquid phases has been observed in some cases.
Carbon dioxide, which is relatively inexpensive compared to LPG, has been used as an oil-recovery solvent. Carbon dioxide is miscible with crude oil in certain reservoirs, but usually at a reservoir pressure less than about 2,000 psia at ambient reservoir temperatures. The minimum pressure at which carbon dioxide is miscible with crude oil from a reservoir is determined at the ambient reservoir temperature and is referred to as the minimum miscibility pressure (MMP).
Carbon dioxide can be mixed with hydrocarbons to produce a displacing fluid that develops miscibility with the crude oil being displaced at the ambient temperature and pressure of the reservoir when the pressure of the reservoir to be flooded lies below the pure carbon dioxide minimum miscibility pressure. Processes utilizing these methods are disclosed in U.S. Pat. Nos. 3,811,501 and 3,811,503, both issued to D. Burnett, et al., on May 21, 1974.
The processes described to produce such carbon dioxide mixtures require mixing carbon dioxide with the required hydrocarbon. The hydrocarbon is expensive and, in some cases, unavailable at field locations.
Other pertinent publications include "Multiple Phase Generation During Carbon Dioxide Flooding", R. L. Henry and R. S. Metcalfe, SPE/DOE Symposium on Enhanced Oil Recovery, Apr. 20-23, 1980 (SPE Paper No. 8812), and "Determination and Predictability of Carbon Dioxide Minimum Miscibility Pressures", W. F. Yellig and R. S. Metcalfe, Journal of Petroleum Technology, January, 1980, pages 160-167, and "Effects of Impurities on Minimum Miscibility Pressure and Minimum Enrichment Levels for CO 2 and Rich Gas Displacements", R. S. Metcalfe, SPE Annual Meeting, 1980 (SPE Paper No. 9230). These publications describe the methods of determining minimum miscibility pressure and multiple phase miscibity.
SUMMARY OF THE INVENTION
Over limited temperature, pressure and composition ranges, mixtures of carbon dioxide and crude oil exhibit a complex phase equilibria in which a carbon dioxide-rich vapor phase, a carbon dioxide-rich liquid phase, an oil-rich liquid phase, and, in some cases, a solid asphaltene phase, coexist in equilibrium. This invention utilizes this phase equilibria in a novel process to obtain a carbon dioxide-hydrocarbon mixture useful for injection into a reservoir to miscibly displace crude oil. More particularly, the invention relates to the mixture produced from the interaction of a carbon dioxide and crude oil. The process includes contacting the carbon dioxide with the formation crude oil in an extraction zone which is maintained at a temperature and pressure such that multiple phases occur. Included in these phases are carbon dioxide rich phases which contain hydrocarbons extracted from the crude oil. These carbon dioxide rich phases are used to miscibly displace crude oil through subterraneous reservoirs.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates a schematic diagram for the formation of a carbon dioxide displacement fluid which is miscible with a formation crude oil.
DETAILED DESCRIPTION OF THE INVENTION
It has heretofore been believed that the only method of decreasing the minimum miscibility pressure (MMP) of carbon dioxide with crude oil was by bringing an additive such as intermediate hydrocarbons to the injection site for addition to the carbon dioxide, an expensive and time consuming process. However, we have discovered that by contacting the carbon dioxide with crude oil produced from the reservoir to undergo a carbon dioxide miscible flood, under appropriate conditions, a mixture of carbon dioxide and hydrocarbons is generated that is suitable for injection into the formation for miscible displacement of crude oil.
The concentrations of carbon dioxide and additive necessary to develop miscibility between the carbon dioxide/additive mixture and the reservoir crude oil at ambient reservoir pressures and temperatures can be determined by means of a slim tube displacement test which is well known in the art and described in the publications cited above by Yellig and Metcalfe, and Henry and Metcalfe.
Referring now to FIG. 1, as using for purposes of illustration the case where carbon dioxide is not miscible, at ambient reservoir conditions, with crude oil produced from a subterranean reservoirs. The miscibility of the carbon dioxide with the crude oil is adjusted by addition of hydrocarbons to develop miscibility, carbon dioxide via line 12 is mixed with crude oil introduced via line 14 into a mixing conduit 16. The mixed stream is introduced into an extraction zone, in the form of an extraction vessel 18, which is a pressure vessel operated under suitable conditions of pressure and temperature to assure the formation of a plurality of fluid phases. Pressure and temperature in the extraction vessel 18 are maintained such that the concentration of hydrocarbons in the carbon dioxide-rich phase is in excess of the concentration required for the carbon dioxide-rich phase to develop miscibility with the crude oil at the ambient pressure and temperature of the reservoir from which the crude oil was produced. Within the extraction vessel 18, a carbon dioxide-rich gaseous phase 20, carbon dioxide-rich liquid phase 22 and an oil-rich liquid phase 24 are illustrated. The gaseous phase 20, comprising carbon dioxide and hydrocarbons is withdrawn from extraction vessel 18 via line 26, and is transported to line 28 which conducts the miscible fluid to a wellhead for injection into the reservoir from which the crude oil was produced.
Phase 24, which may contain some carbon dioxide, is removed from extraction vessel 18 via line 30 and is introduced into a flash separator 32. In the flash separator 32, pressure is reduced and whatever carbon dioxide is present in stream 30 is vaporized and exits via line 34 with entrained methane. This stream can be sent to a gas plant for carbon dioxide stripping with the methane ultimately being sold or used on site for fuel. A stream of crude oil is recovered via line 36 for eventual sale as separator oil. The carbon dioxide in line 26 may be recycled to vessel 18 through line 12 or withdrawn via line 28 for injection. The carbon dioxide-containing liquid phase 22 can be introduced into line 30 via line 40 and flash separated in the flash tank 32 into carbon dioxide and hydrocarbon components.
The carbon dioxide containing gaseous phase 20 may contain a concentration of intermediate hydrocarbons which exceeds the concentration required for miscibly mixing with the crude oil. This phase withdrawn in line 26 may then be blended with a quantity of carbon dioxide via line 42 such that line 28 contains the carbon dioxide mixture desired for miscible flooding.
While either the upper or middle carbon dioxide-rich phases can be utilized for miscible oil recovery, it is contemplated that the carbon dioxide-rich liquid middle phase is preferred since most of the methane absorbed by the carbon dioxide will be contained in the upper phase 20. Methane tends to increase the MMP of carbon dioxide. The total amount of methane is anticipated to be small since line 14 will contain flashed separator oil.
In either case, the appropriate fluid is withdrawn from vessel 18 and is transported to line 28 which conducts the crude oil displacing fluid to a wellhead for injection into the reservoir.
In the embodiment wherein the carbon dioxide-rich gaseous phase 20 is not used in the miscible flooding, it is withdrawn in line 26, and introduced into line 30, containing the oil-rich liquid phase 24 via line 44. In the embodiment wherein the carbon dioxide-rich liquid phase 22 is maintained at a concentration of hydrocarbons such that the carbon dioxide-rich liquid phase 22 withdrawn through line 38 contains excess hydrocarbon than is required for the phase 22 to be miscible with the formation crude oil, it can be blended with additional carbon dioxide. This is illustrated by phase 22 being withdrawn in line 38 and blended with a quantity of carbon dioxide delivered through line 42 such that line 28 contains a carbon dioxide mixture having a concentration of hydrocarbons such that the mixture is miscible with the formation crude oil.
Reasonable variations and modifications which will become apparent to those skilled in the art can be made in the present invention without departing from the spirit and scope thereof. | A method is disclosed for forming a carbon dioxide-containing mixture which is miscible with crude oil. The method comprises maintaining a mixture of crude oil and carbon dioxide in an extraction zone at a temperature and pressure such that multiple phase equilibrium is achieved therebetween. A carbon dioxide-rich phase that includes a mixture of carbon dioxide and hydrocarbons is withdrawn and is miscible with the reservoir crude oil when injected into the reservoir from which the crude oil was produced. | 4 |
BACKGROUND OF THE INVENTION
The present invention generally relates to material displacement apparatus such as excavating equipment and, in illustrated embodiments thereof, more particularly relates to apparatus for releasably coupling a replaceable excavating tooth point or other wear member to an associated adapter nose structure.
A variety of types of material displacement apparatus, such as excavating equipment, are provided with replaceable wear portions that are removably carried by larger base structures and come into abrasive, wearing contact with the material being displaced. For example, excavating tooth assemblies provided on digging equipment such as excavating buckets or the like typically comprise a relatively massive adapter portion which is suitably anchored to the forward bucket lip and has a reduced cross-section, forwardly projecting nose portion, and a replaceable tooth point having formed through a rear end thereof a pocket opening that releasably receives the adapter nose. To captively retain the point on the adapter nose, generally aligned transverse openings are formed through these telescoped elements adjacent the rear end of the point, and a suitable connector structure is driven into and forcibly retained within the aligned openings to releasably anchor the replaceable tooth point on its associated adapter nose portion.
The connector structure typically has to be forcibly driven into the aligned tooth point and adapter nose openings using, for example, a sledge hammer. Subsequently, the inserted connector structure has to be forcibly pounded out of the point and nose openings to permit the worn point to be removed from the adapter nose and replaced. This conventional need to pound in and later pound out the connector structure can easily give rise to a safety hazard for the installing and removing personnel.
Various alternatives to pound-in connector structures have been previously proposed for use in releasably retaining a replaceable wear member, such as a tooth point, on a support structure such as an adapter nose. While these alternative connector structures desirably eliminate the need to pound a connector structure into and out of an adapter nose they typically present various other types of problems, limitations and disadvantages including, but not limited to, complexity of construction and use, undesirably high cost, difficult installation and removal and unintentional operational dislodgment of the installed connector structure from its associated tooth point and support structure.
A need accordingly exists for an improved wear member/support member connector structure. It is to this need that the present invention is directed.
SUMMARY OF THE INVENTION
In carrying out principles of the present invention, in accordance with representative embodiments thereof, first and second members, illustratively an excavating adapter and associated tooth point, are captives retained in a telescoped relationship by a specially designed connector pin assembly embodying principles of the present invention. The connector pin assembly basically includes a body, a lock member and a resilient detent structure.
The body is removably received in aligned connector openings in the telescoped first and second members and blocks separation thereof from one another, the body having a passage extending inwardly through an outer surface thereof, the passage having a noncircularly shaped side surface section. Preferably, this noncircularly shaped side surface section has a polygonal shape which is representatively square. In a representatively illustrated version thereof, the body has an elongated flat shape with an exterior surface that extends between opposite end portions of the body, outwardly circumscribes its passage, and is substantially parallel to the length of the body.
The lock member is received in the body passage and is circumscribed by its noncircular side section, the lock member being rotatable relative to the body between a locking position in which a portion of the lock member, representatively a transverse lobe on an outer end portion thereof, blocks removal of the body from the aligned connector openings, and an unlocking position in which the lock member permits removal of the body from the aligned connector openings. The resilient detent member is carried by the lock member for rotation therewith, and is operative to releasably retain the lock member in its locking position.
In a first representative embodiment of the connector pin assembly, the resilient detent member has a periphery circumscribing the lock member and complementarily and slidably engaging the noncircularly shaped side surface section of the body passage. The lock member is captively retained within the body passage by a snap ring member carried by the lock member and received in a corresponding groove in the surface of the body passage.
In a second representative embodiment of the connector pin assembly, the lock member has a slot extending there-through and opening outwardly through opposite outer side portions thereof. The resilient detent member extends through the slot and has opposite end portions projecting outwardly beyond these outer side portions and slidably engaging the noncircularly shaped side surface section of the body passage. The lock member is captively retained within the body passage by an annular bushing circumscribing the lock member and press-fitted into the body passage. An O-ring seal on the lock member slidingly and sealingly engages a circular interior side surface portion of the bushing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinally foreshortened, partially cut away side elevational view of a replaceable excavating tooth point telescoped onto a nose portion of an adapter structure and releasably retained thereon by a specially designed connector pin assembly embodying principles of the present invention;
FIG. 2 is an enlarged scale exploded perspective view of the connector pin assembly;
FIG. 3 is a reduced scale, partially phantomed side elevational view of the connector pin assembly;
FIG. 4 is laterally directed cross-sectional view through the connector pin assembly;
FIG. 5 is a reduced scale side edge elevational view of the connector pin assembly;
FIG. 6 is a reduced scale end elevational view of the connector pin assembly;
FIG. 7 is an enlarged scale partial interior cross-sectional view through the connector pin assembly taken along line 7 — 7 of FIG. 5 ;
FIGS. 8 and 9 , respectively, are end and side elevational views of a hollow, square cross-sectioned resilient detent member utilized in an alternate embodiment of the connector pin assembly;
FIG. 10 is a simplified, somewhat schematic cross-sectional view, partially phantomed, through a lock member portion of the alternate connector pin assembly embodiment;
FIG. 11 is an end view of the lock member portion of the alternate connector pin assembly embodiment;
FIG. 12 is a cross-sectional view through the FIG. 11 lock member taken along line 12 — 12 of FIG. 10 ; and
FIGS. 13 and 14 , respectively, are schematic cross-sectional views through the FIG. 11 lock member in retention/locking and insertion/unlocking orientations thereof.
DETAILED DESCRIPTION
AS illustrated in FIGS. 1-7 , this invention provides a specially designed connector pin assembly 10 which is used to releasably interconnect two telescoped members such as the illustrated excavating tooth point 12 (or other wear member) which is telescoped onto the nose portion 14 of an associated adapter structure 16 (or other support structure). The connector assembly 10 is passed inwardly through aligned connector openings 18 , 20 respectively formed in the tooth point 12 and the adapter nose 14 and locked therein to block outward removal of the point 12 from the adapter nose 14 . For a more detailed description of this general type of excavating equipment connector pin structure, see U.S. Pat. No. 6,108,950 which is assigned to the assignee of the present application and is hereby incorporated herein by reference.
In addition to its applicability to material displacement and excavating equipment, the connector pin assembly 10 may also be advantageously utilized in joining a wide variety of other types of telescoped members. Accordingly, it is to be clearly understood that principles of the present invention are in no way limited to the fields of material displacement and excavation equipment although such inventive principles are particularly well suited to such fields.
Connector pin assembly 10 includes an elongated metal main body portion 22 having an opening or passage 24 longitudinally extending inwardly through one end thereof, and opposite, longitudinally outwardly projecting end portions 23 that, as shown in FIG. 1 , block removal of the point 12 from the adapter nose 14 . Representatively, but not by way of limitation, the entire exterior periphery of the main body portion 22 is parallel to its length (i.e., the main body portion 22 does not appreciably taper laterally inwardly along its length) in a manner similar to that of the flat connector member 60 illustrated and described in copending U.S. application Ser. No. 10/287,406 assigned to the assignee of the present application and which is hereby incorporated herein by reference.
Opening or passage 24 has a circularly cross-sectioned longitudinally outer portion 24 a (see FIG. 2 ), a square cross-sectioned longitudinally intermediate portion 24 b (see FIGS. 3 and 7 ), and a smaller diameter longitudinally inner circularly cross-sectioned portion 24 c (see FIG. 3 ) inwardly tangential to the square cross-sectioned opening portion 24 b. Outer opening portion 24 a is outwardly tangential to the opening portion 24 b (i.e., tangential to its corner portions).
Still referring to FIGS. 1-7 , connector pin assembly 10 also includes a rotatable metal lock member 26 , an elongated rectangular detent member 28 formed from a resilient plastic or nylon material, an annular metal bushing 30 , and a resilient O-ring seal member 32 . The lock member 26 has an elongated cylindrical body 34 with a rectangularly cross-sectioned slot 36 transversely extending through a longitudinally intermediate portion thereof and sized to complementarily receive the detent member 28 with opposite end portions thereof projecting outwardly from opposite outer side surface portions of the body 34 . At the outer end of the body 34 is a hexagonal driving head 38 from which a retaining lobe 40 outwardly projects.
The connector pin structure 10 is assembled by first placing the O-ring 32 in an associated annular groove on the body 34 between the lobe 40 and the transverse slot 36 , and then placing the metal bushing 30 on the body 34 over the O-ring 32 (see FIG. 4 ). The resilient detent member 28 is then inserted into the slot 36 and the lock member body 34 is driven into the opening 24 in the main body portion 22 to press fit the bushing 30 into the opening portion 24 a and bring the assembled lock member 26 to its FIG. 4 position within the main body portion 22 . After the body portion 34 is driven to this position, the resilient detent member 28 (which is representatively of a nylon material) enters the square portion 24 b of the body opening 24 as shown in FIG. 7 .
With the inserted lock member 26 in its solid line insertion/unlocking orientation shown in FIG. 6 , the lobe 40 is disposed within the periphery of the main body portion 22 , and opposite end portions of the detent member 28 are received in opposite corner portions C 1 ,C 2 of the square opening portion 24 b (see FIG. 7 ). The completed connector pin assembly 10 is then inserted into the aligned point and adapter openings 18 , 20 as shown in FIG. 1 and the lock member 26 is rotated 90 degrees from its FIG. 6 solid line insertion/unlocking position to a retention/locking position in which the lobe 40 reaches its dotted line orientation in FIG. 6 . In this position the lobe 40 extends outwardly beyond the periphery of the main body portion 22 and, as shown in FIG. 1 , underlies a ledge 41 within the tooth point 12 , thereby releasably locking the inserted connector pin assembly 10 within the aligned point/adapter openings 18 , 20 by blocking its longitudinal removal or dislodgement therefrom.
When the lock member 26 is rotated from its insertion/unlocking position to its retention/locking position, the opposite ends of the resilient detent member 28 are initially inwardly compressed against opposite side surfaces of the opening portion 24 b (as indicated by the dotted line position of the detent member 28 in FIG. 7 ) and then snap outwardly into the opposite corner portions C 3 ,C 4 of the opening section 24 b as the lock member 26 reaches its retention/locking position.
Since the resilient detent member 28 must be compressed during its rotational movement between the insertion and retention positions of the lock member 26 , it resiliently resists undesired rotational movement of the lock member 26 from its retention/locking position to its insertion/unlocking position to thereby prevent accidental dislodgement of the inserted connector pin assembly 10 from the tooth point/adapter openings 18 , 20 . The press-fitted bushing 30 overlies and outwardly blocks the opposite ends of the detent member 28 to thereby captively retain the lock member 26 within the opening 24 of the main body portion 22 . The O-ring seal 32 disposed within the press-fitted bushing 30 functions to inhibit dirt and other debris from entering the interior of the connector assembly 10 inwardly past such seal.
AS can be seen, the interior opening or passage portion 24 b within the main connector pin body portion 22 has a polygonal shape (representatively square) which circumscribes the inserted lock member 26 . However, a variety of alternate polygonal and other non-circular shapes for this opening portion 24 b could be utilized if desired.
An alternate embodiment 26 a of the lock member 26 is shown in FIGS. 8-12 and is incorporated in an alternate embodiment 10 a (see FIG. 10 ) of the previously described connector pin assembly 10 in turn, the illustrated connector pin assembly 10 a is operatively installed in the previously described telescoped point 12 and adapter nose 14 in place of the previously described connector pin assembly 10 shown in FIG. 1 . Lock member 26 a has a cylindrical body portion 42 with a laterally inset square cross-sectioned central section 44 . At the outer end of the body portion 42 is a hex head section 46 from which the retention lobe 40 outwardly projects.
The square central section 44 is received in a corresponding square central opening 48 of a square rubber detent member 50 captively retained on the body portion 42 between facing ledges on the cylindrical portions of the body portion 42 disposed on opposite ends of its central square section 44 . When the lock member 26 a is driven into the opening 24 of the main body portion 22 , the resilient detent member 50 enters the opening section 24 b as shown in FIG. 13 . Additionally, a snap ring 52 (see FIG. 10 ) carried on the inner end of the lock member body 42 is inwardly deformed and then snaps outwardly into a corresponding interior groove in the opening portion 24 c to captively retain the inserted lock member 26 a within the main connector pin body
With the inserted lock member 26 a in its FIG. 13 retention/locking position, the corners C 1 ′,C 2 ′,C 3 ′,C 4 ′ of the detent member 50 are respectively received in the corners C 1 ,C 2 ,C 3 ,C 4 of the square opening section 24 b so that the detent member 50 is complementarily received in the opening portion 24 b and resiliently resists rotation of the lock member 26 a to its insertion/unlocking orientation shown in FIG. 14 . Such resistance is provided due to the fact that to effect such rotation, each opposite pair of corner sections of the detent member must be compressed toward one another during such rotation. During such compression thereof the detent member 50 continues to fill the opening portion 24 b. Accordingly, the detent member 50 (in all of its rotational orientations) also serves as a sealing element to inhibit the entry of dirt and other debris into the interior of the connector pin assembly 10 a. Because of this, the previously described O-ring 32 may be omitted. When the lock member 26 a is rotated to its FIG. 14 insertion/unlocking orientation, the resilient detent member 50 is again complementarily received within the interior opening portion 24 b, with the detent member corner portions C 1 ′,C 4 ′,C 2 ′,C 3 ′ being respectively received in the corner portions C 4 ,C 2 ,C 3 ,C 1 of the opening section 24 b.
As can be seen from the foregoing, each of the representatively illustrated and described connector pin assemblies 10 and 10 a may be inserted into the telescoped point 12 and adapter nose 14 (or other types of telescoped members as the case may be) without the necessity of pounding the assembly into place. Moreover, the assemblies 10 and 10 a are each of a simple construction, are easy to install and remove, and provide, via their unique locking member detent structures, for improved retention of the installed connector pin assemblies in the members which they releasably retain in a telescoped orientation.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims. | Telescoped excavating support and wear members are releasably retained in their telescoped relationship by a connector pin assembly removably received in aligned connector openings in the members. A body portion of the pin assembly blocks removal of the wear member from the support member, and a lock member portion of the assembly is rotatable relative to the body, toward and away from a locking orientation, to releasably lock the body within the connector openings. A resilient detent member carried by the lock member slidingly and deformably engages a polygonally shaped interior side surface section of a body passage that rotatably receives the lock member, the detent member yieldingly resisting rotational movement of the lock member away from its locking orientation. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electronic control fuel supply system for use in controlling the air-fuel ratio of the mixture of air and fuel being supplied to an internal combustion engine.
2. Description of the Prior Art
In a known electronic control fuel supply system, a λ sensor is utilized to detect the actual air-fuel ratio of the mixture being supplied to an engine. Report No. 730566 of The Society of Automotive Engineers discloses a detailed arrangement of a λ sensor positioned in the exhaust system of an engine, the λ sensor being one type of oxygen sensor. The output voltage of the λ sensor varies in a digital manner as the air-fuel ratio of the mixture supplied to the internal combustion engine changes between values lower and higher than the predetermined stoichiometric air-fuel ratio.
The input of an integrating circuit in the electronic control fuel supply system is connected to the output of the λ sensor, and the output of the integrating circuit is connected to a fuel injection valve which injects fuel into the intake system of the engine. In this connection, the air-fuel ratio control is subjected to a hunting phenomenon because a time lag occurs between the variation of the air-fuel ratio of the introduced mixture and the variation in output voltage of the λ sensor; i.e., there is a dead time for the response of this control system.
If the level of hunting is to be minimized, the time constant of the integrating circuit must be set to an optimum value. However, it is difficult to achieve compatibility between the follow-up characteristics of the actual air-fuel ratio and the stoichiometric air-fuel ratio during the transient phase of the engine.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide an electronic control fuel supply system for use in an internal combustion engine which minimizes the level of hunting and provides excellent follow-up characteristics during the transient phase.
According to the present invention, there is provided an electronic control fuel supply system for use in an internal combustion engine in which a λ sensor provided in the exhaust system of the engine is connected by means of a Schmidt circuit, an integrating circuit and a fuel-amount control circuit to a fuel injection valve which opens into the intake system of the engine. An acceleration switch positioned in the intake system of the engine is connected by means of a first differentiating circuit, one input of an adding circuit, a flip-flop, one input of an AND gate and a second drive circuit to a control terminal of the integrating circuit. In addition, the Schmidt circuit is connected to a second differentiating circuit which is connected by way of a first switch to a second input of the adding circuit. The output of the Schmidt circuit is further connected to a NOT circuit, which is connected to a second input of the AND gate. The flip-flop is also connected to a first drive circuit which controls the first switch interposed between the second differentiating circuit and the adding circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrative of one embodiment of the present invention;
FIG. 2 shows waveform diagrams illustrating the relationship between respective output pulses and time; and
FIG. 3 is a detailed circuit diagram of the embodiment of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One embodiment of the present invention will now be described in detail with reference to FIG. 1.
Hereinafter, a digital signal of a high voltage level will be designated `1`, and a signal of a low voltage level will be designated `0`. A λ sensor 11 provided in the exhaust system of an internal combustion engine 5 generates a digital signal `1` when the air-fuel ratio of the mixture being supplied to the internal combustion engine 5 is smaller than the stoichiometric air-fuel ratio; that is, when the mixture is rich. The λ sensor 11 generates a digital signal `0`, when the air-fuel ratio of the mixture is larger than the stoichiometric air-fuel ratio; that is, when the mixture is lean. The output of the λ sensor 11 is connected to the input of a Schmidt circuit 12. The output of the Schmidt circuit 12 is connected to the respective inputs of a NOT circuit 13, a differentiating circuit 14 and an integrating circuit 15.
An acceleration switch 16 is provided in the intake system 7 of engine 5 and generates a digital signal `1` when the level of the intake vacuum is being lowered. In other words, when a throttle valve 8 in the carburetor of the engine has been maintained at a given opening and a force is then applied to the accelerator pedal, the opening of the throttle valve 8 is increased so that the level of the intake vacuum is lowered. The acceleration switch 16 detects this accelerated condition of the engine.
The output of the acceleration switch 16 is connected by differentiating circuit 17 to one input of an adding circuit 21. The output of the differentiating circuit 14 is connected by a switch SW1 to a second input of the adding circuit 21 and the output of the adding circuit 21 is connected to the input of a flip-flop 22. The output of the flip-flop 22 is connected to one input of an AND gate and to the input of a first drive circuit 24.
During the time that a digital signal `1` is being fed to the first drive circuit 24, the first drive circuit 24 keeps the switch SW1 closed. On the other hand, during the time that a digital signal `0` is being fed thereto, the first drive circuit keeps the switch SW1 open. The output of the NOT circuit 13 is connected to a second input of the AND gate 23 and the output of the AND gate 23 is connected to the input of a second drive circuit 27.
The second drive circuit 27 controls the switch SW2 in the integrating circuit 15. During the time that a digital signal `1` is being fed to the second drive circuit 27, the switch SW2 is maintained connected to a resistor R 1 . On the other hand, during the time that a digital signal `0` is being fed to the second drive circuit 27, the switch SW2 is maintained connected to a resistor R 2 having a resistance higher than that of the resistor R 1 . The integrating circuit 15 also includes an operational amplifier 15' coupled to switch SW2 and to the input of a fuel-amount control circuit 25.
The integrating circuit 15 provides an output voltage having a phase which is the reverse of the phase of the voltage applied to its input. The fuel-amount control circuit 25 compensates for the input voltage thereto according to signals associated with the temperature of the engine, the actual air-fuel ratio of the mixture supplied to the engine, as well as other engine parameters, and generates a signal corresponding to the optimum open duration of the fuel injection valve 26. A typical fuel-amount control circuit suitable for use with the present system is described in the U.S. Pat. No. 3,815,561.
FIG. 2 is a timing diagram showing the voltage waveforms existing at similarly designated points of the system of FIG. 1. In FIGS. 1 and 2, a represents the output of the acceleration switch 16, b the output of the first differentiating circuit 17, c the output of the Schmidt circuit 12, d the output of the second differentiating circuit 14, e the output of flip-flop 22, f the output of AND gate 23 and g the output of the integrating circuit 15.
Prior to the time t 1 , the internal combustion engine is in a normal running mode and is not being accelerated. Under this condition, the acceleration switch 16 is in its open position and the output a is zero. According, the output e of the flip-flop 22 is also zero, switch SW1 is open and switch SW2 is connected to resistor R 2 having a high resistance relative to the resistance of resistor R 1 . In other words, the time constant of the integrating circuit 15 is relatively high and the output g of the integrating circuit 15 increases at 30 and decreases at 31 with a slight gradient S 1 in accordance with the output of the Schmidt circuit 12.
Assuming that acceleration of the internal combustion engine is started at the time t 1 , the opening of the throttle valve 8 in the carburetor is increased. Consequently, the vacuum level in the intake system 7 of the internal combustion engine is lowered, the acceleration switch 16 is closed and the output a of switch 16 changed from `0` to `1`. The output a is differentiated by the differentiating circuit 17, and the output b of the differentiating circuit 17 fed by way of adding circuit 21 to the flip-flop 22 which reverses its output e from `0` to `1`. Consequently, a digital signal `1` is fed to the drive circuit 24 and circuit 24 closes the switch SW1.
In the time interval t 0 to t 2 , the output of the sensor 11 is `1` corresponding to a rich mixture so that the output of the NOT circuit 13 is `0`. The output f of the AND gate 23 causes the switch SW2 to be connected to resistor R 2 . Thus, during the interval between the time t 1 and the time t 2 , the output g of the integrating circuit 15 maintains the slight negative gradient S 1 .
An increase in the opening of the throttle valve 8 leads to an increase in the air-fuel ratio of the mixture being supplied to the engine. However, there necessarily takes place a time lag until the mixture is burned and then reaches the exhaust system, so that the output of the λ sensor remains at `1` (indicating a rich mixture) up to the time t 2 . At time t 2 , the effect of the increase in the air-fuel mixture is sensed by the λ sensor 11 at the exhaust system and the output c of the Schmidt circuit 12 switched from `1` to `0`. As a result, the output of the NOT circuit 13 switches from `0` to `1`, the drive circuit 27 is energized and switch SW2 changes the resistance of the integrating circuit from the high value R 2 to the lower value R 1 . This causes the output voltage g of the integrating circuit 15 to switch from a linearly decreasing waveform 31 having a slight gradient S 1 to a lineraly increasing voltage 32 having a relatively steep gradient S 2 .
Under the operating conditions depicted in FIG. 2, the air-fuel ratio being sensed by the λ sensor 11 shortly after acceleration is rich and the output g of the integrating circuit 15 is decreasing as shown at 31. If the air-fuel ratio at the beginning of the acceleration is lean, the output g of the integrating circuit will be increasing and the rate of increase will change from S 1 to S 2 at time t 1 rather than t 2 because the input to AND gate 23 from NOT circuit 13 will be "1". That is, as soon as the output e of flip-flop 22 changes to "1" as a consequence of the closing of acceleration switch 16, switch SW2 will be switched from the large resistor R 2 to the smaller resistor R 1 and this will occur at time t 1 .
As the voltage of the output g of the integrating circuit 15 increases, the time interval during which the fuel injection valve 26 is open will be increased. Consequently, the air-fuel ratio of the mixture being supplied to the engine will be decreased and the mixture will become rich as compared to the stoichiometric air fuel-ratio. Thus, at time t 3 , the output of the λ sensor 11 will become `1`. Accordingly, a digital signal `1` is fed to the flip-flop 22 by way of the Schmidt circuit 12, differentiating circuit 14 and adding circuit 21. In this manner, the output e of the flip-flop 22 is changed to the initial level `0` and the switch SW1 opened by the first drive circuit 24. In addition, the output f of the AND circuit 23 is switched to `0` and the switch SW2 connected to resistor R 2 having a high resistance by means of the second drive circuit 27. As a result, the output g of the integrating circuit 15 again fluctuates with a slight gradient S 1 from the time t 3 until the time at which the next acceleration is begun.
The broken line labeled Prior Art in FIG. 2 represents changes in the output g of the integrating circuit 15 in a known electronic control fuel supply system. As can be seen from FIG. 2, the output g of the prior art integrating circuit 15 maintains a slight gradient S 1 even at the time of acceleration, presenting a poor follow-up characteristic by the actual air-fuel ratio with respect to the stoichiometric air-fuel ratio.
FIG. 3 is a detailed circuit diagram of the embodiment of FIG. 1.
The Schmidt circuit 12 consists of an amplifier 121 and a zener diode 122. The positive input terminal of the amplifier 121 is connected to the output of the λ sensor 11 and the negative input terminal of the amplifier is grounded by the zener diode 122 and connected by a resistor 31 to the positive side of a D.C. power source 32, the negative side of the power source being grounded. The second differentiating circuit 14 consists of a capacitor 141 and a resistor 142. One end of differentiating circuit 14 is connected to the output of amplifier 121 and the other end thereof through switch SW1 to an input of adding circuit 21.
One end of the acceleration switch 16 is connected to the positive side of the electric power source 32 and the other end to the input of the first differentiating circuit 17. Differentiating circuit 17 consists of a capacitor 171 and a resistor 172, the output thereof being connected to an input of the adding circuit 21. The adding circuit 21 consists of resistors 211, 212, 213 and an amplifier 214. The input of the flip-flop 22 is connected to the output of the amplifier 214 and the output thereof is connected to an input of the AND gate 23 and to the input of the first drive circuit 24.
The first drive circuit 24 consists of a transistor 241 and a coil 242. One end of the coil 242 is connected to the positive side of the electric power source 32 and the other end thereof is connected to the collector of transistor 241, thereby controlling the opening and closing operation of switch SW1.
The input of the NOT circuit 13 is connected to the output of the amplfier 121. The NOT circuit 13 consists of a transistor 131 and a resistor 132. The collector of transistor 131 is connected by the resistor 132 to the positive side of the electric power source 32 and to the second input of the AND gate 23. The AND gate 23 consists of diodes 231, 232 and a resistor 233, the output of the AND gate 23 being connected to the input of the second drive circuit 27.
In the second drive circuit 27, the collector of a transistor 271 is connected by way of a coil 272 to the positive terminal of the electric power source 32. When excited, the coil 272 causes the switch SW2 to be connected to the resistor R 1 . When deenergized, switch SW2 is connected to resistor R 2 .
The integrating circuit 15 consists of resistors R 1 , R 2 , switch SW2, capacitor 151 and amplifier 152. Integrating circuit 15 is also referred to as a mirror integrating circuit because it reverses the phase of its output voltage relative to that of the applied input voltage. The input of the integrating circuit 15 is connected to the output of amplifier 121 and the output thereof is connected to the input of the fuel-amount control circuit 25. The output of the fuel-amount control circuit 25 is connected to the fuel injection valve 26.
As is apparent from the foregoing description of the electronic control fuel supply system according to the present invention, the level of hunting may be reduced to less than a given value.
While the present invention has been described herein with reference to one embodiment thereof, it should be understood that various changes, modifications and alterations may be effected without departing from the spirit and scope of the present invention, as defined in the appended claims. | An electronic control fuel supply system for use in an internal combustion engine. The system includes a λ sensor adapted to digitally vary an output signal in response to the air-fuel ratio of an air-fuel mixture being supplied to the engine, and an integrating circuit. The input of the integrating circuit is connected to the output of the λ sensor and has a time constant whereby the open duration of a fuel injection valve provided in the engine intake system is controlled by the output voltage of the integrating circuit. In this fuel supply system, the time constant of the integrating circuit is changed from a first value to a smaller second value after the start of acceleration of the internal combustion engine and during the time that the air-fuel ratio of the mixture is larger than a predetermined value. The integrating circuit is connected to a fuel-amount control circuit which in turn is connected to the fuel injection valve which opens into the intake system of the engine. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a Division of U.S. patent application Ser. No. 10/402,293, filed Mar. 31, 2003, now U.S. Pat. No. 7,645,512.
FIELD OF THE INVENTION
The invention pertains to electrical circuit interconnections and, more particularly, to the addition of nano-structures that facilitate thermal dissipation and electrical conductivity in microcircuits that are fabricated using conductive adhesives and anisotropic conductive adhesives.
BACKGROUND OF THE INVENTION
Discussion of the Related Art
Clearly, the continuing development of microcircuits includes, among others, the objectives of: application of flexible printed circuits, increased capacity (more switching functions in smaller devices), and a host of robustness issues, such as moisture control, improved shock-resistance, and use in higher temperature applications. These issues become more crucial when printed circuits are used in environments in which they are shocked or vibrated, as in machinery or fighter planes, or when high temperature, moisture, or contamination is experienced, as in industrial corrosive and high-humidity environments and in the engine compartment vehicle. To achieve these objectives, improvements in the connections between microcircuit components and the circuit chip or printed circuit board must be made.
Conductive adhesives and anisotropic conductive adhesives (ACA) have been used regularly in microcircuit fabrication, and their composition has been well described. Isotropic conductive adhesives (ICA) are hereinafter referred to as conductive adhesives.
These adhesive compositions consist primarily of an insulating adhesive resin carrier in which a matrix of interconnect fine particles is suspended. For the purpose of this description, such fine particles and the device and circuit board connections, including metal, metallized polymer, carbon or carbonaceous, micron or sub-micron sized shapes, including spheres, rods, tubes, conductors for heat transfer or electrical connection, printed circuit substrates and lands, and/or other regular and irregularly shaped particles and connectors, upon which nano-structures are attached or grown, are referred to as spheres. The spheres in the adhesive compositions, when squeezed under pressure during microcircuit fabrication, interconnect the components and layers of the microcircuit chip or circuit board. It is to be particularly emphasized that the nano-structures are grown on the flat surfaces of the conductor pads, printed circuit substrates and connectors and are not limited to the surface of particles in dispersion in an adhesive matrix. In other words, any body on which surface these nano-structures are grown is referred to as a sphere regardless of its shape.
For the purpose of description, the nano-structures are drawn as columns in the figures, but they may be spikes, cylinders, tubes, hemispheres, fibers, or any other regular or irregular shape; they are referred to as nano-structures.
The adhesive compositions have several purposes including, but not limited to: providing the carrier medium for the matrix of interconnect spheres to be distributed between the microcircuit devices and conductor pads; providing the thermal path for heat that is generated by the switching functions; the cured adhesive supports and electrically insulates between interconnection particles and conductors on the microcircuits, and it prevents moisture or other contaminants from getting into or being entrapped within the interconnections.
Several problems arise from the use of conductive adhesives and anisotropic conductive adhesive that affect the capacity of the microcircuit, specifically, thermal dissipation and electrical interconnection. Those effects, in turn, can limit the number of circuit switches on, or logic operations performed by, a microcircuit. One of these problems is a need to apply high pressure to the microcircuit during fabrication that can damage or misalign parts of the circuit. Also, entrapped air in voids has lower thermal conductivity and can limit heat dissipation from the microcircuit. Third, increased resistance in the interconnect can result from insufficient interconnect particle to contact surface connection.
It would be advantageous to provide conductive adhesives and anisotropic conductive adhesive interconnects in which thermal and electrical interconnection resistance and distortion or damage of circuit boards are reduced or eliminated. With existing interconnects, regardless of specific metal or metallized polymer or carbonaceous material used for interconnects, or whether their surfaces are smooth or irregular, the thermal and electrical conductivity and board distortion or damage problems described above exist to varying degrees.
SUMMARY OF THE INVENTION
The present invention adds nano-structures to interconnect conductor spheres to: reduce thermal interface resistance by using thermal interposers that have high thermal conductivity nano-structures at their surfaces; improve the conductive adhesives and anisotropic conductive adhesive interconnection conductivity with microcircuit contact pads; and, allow lower compression forces to be applied during the microcircuit fabrication processes which then results in reduced deflection or circuit damage.
Accordingly, the present invention provides an innovative improvement in conductive adhesives and anisotropic conductive adhesive interconnection technology by growing or attaching nano-structures to the interconnect particles and the microcircuit connection pads which address the problems listed above. When pressure is applied during fabrication to spread and compress conductive adhesives and anisotropic conductive adhesive and the matrix of interconnect particles and circuit conductors, the nano-structures mesh and compress into a more uniform connection than current technology provides, thereby eliminating voids, moisture, and other contaminants, increasing the contact surfaces for better electrical and thermal conduction.
BRIEF DESCRIPTIONS OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which:
FIGS. 1 a , 1 b , and 1 c , taken together, show a schematic diagram depicting, in general, the prior art process of anisotropic conductive adhesive with a matrix of interconnect spheres electrically and thermally connecting contacts and conductors of a microcircuit or circuit board;
FIG. 2 is a schematic diagram of one example of prior art liquid crystal display (LCD) technology showing the compressed metallized polymer conductive sphere within the anisotropic conductive adhesive interconnecting the circuit conductor to the ITO metallization layer on the LCD glass;
FIG. 3 is a schematic diagram depicting a prior art thermal interposer wherein a single smooth-walled particle contacts similarly smooth surfaces.
FIGS. 4 a , 4 b , 4 c and 4 d , taken together, show a schematic diagram depicting, in general, the nano-structures of the present invention attached to or grown from an interconnect sphere and a thermally conductive tube;
FIG. 5 is a schematic diagram depicting an assembly of a chip to a heat sink using a thermal plane as an interface with nano-structures attached; and
FIGS. 6 a , 6 b , and 6 c , taken together, show a schematic diagram depicting the nano-structures meshing and compressing into a more uniform connection than current technology provides, thereby eliminating voids, moisture, and other contaminants, increasing the contact surfaces for better electrical and thermal conduction.
FIGS. 6 d and 6 e , taken together, show a schematic diagram depicting the nano-structures grown on filler material particles and heat sink to improve their contact within the anisotropic adhesive system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally speaking, the invention pertains to electrical circuit interconnections. More specifically, the invention features the addition of nano-structures that facilitate thermal dissipation and electrical conductivity in microcircuits, and reduce circuit board deflection when fabricated using anisotropic conductive adhesives.
An anisotropic conductive adhesive system for fabricating microcircuits consists primarily of an insulating adhesive resin carrier in which a matrix of interconnect spheres is suspended. The spheres in the adhesive compositions, when squeezed under pressure during microcircuit fabrication, interconnect the components and layers of the microcircuit chip or circuit board.
Referring to FIGS. 1 a , 1 b , and 1 c , there are shown schematic drawings of typical microcircuit fabrication of the prior art. Assemblies of circuit fabrication are schematically represented in FIG. 1 a by upper and lower circuit boards 10 and 12 , respectively, which may be conductors, components, substrates, circuit boards, chips, or devices. Boards 10 and 12 have device connectors or printed circuits or thermal conductors 14 as shown on the lower board 12 .
An anisotropic conductive adhesive 16 ( FIG. 1 b ) is applied between the upper and lower boards 10 , 12 . The anisotropic conductive adhesive 16 consists of a polymer carrier 18 with a matrix of interconnect spheres 20 .
Pressure (arrows 24 ) is applied to the upper and lower boards 10 , 12 ( FIG. 1 c ) forcing the anisotropic conductive adhesive 16 throughout the spaces on and between the boards 10 , 12 , and compressing the interconnect spheres 20 to make the interconnections between the boards 10 , 12 and device connectors or printed circuits or thermal conductors 14 .
Referring now to FIG. 2 , there is shown a schematic diagram of a liquid crystal device (LCD), which is one specific type of microelectronic circuit using anisotropic conductive adhesive fabrication. The anisotropic conductive adhesive 16 with the polymer carrier 18 and spheres 20 has been pressed so that conductor 25 , an example of the upper assembly 10 ( FIG. 1 a ), is interconnected to ITO metallized layer 26 on glass substrate 28 , an example of the lower board 12 ( FIG. 1 a ).
Referring now to FIG. 3 , which is an enlarged view of FIG. 2 showing the contact between a single particle 20 ( FIG. 20 ), the device surface 10 and the board 28 . Voids or pockets 22 ′ of adhesive carrier 16 or contaminants in those pockets 22 ′, such as moisture, keep the heat transfer and electrical conductivity low between the device surface 10 , device connectors or printed circuits or thermal conductors, not shown, and the interconnect spheres 20 .
Referring now to FIGS. 4 a , 4 b , 4 c and 4 d , there are shown two of many shapes onto which nano-structures 50 are attached or grown. FIG. 4 b shows an interconnect sphere 20 with nano-structures 50 , enlarged in FIG. 4 a . FIG. 4 d shows a thermally conductive tube 52 with nano-structures 50 , enlarged in FIG. 4 c.
It should be understood that interconnects and thermal conductors may be made in shapes other than spheres and tubes. Also, it should be understood that shapes other than the flat surfaces shown in diagrams for conductors and circuit boards can be used. And, further, shapes other than the columns shown may be used for the nano-structures.
Typically, the size range of fine particle interconnects and thermal conductors, represented here by a sphere 20 and a tube 52 , are 1 to 20 microns (1.times.10.sup.−6 meter) in diameter.
The nano-structures 50 attached to or grown from the surfaces of spheres 20 and thermal conductor tubes 52 are 1 to 200 nano-meters (1.times.10.sup.−9 meter) in size. The materials the nano-structures can be made from include: carbon, metal, polymers, metallized polymers, electrical and thermal conducting materials and the like; the shapes of these nano-structures include columns, spikes, cylinders, tubes, hemispheres, fibers, regular, and irregular shapes.
Referring now to FIG. 5 , there is shown a schematic diagram of a fabricated circuit with the inventive nano-structures 50 attached to or grown from interconnect spheres 20 or thermal conductor tubes 52 , and inventive nano-structures 50 attached to or grown from boards 10 , 12 . Anisotropic conductive adhesive 16 is disposed throughout the spaces between the boards 10 , 12 . The invention improves the prior art by adding nano-structures 50 to the interconnect spheres 20 , and the surfaces of boards 10 , 12 , which mesh and compress into a more uniform connection 22 ″, thereby eliminating voids, moisture and other contaminants 22 ′″, increasing the contact surfaces 22 ″ for better electrical and thermal conduction.
As the number of nano-structures 50 attached to or grown on the surfaces of boards 10 , 12 , spheres 20 , and thermal conductor tubes 52 are increased by making them uniform and consistently spaced, the thermal conduction and electrical connection are improved.
Additionally, because the interconnect contact surface 22 ″ is increased with the meshing of the nano-structures, improved contact can be achieved with lower pressure (arrows 24 , FIG. 1 c ) applied to the circuit components and circuit boards 10 , 12 , and connections 14 ( FIG. 1 a ) than is required by conventional techniques. Lower pressure results in reduced distortion and less likelihood of damage of the circuit boards 10 , 12 and connections 14 .
Referring now to FIGS. 6 a , 6 b , and 6 c , there are shown schematic diagrams depicting one specific type of fabricated circuit, assembly of a chip 62 to a heat sink 64 , with a thermal plane 60 , shown for the purpose of example. Nano-structures 50 are attached to or grown from a thermal plane interface 60 and circuit chip 62 and heat sink 64 .
Thermal planes 60 may be made of rigid or flexible metal, metallized soft substrate, or any other high thermal conductivity material. Thermal plane shapes may be corrugated waves as shown or any other regular or irregular shape that fits the needs of the circuit fabrication.
Assemblies of circuit fabrication are schematically represented in FIG. 6 b by thermal plane interface 60 and circuit chip 62 and heat sink 64 .
In FIG. 6 c , pressure (arrows 24 ) is applied to the circuit chip 62 and heat sink 64 to make the interconnections between the thermal plane interface 60 and circuit chip 62 and heat sink 64 .
In operation, the nano-structures 50 may be attached to or grown from the surfaces of the spheres 20 , electrical and thermal conductors, device connectors 14 , and other surfaces of circuit assemblies by sputtering, dissolving in highly volatile solution and spray coat, sol-gel, fluidized bed, epitaxial growth, chemical vapor deposition (CVD), precipitations, or any other process that befits the needs of the circuit fabrication.
Referring now to FIGS. 6 d and 6 e , there are shown schematic diagrams depicting an assembly of a heat sink 64 and a circuit element 62 nano-structures 50 grown on filler material particles 80 or heat sink 64 to improve their contact within the anisotropic adhesive system. In contrast to the arrangement of FIGS. 5 , 6 a , 6 b , and 6 c in this arrangement, the filler particles are much smaller than the gap 82 between the package elements 62 and 64 , and therefore, they will cluster together in the wall layer 84 and core layer 86 , and a thermal path requires several particles 80 to bridge the gap 82 .
In FIG. 6 d , nano-structures 50 are attached to or grown from heat sink 64 , and in FIG. 6 e , nano-structures 50 are attached to or grown from filler material particles 82 .
Alternate embodiments of the present invention may be implemented with nano-structures appended to or grown from the surface of any contact surface, such as a flexible card with bowed circuit lands, where the meshing of the nano-structures maintains better contact between the interconnect spheres, thermal tubes, circuit conductors, and components.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims. | The present invention features additions of nano-structures to interconnect conductor fine particles (spheres) to: (1) reduce thermal interface resistance by using thermal interposers that have high thermal conductivity nano-structures at their surfaces; (2) improve the anisotropic conductive adhesive interconnection conductivity with microcircuit contact pads; and (3) allow lower compression forces to be applied during the microcircuit fabrication processes which then results in reduced deflection or circuit damage. When pressure is applied during fabrication to spread and compress anisotropic conductive adhesive and the matrix of interconnect particles and circuit conductors, the nano-structures mesh and compress into a more uniform connection than current technology provides, thereby eliminating voids, moisture and other contaminants, increasing the contact surfaces for better electrical and thermal conduction. | 7 |
[0001] This application claims the benefit pursuant to 35 U.S.C. § 119(e) to U.S. Provisional Patent Application Ser. No. 60/595,997 entitled, “PACKER ELEMENT WITH SUPPORT,” filed on Aug. 23, 2005, which is hereby incorporated in reference in its entirety.
BACKGROUND
[0002] The invention generally relates to a packer.
[0003] Hydrocarbon fluids, such as oil and natural gas, are obtained from a subterranean geologic formation, referred to as a reservoir, by drilling a well that penetrates the hydrocarbon-bearing formation. Once a wellbore has been drilled, the well must be completed before hydrocarbons can be produced from the well. A completion involves the design, selection, and installation of equipment and materials in or around the wellbore for conveying, pumping, or controlling the production or injection of fluids. After the well has been completed, production of oil and gas can begin.
[0004] In such well completion operations, packers are used to prevent fluid flow through an annulus formed by a tubing within the well and the wall of the wellbore or a casing. The packer is generally integrally connected to the tubing, using, for example, means such as a threaded connection, a ratch-latch assembly, or a J-latch, all of which are well known in the art. The tubing/packer connection generally establishes the seal for the inner radius of the annulus. The seal for the outer radius of the annulus is generally established by a deformable element such as rubber or an elastomer. A compressive force is generally applied to the deformable element, causing it to extrude radially outward. The element extends from the outer portion of the packer to the wellbore wall or casing and seals between those structures.
SUMMARY
[0005] In an embodiment of the invention, a packer that is usable with a well includes a resilient seal element and a support member. The resilient seal element is adapted to radially expand in response to the longitudinal compression of the element. The support member is at least partially surrounded by the seal element and is adapted to radially expand with the seal element to support the element. The support sleeve is substantially harder than the seal element.
[0006] In another embodiment of the invention, a technique that is usable with a well includes compressing a resilient seal element to cause the seal element to radially expand. The technique includes in concert with the radial expansion of the seal element, deforming a material that is substantially harder than the seal element to support the seal element.
[0007] Advantages and other features of the invention will become apparent from the following drawing, description and claims.
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 is a schematic diagram of a well according to an embodiment of the invention.
[0009] FIG. 2 is a schematic diagram depicting a seal assembly of the packer of FIG. 1 according to an embodiment of the invention.
[0010] FIG. 3 depicts the seal assembly when the packer is set according to an embodiment of the invention.
[0011] FIGS. 4, 5 , 6 and 7 depict seal assemblies according to other embodiments of the invention.
DETAILED DESCRIPTION
[0012] A packer is a device that is used in an oilfield well to form a seal for purposes of controlling production, injection or treatment. The packer is lowered downhole into the well in an unset state, and once in the appropriate position downhole, the packer is set, which means a seal of the packer radially expands to seal off an annular space. As an example, for a mechanically-set packer, a tubular string that extends from the surface to the packer may be moved pursuant to a predefined pattern to set the packer. For a hydraulically-set packer, fluid inside the tubular string may be pressurized from the surface, to create a tubing pressure differential to set the packer.
[0013] In its set state, the packer anchors itself to the casing wall of the well (or to the wellbore wall in an uncased or open well) and forms a seal in the annular region between the packer and the interior surface of the casing wall. This seal subdivides the annular region to form an upper annular region above the packer that is sealed off from a lower annular region below the packer. The packer also forms a seal for conduits that are inserted through the packer between the upper and lower annular regions. As examples, one of these conduits may communicate production fluid from a production zone that is located below the packer, one of the conduits may communicate control fluid through the packer, one of the conduits may house electrical wiring for a submersible pump, allow production or injection through two different reservoir zones, and so forth.
[0014] FIG. 1 depicts a well 10 (a subterranean or subsea well) that includes a packer 20 in accordance with an embodiment of the invention. The packer 20 may be connected to a tubular string 16 that extends downhole into the well. The packer 20 forms an annulus seal with the interior surface of a wall of a casing string 12 that circumscribes the packer 20 and lines a wellbore 11 . The wellbore 11 may be uncased in some embodiments of the invention. Additionally, the wellbore 11 may be a vertical or a lateral wellbore, depending on the particular embodiment of the invention.
[0015] The packer 20 includes at least one seal assembly 24 to form the annular seal and at least one set of slips 22 to anchor the packer 20 to the casing string 12 . In this manner, when run into the well, the seal assembly 24 and the slips 22 are radially retracted to allow passage of the packer 20 through the central passageway of the casing string 12 . However, when the packer 20 is in the appropriate downhole position, the packer 20 is set to place the packer 20 in a state in which the seal assembly 24 and slips 22 are radially expanded. When radially expanded, the slips 22 grip the interior surface of the wall of the casing string 12 to physically anchor the packer 20 in position inside the well. The radial expansion of the seal assembly 24 , in turn, seals off the annular space between the string 16 and the casing string 12 to form a sealed annular region above the seal assembly 24 and a sealed annular region below the seal assembly 24 .
[0016] In some embodiments of the invention, the packer 20 may be hydraulically-actuated for purposes of controlling the packer 20 from the surface of the well to set the packer 20 . This means that pressure may be communicated through fluid inside the string 16 to the packer 20 . In response to this pressure reaching a predefined threshold level, pistons (not shown in FIG. 1 ) move to radially expand the slips 22 and apply compressive forces on the seal assembly 24 to radially expand the assembly 24 . A retention mechanism of the packer 20 serves to hold the packer 20 in the set state when the pressure that is used to set the packer 20 is released.
[0017] One or more mandrels 21 , or tubular members, may extend through the packer 20 for purposes of providing communicating paths through the packer 20 . Depending on the particular application of the packer 20 , a particular mandrel 21 may contain one or more communication paths, such as paths to communicate production fluid, electrical lines, or control fluid through the packer 20 . For example, in a particular application, a single mandrel 21 may extend through the packer 20 for purposes of communicating production fluid from a tubular string 23 located below the packer 20 to the string 16 located above the packer 20 . However, in other applications, more than one mandrel 21 may be extended through the packer 20 . Thus, one mandrel 21 may be used for purposes of communicating electrical or hydraulic lines, for example, and another mandrel 21 may be used for purposes of communicating production fluid through the packer 20 .
[0018] The packer 20 may be retrievable, and thus may include a release mechanism that when engaged, releases the retention mechanism of the packer 20 to radially retract the slips 22 and seal assembly 24 to permit retrieval of the packer 20 to the surface of the well.
[0019] The packer 20 establishes two general seals: an interior seal between the interior of the packer 20 and the exterior of the one or more mandrels 21 that are extended through the packer 20 and an exterior seal between the exterior of the packer 20 and the interior surface of the wall of the casing string 12 (or the wellbore wall in alternative embodiments). The seal assembly 24 includes a resilient seal element (such as one or more elastomer or rubber sleeves, or rings) for establishing the seal between the packer exterior and the casing 12 (or wellbore wall).
[0020] In general, as the requirements for packer designs tend towards larger and larger inner diameters through the packer, the annular seal element of the packer is forced to become thinner and thinner. Additionally, there may also desire to cover multiple casing weights with one size of packer, leading to larger gaps that must be bridged off by the annular seal element. Bridging off a large gap with a thin element may be very difficult, unless the rubber is supported. Embodiments of the invention that are described herein include a packer that has a resilient seal element, which has a support that is fabricated from a hardened material.
[0021] In the context of this application, a “hardened material” means a material that has a substantially greater resistance to deformation relative to the seal element of the packer. For example, in some embodiments of the invention, the hardened material may be a metal that has substantially more resistance to deformation than an elastomer or rubber material that forms the seal element. Alternatively, in accordance with other embodiments of the invention, the hardened material may be a composite or plastic material, which has substantially more resistance to deformation that an elastomer or rubber material that forms the seal element. Furthermore, in accordance with other embodiments of the invention, the hardened material may be a combination of the above-mentioned materials. Thus, many variations are contemplated and are within the scope of the appended claims.
[0022] As a more specific example, for some embodiments of the invention, the hardened material is a soft metal, such as low carbon steel or copper, in accordance with some embodiments of the invention. However, in accordance with other embodiments of the invention, the hardened material may be a relatively resilient material. For example, in accordance with some embodiments of the invention, the hardened material may be a metallic spring material. Thus, many variations are possible and are within the scope of the appended claims.
[0023] FIG. 2 depicts a more detailed section 50 (see FIG. 1 ) of the packer 20 in accordance with some embodiments of the invention. As shown in FIG. 2 , the packer 20 includes sleeves, or gages 54 and 55 (also called “thimbles”), which are designed to longitudinally compress the seal assembly 24 (which is disposed in between) to radially expand the assembly 24 when the packer 20 is set. It is noted that FIG. 2 depicts the packer 20 in its unset state.
[0024] In general, the seal assembly 24 includes a resilient seal element that may be formed from multiple seal sleeves, or rings, such as upper 56 , middle 60 and lower 64 seal rings. The seal rings 56 , 60 and 64 generally circumscribe the inner mandrel 16 of the packer 20 and may be formed from a rubber or an elastomer material (as examples). It is noted that the seal assembly 24 may include fewer or more seal rings, depending on the particular embodiment of the invention.
[0025] As also depicted in FIG. 2 , the seal assembly 24 may include upper 88 and lower 90 metallic shoes for purposes of minimizing the longitudinal extrusion of the seal element 24 when the packer 20 is set. In the packer's unset state, the upper shoe 88 generally conforms to the upper edge of the seal ring 56 and is located between the upper edge of the seal ring 56 and the upper gage 54 ; and the lower shoe 90 generally conforms to the lower edge of the lower seal ring 64 and is located between this lower edge and the lower gage 55 .
[0026] In addition to the resilient seal element, the seal assembly 24 includes a hardened (relative to the seal rings 56 , 60 and 64 ) support sleeve 80 that is located between the resilient seal element and the mandrel 16 . As a more specific example, as depicted in FIG. 2 , in some embodiments of the invention, the support sleeve 80 may be located (as an example) between the middle seal ring 60 and the outer surface of the mandrel 16 . The support sleeve 80 , which may have a substantially thinner radial thickness than the middle seal ring 60 (before the packer 20 is set), is designed to be radially expanded (and deformed) with the seal rings 56 , 60 and 64 so that the sleeve 80 supports the seal rings 56 , 60 and 64 in their radially-expanded states. Although FIG. 2 depicts the support sleeve 80 as being located radially inside the middle seal ring 60 , in accordance with other embodiments of the invention, the support sleeve 80 may longitudinally extend inside all or part of the upper 56 and lower 64 seal rings (as another example). Therefore, many variations are possible and are within the scope of the appended claims.
[0027] The support sleeve 80 may or may not be bonded to the middle seal ring 60 , depending on the particular embodiment of the invention. For embodiments of the invention in which the support sleeve 80 is bonded to the middle seal ring 60 , all or only part of the outer surface of the support sleeve 80 may be bonded to the inner surface of the middle seal ring 60 . It is noted that depending on the particular embodiment of the invention, the support sleeve 80 may be bonded to all, part or none of the upper 56 and lower 64 seal rings.
[0028] In some embodiments of the invention, the support sleeve 80 includes an annular crimped section 82 at its longitudinal midpoint, which radially extends away from the outer surface of the mandrel 16 . The crimped section 82 configures the support sleeve 80 to bend at the section 82 during the radial expansion of the seal assembly 24 , as depicted in FIG. 3 , which shows a section 95 of FIG. 2 when the packer 20 is set. Referring to FIG. 3 , in the radially expanded state of the seal assembly 24 , the seal rings 56 , 60 and 64 are radially expanded and deformed to at least partially contact the inner surface of the casing 12 . As also shown in FIG. 3 , the support sleeve 80 is also radially expanded and deformed to support the seal rings 56 , 60 and 64 . The shoes 88 and 90 minimize longitudinal extrusion of the seal element, in this state of the packer 20 .
[0029] Referring back to FIG. 2 , in accordance with some embodiments of the invention, the region between the inner surface of the crimped section 82 and the outer surface of the mandrel 16 may be a void space. However, in accordance with other embodiments of the invention, this space may be filled with a seal element that partially or totaling conforms to the boundaries of the space before the packer 20 is set.
[0030] FIG. 4 depicts an exemplary section 100 of another packer in accordance with another embodiment of the invention. The section 100 is to be compared to the corresponding section 95 of the packer 20 . In general, the packer has the same overall design as the packer 20 , except the seal assembly of this packer includes a single seal ring 124 (made from elastomer or rubber, for example) and an inner o-ring 110 behind a support sleeve 112 (made from a hardened material relative to the seal ring 124 ). The support sleeve 112 extends over the entire inner surface of the seal ring 124 . The support ring 112 also includes a crimped section 114 that, in the unset state of the packer 20 , radially extends away from the outer surface of the mandrel 16 . The crimped section 114 creates a void 116 that receives the o-ring seal 110 . Other seals may be located inside the space 116 , in accordance with other embodiments of the invention.
[0031] Referring to FIG. 5 , in accordance with other embodiments of the invention, another packer, which is illustrated by an exemplary section 150 (to be compared to sections 95 and 100 ), includes expandable rings 160 and 178 that are located between the gages and a single seal ring 190 . More specifically, an upper expandable ring 160 is located between an upper gage 154 and an upper edge of the seal ring 190 . The upper gage 154 may include a sloped, or beveled, surface 156 for purposes of slidably engaging with the upper expandable seal ring 160 . Likewise, a lower expandable seal ring 178 may be located between a lower gage 164 and the lower surface of the seal ring 190 . Similar to the upper gage 154 , the lower gage 164 includes a sloped, or beveled, surface 166 for purposes of slidably engaging the lower expandable ring 178 .
[0032] As also shown in FIG. 5 , the packer includes a support sleeve 180 (made from a hardened material) that extends over the entire surface of the seal ring 190 for purposes of providing support to the ring 190 for the set state of the packer. The seal ring 180 includes a crimped section 182 that is predisposed to cause the support ring 180 to radially expand at the section 182 during the setting of the packer, similar to the support rings 80 and 112 that are described above.
[0033] As yet another variation, FIG. 6 depicts an exemplary section 200 of a packer in accordance with another embodiment of the invention. As shown, the packer includes garter springs that are located between the gages and the seal assembly. More specifically, an upper garter spring 210 is located between an upper gage 202 and the upper edge of a seal ring 230 . A lower garter spring 212 is located between the upper edge of a lower gage 220 and the lower edge of the seal element 230 . Additionally, the packer includes a support sleeve 232 (made from a hardened material) that is located over the entire inner surface of the seal ring 230 between the seal ring 230 and the outer surface of the mandrel 16 ; and the sleeve 232 includes a crimped portion 234 to predispose the sleeve 232 to radially expand at the section 234 during the setting of the packer.
[0034] As yet another example, FIG. 7 depicts an exemplary section 250 of a packer in accordance with another embodiment of the invention. The section 250 is similar to the section 50 (see FIG. 2 ) (with like reference numerals being used), with the following differences. In particular, the packer includes support rings 260 and 270 that are located at the ends of the seal assembly 24 for purposes of minimizing longitudinal extrusion of the packer's seal element. The support ring 260 is located between the upper shoe 88 and the upper gage 54 ; and the lower ring 270 is located between the lower gage 55 and the shoe 90 .
[0035] Each of the rings 260 and 270 has a V-shaped cross-section and provides support to minimize longitudinal extrusion of the seal element (seal rings 56 , 60 and 64 ) when the packer is set. More specifically, when the packer is set, the V-shaped rings 260 and 270 each flatten to be substantially horizontal and rise above the gauge diameter, thereby minimizing the extrusion gap and supporting the seal element.
[0036] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. | A packer that is usable with a well includes a resilient seal element and a support member. The resilient seal element is adapted to radially expand in response to the longitudinal compression of the element. The support member is at least partially surrounded by the seal element and is adapted to radially expand with the seal element to support the element. The support sleeve is substantially harder than the seal element. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus and methods for opening perforations in well casings, and more particularly, to a casing section having a plurality of holes plugged with ceramic rupture discs or inserts which can be ruptured by a mild explosive charge.
2. Description of the Prior Art
In the completion of oil and gas wells, it is a common practice to cement a casing string or liner in a wellbore and to perforate the casing string at a location adjacent to the oil or gas containing formation to open the formation into fluid communication with the inside of the casing string. To carry out this perforating procedure, numerous perforating devices have been developed which direct the explosive charge to penetrate the casing, the cement outside the casing and the formation.
In many instances in the completion and service of oil and gas wells, it is desirable to have a method and apparatus whereby perforations can be opened in the well casing string without penetrating the various layers of cement, resin-coated sand or other material located around the exterior of the casing string. Also, in some instances it is desirable to isolate sections of the well casing such that the sections do not have cement or other materials around the exterior of the isolated section. That is, there is cement above and below a casing section but not around it, which leaves an open annulus between the casing and the wellbore and associated formation. It may further be desirable to perforate such a section without the perforation penetrating the formation itself.
The present invention provides an apparatus and method for carrying out such procedures by utilizing a casing section which is plugged with ceramic discs or inserts which can be ruptured in response to an explosive charge detonated within the well casing and adjacent to the ceramic discs.
SUMMARY OF THE INVENTION
The present invention includes an apparatus for opening perforations in a casing string disposed in a wellbore and also relates to a method of perforating using this apparatus.
The apparatus comprises a casing string positionable in the wellbore, the casing string itself comprising a casing section defining a plurality of holes through a wall thereof. The apparatus further comprises a rupturable plug means disposed in each of the holes in the casing section for rupturing in response to impact by a mild explosive force, and explosive means for generating the explosive force in the casing section adjacent to the holes. The explosive force fractures the rupturable plug means and thereby opens the holes so that an inner portion of the casing string section is placed in communication with an outer portion thereof. The rupturable plug means is preferably characterized by a disc or insert made of a ceramic material which will withstand differential pressure thereacross but will fracture in response to impact by the explosive charge.
The apparatus further comprises retaining means for retaining the inserts in the holes prior to rupture of the inserts. The retaining means may comprise a shoulder in each of the holes for preventing radially inward movement of the inserts. The retaining means may also comprise a retainer ring disposed in each of the holes for preventing radially outward movement of the inserts. In another embodiment, the retaining means may comprise an adhesive disposed between the inserts and a portion of the casing string defining the holes. In an additional embodiment, the retaining means may comprise a backup ring threadingly engaged with each of the holes for preventing radially outward movement of the inserts. In still another embodiment, the retaining means may comprise a case threadingly engaged with each of the holes and defining an opening therein, wherein each of the inserts is disposed in one of the openings in a corresponding case. In this latter embodiment, the inserts are preferably shrink-fitted in the openings of the cases, and the retaining means may be further characterized by an adhesive between the inserts and the cases.
The apparatus may further comprise a sealing means for sealing between the inserts and the casing string section. The sealing means may be characterized by a sealing element, such as an O-ring, or may include the adhesive previously described.
In the preferred embodiment, the explosive means is characterized by a length of det-cord disposed along a longitudinal center line of the casing section. The det-cord preferably comprises an explosive present in the amount of about forty grams per foot to about eighty grams per foot, but additional types of det-cord or other explosive means may also be suitable.
The method of the present invention for opening perforations in a well casing may be said to comprise the steps of providing a casing string in the wellbore, wherein the casing string has a section defining a plurality of plugged holes therein, and detonating an explosive charge in the casing string adjacent to the holes and thereby unplugging the holes. The step of providing the casing string preferably comprises plugging the holes with a ceramic material which will rupture in response to detonation of the explosive charge.
The method may further comprise, prior to the step of detonating, a step of isolating the section of the casing string by placing material above and below the section of the casing string in a well annulus defined between the casing string and the wellbore. In one embodiment, this step of placing comprises cementing the well annulus above and below the section of the plugged casing string section.
In the preferred embodiment, the method also comprises placing the explosive charge in the well casing in the form of a portion of det-cord. Preferably, the det-cord is placed on the longitudinal center line of the casing string.
Numerous objects and advantages of the invention will become apparent as the following detailed description of the preferred embodiments is read in conjunction with the drawings which illustrate such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the apparatus for opening perforations in a casing string of the present invention embodied as a plugged casing string section positioned in a wellbore.
FIG. 2 shows a longitudinal cross section of a first preferred embodiment of the casing string section.
FIG. 3 is an enlargement of a portion of FIG. 2.
FIG. 4 is a cross-sectional enlargement showing a second embodiment.
FIG. 5 presents an enlarged cross-sectional view of a third embodiment.
FIG. 6 is a side elevational view of the third embodiment.
FIG. 7 shows an enlarged cross section of a fourth embodiment of the present invention.
FIG. 8 is a side elevational view of the fourth embodiment of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and more particularly to FIG. 1, the apparatus for opening perforations in a casing string of the present invention is shown and generally designated by the numeral 10. Apparatus 10 comprises a casing string 12 disposed in a wellbore 14.
Casing string 12 itself comprises a special casing string section 16 having a plurality of rupturable plug means 18 disposed in holes 19 in section 16. Section 16 is positioned in wellbore 14 such that rupturable plug means 18 are generally adjacent to a well formation 20.
In the illustrated embodiment, an upper column of cement 22 is disposed above plug means 18 and in the annulus between casing string 12 and wellbore 14. Similarly, a lower column of cement 24 is disposed in the well annulus below plug means 18. That is, in the illustrated position of apparatus 10, a generally open annulus 26 is defined between section 16 and well formation 20. Annulus 26 is bounded at its upper end by upper cement column 22 and at its lower end by lower cement column 24.
Referring now to FIGS. 2 and 3, a first embodiment of the apparatus will be discussed. In this embodiment, the casing section is identified by the numeral 16A with holes 19A therein and the rupturable plug means by 18A. Holes 19A in section 16A include a plurality of first bores 28 transversely therein with substantially concentric and smaller second bores 30 radially inwardly thereof.
Plug means 18A is characterized by a cylindrical disc or insert 32 which fits closely within first bore 28 and is disposed adjacent to a shoulder 34 extending between first bore 28 and second bore 30. Shoulder 34 prevents radially inward movement of disc 32. A retainer ring 36 holds disc 32 in place and prevents radially outward movement thereof.
A sealing means, such as an O-ring 38, provides sealing engagement between section 16A and the outside diameter of disc 32.
FIG. 4 illustrates a second embodiment with casing section 16B having holes 19B therein and plug means 18B. Each hole 19B in section 16B includes a first bore 40 with a smaller, substantially concentric second bore radially inwardly thereof. Plug means 18B is characterized by a substantially cylindrical disc or insert 44 which is positioned adjacent to a shoulder 46 extending between first bore 40 and second bore 42. Shoulder 46 prevents radially inward movement of disc 44. As with the first embodiment, a retainer ring 48 is used to hold disc 44 in place, preventing radially outward movement thereof.
It will be seen that the second embodiment is substantially similar to the first embodiment except that it does not use an O-ring for a sealing means. In the second embodiment, a layer of an adhesive 50 is disposed around the outside diameter of disc 44 to glue the disc in place and to provide sealing between the disc and second 16B. Adhesive may also be placed along the portion of the disc which abuts shoulder 46. It will thus be seen that this adhesive assists retainer ring 48 in holding disc 44 in place and in preventing radial movement thereof.
Referring now to FIGS. 5 and 6, a third embodiment is shown which includes special casing section 16C having holes 19C therein and plug means 18C. Each hole 19C in section 16C includes a first bore 52 therein with a smaller, substantially concentric second bore 54 radially inwardly thereof. Each hole 19C also includes a threaded inner surface 56 formed in casing section 16C radially outwardly from first bore 52.
Plug means 18C is characterized by a rupturable disc or insert 58 which is disposed in first bore 52 adjacent to a shoulder 60 extending between first bore 52 and second bore 54. Shoulder 60 prevents radially inward movement of disc 58.
Disc 58 is held in place by a threaded backup ring 62 which is engaged with threaded inner surface 56 of section 16C, thereby preventing radially outward movement of disc 58. Backup ring 64 may be formed with a hexagonal inner socket 64 so that the backup ring may be easily installed with a socket wrench.
In a manner similar to the third embodiment, a layer of adhesive 66 may be disposed between disc 58 and casing section 16C to provide sealing therebetween and to assist in retaining disc 58 in place.
Referring now to FIGS. 7 and 8, a fourth embodiment of the invention is shown including special casing section 16D having holes 19D therein and plug means 18D. In this embodiment, a disc or insert 68 characterizes plug means 18D. Insert 68 is held by shrink fit in a bore 70 of a case 72. A layer of adhesive 74 may be disposed around the outside diameter of insert 68 prior to shrinking case 72 thereon.
Case 72 has an outer surface 76 which is formed as a tapered pipe thread and engages a corresponding tapered pipe thread inner surface 78 which characterizes each hole 19D of casing section 16D. Thus, case 72 prevents radial movement of insert 68 in either direction.
A pair of opposite notches 80 are formed in case 72 and extend outwardly from bore 70. Notches 80 are adapted for fitting with a spanner wrench so that case 72 may be easily installed in inner surface 78 of section 16D.
Preferably, but not by way of limitation, case 72 is made of stainless steel.
In all of the embodiments, the preferred material for discs or inserts 32, 44, 58 and 68 is a ceramic. This ceramic material is provided to first withstand static differential pressure as casing string 12 is positioned in wellbore 14 and other operations prior to perforating. It is necessary to first hold differential pressure so that fluids can be displaced past the rupturable plug means 18 and into the annulus between casing string 12 and wellbore 14. At this point, it is then desired to unplug casing string section 16.
The ceramic material has sufficient strength to permit it to withstand the differential pressures, but its brittleness permits it to be removed by means of impacting with a mild explosive charge. Referring back to FIG. 1, an explosive means 82 is thus disposed in casing string 12 adjacent to plug means 18. In the preferred embodiment, but not by way of limitation, this explosive means is characterized by a length of det-cord 84 connected to a detonating means such as a blasting cap 86. This assembly of blasting cap 86 and det-cord 84 may be positioned in casing section 16 by any means known in the art, such as by lowering it into the wellbore at the end of electric wires 88.
Two examples of det-cord which would be satisfactory are eighty grams per foot round RDX nylon sheath cord or forty grams per foot round HMX nylon sheath cord, although other materials would also be suitable. Therefore, the invention is not intended to be limited to any particular explosive means. Preferably, det-cord 84 is positioned along the center line of casing string 12.
Upon detonation of det-cord 84, the mild explosive force with fracture the ceramic material in rupture means 18. That is, in the various embodiments, discs or inserts 32, 44, 58 or 68 will be fractured and thereby respectively open holes 19A-19D through the walls of corresponding casing string sections 16A-16D. This explosive force from det-cord 84 is sufficient to blow out the discs or inserts but will not cause damage to the surrounding well formation 20.
With each of the four embodiments illustrated herein, rupturable plug means 18 may be installed either at a manufacturing facility or at the well site. Thus, there is great flexibility in preparing the apparatus.
It will be seen, therefore, that the apparatus and method for opening perforations in a casing string of the present invention are well adapted to carry out the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments of the invention have been shown for the purposes of this disclosure, numerous changes in the arrangement and construction of parts in the apparatus and steps in the method may be made by those skilled in the art. All such changes are encompassed within the scope and spirit of appended claims. | An apparatus for opening perforations in a casing string. The casing string has a special casing section defining a plurality of holes therethrough. Rupturable ceramic discs or inserts are disposed in said holes and retained therein. The ceramic discs or inserts are adapted to withstand the fluid differential pressures normally present in the wellbore but are rupturable in response to impact by a mild explosive charge. The explosive charge is provided by detonating a length of det-cord disposed in the casing string adjacent to the holes in the special casing section. A method of perforating using this apparatus is also disclosed. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method and system for designing and ordering printed promotional items such as labels and coupons. In particular, the present invention relates to a method and system for designing and ordering such promotional items by way of the Internet.
BACKGROUND OF THE INVENTION
[0002] Printed promotional items such as labels and coupons are an important mechanism by which manufacturers, retailers and other promoters are able to promote their products. In addition to the common cut-out coupons that are provided in, for example, newspapers, a variety of more specialized types of printed promotional items are now made available in numerous promotional settings. Such printed promotional items need not be strictly limited to promotional items having only one sheet; that is, printed promotional items can be understood to include two or more sheets that are attached to one another, multi-fold promotional items or promotional items with multiple pages.
[0003] Two specialized types of printed promotional items that are commonly utilized today are the “On-Pack” promotional item and the “Off The Shelf” promotional item, both of which have become ubiquitous within retail establishments. The On-Pack promotional item is a two-layer or “two-ply” adhesive label that is affixed to the packaging of a product or a product container. Typically, a top sheet of the On-Pack promotional item has promotional information such as a coupon printed on it, while a bottom or base sheet of the promotional item may be made from a clear or transparent material such as plastic. A dry residue adhesive is employed to attach the top layer to the bottom layer, while the bottom layer is attached directly to the product packaging or container by way of a more permanent adhesive. Through the use of the dry residue adhesive between the top and bottom layers, the top layer can be removed from the bottom layer by a customer without leaving any sticky residue behind on the exposed surface of the bottom layer. Such a coupon is described more fully in U.S. Pat. No. 4,479,838 to Dunsirn et al., which is hereby incorporated by reference herein. In alternate embodiments, On-Pack promotional items can include more than two sheets that are attached together.
[0004] The Off The Shelf promotional item is a it dispenser of sheet items that is made available on a shelf within a store so that the customer can take the sheet items (e.g., coupons) “off the shelf”. Typically, numerous copies of the Off The Shelf promotional item are provided at a particular location in a dispenser or coupon holder. The dispenser of Off The Shelf promotional items is located on or near the particular shelf or shelves at which the products that are the subject of the Off The Shelf promotional items are located. Depending upon the circumstance, Off The Shelf promotional items need not be limited to single-sheet promotional items, and instead can be multi-fold promotional items or multiple-page promotional items.
[0005] Of course, these are just two different types of printed promotional items. There are many others to which the present invention could be applied.
[0006] Promoters wishing to use printed promotional items typically order the promotional items from companies or other parties that print or otherwise manufacture or provide the promotional items (who can generally be referred to as “providers”). Despite the great popularity of printed promotional items such as the On-Pack and Off The Shelf promotional items, certain inefficiencies exist in the process by which new promotional items are designed and then ordered. In order for a provider to produce a promotional item that sufficiently meets the expectations of a promoter, often the provider and promoter must repeatedly communicate with one another and revise the tentative design of the promotional item. There are many variables in the design of printed promotional items, among them, color, font style and size, background design, size, logos, trademarks, layouts, promotion terms, discounts, etc. all of the decisions that must be made to create the artwork, terms, and size of the item. This is particularly the case where the preferences of a given promoter differ from what the promoter has done in the past. Further, the design and ordering process requires a significant amount of bureaucratic work, such as the taking and processing of orders by the provider. It is often difficult to streamline this bureaucratic work, even where a promoter and provider have an ongoing relationship concerning numerous promotional items. Oftentimes many iterations and exchanges of samples are necessary for the promoter to proof and ultimately approve the finished design of the item.
[0007] These inefficiencies in the process of designing and ordering promotional items are significant, particularly since the useful lifetime of any given promotional item is usually short, and since new promotional items can become necessary for any of a number of reasons. For example, new or modified promotional items typically must be generated each time a new product is being offered, or each time the promoter of a product desires to offer new terms of sale, discount or promotion. Consequently, this process of designing and ordering printed promotional items must necessarily be repeated over and over again at a frequent pace.
[0008] Because of the inefficiencies that currently exist in the process of designing and ordering printed promotional items, and because this process must frequently be repeated each time a new promotional item is desired, it would be advantageous if a new, simpler method and system were developed to allow promoters to work with providers in designing, and then ordering, printed promotional items. It would further be advantageous if the method and system provided standardization of the design process, and yet at the same time offered sufficient design flexibility to account for most design preferences of promoters ordering the promotional items. It would additionally be advantageous if the method and system eliminated or streamlined bureaucratic work that currently exists in the process for designing and ordering promotional items. It would further be advantageous if the method and system accounted for ongoing relationships between certain promoters and providers, and thereby further streamlined the process of designing and ordering promotional items with respect to these parties, thereby speeding time to market.
SUMMARY OF THE INVENTION
[0009] The present inventors have discovered a new method and system by which promoters are able to work with providers to design custom printed promotional items by way of the Internet, proof them on their computer terminal screen and place an order. The method and system in particular allows a promoter to establish an account with the provider of the promotional items and, upon establishment of the account, allows the promoter to log in to the account. Once logged in, the promoter is able to interact with web pages in order to design a desired customized promotional item. During this interaction, the promoter is presented with a number of options concerning the type of printed promotional item that is desired and, once a particular type of promotional item is selected, options concerning various features of the promotional item that can be selected by the promoter.
[0010] Additionally, the promoter is required, or presented with an option, to enter specific information where appropriate to complete certain fields or other features within the promotional item. The nature and scope of specialized information that is provided by the promoter will vary depending upon the embodiment or circumstance. For example, in certain embodiments, the information supplied by the promoter will concern only limited, substantive information necessary for setting forth or identifying a promotion, e.g., the expiration date of a coupon. In alternate embodiments, the information supplied by the promoter can more generally concern the form or appearance of the promotional item, e.g., graphic images to appear within a coupon. Once the design and proofing of the promotional item is completed, the promoter is further provided with an order form by which the promoter can order a desired quantity of the promotional items from the provider. Another benefit of the invention is that a method of the invention consolidates all of the promotional item design elements and allows them to be used by geographically disparate users to promote promotion consistency and ease of use.
[0011] In particular, the present invention relates to a method of designing printed promotional items. The method includes providing onto a computer network first information concerning a plurality of possible characteristics of a printed promotional item. The method further includes receiving from the computer network second information submitted by a user customer and concerning a desired characteristic of the printed promotional item. The method additionally includes providing onto the computer network third information concerning a proposed design for the printed promotional item for review by the user customer.
[0012] The present invention further relates to a method of designing and ordering a printed promotional item. The method includes providing a first web page onto the Internet, where the first web page includes at least a first field within which a user customer identity can be specified, and receiving first information including an identifier indicative of a particular user customer identity. The method additionally includes providing a second web page onto the Internet, where the second web page includes a list of different printed promotional items, and receiving second information indicative of a particular printed promotional item selected from the list of different printed promotional items. The method further includes providing a third web page onto the Internet, where the third web page includes at least one of a second field and a list of selectable characteristics, and receiving third information indicative of a specified characteristic for the particular printed promotional item. The third information is one of specified information that was entered by the user customer into the second field and selected information that was selected by the user customer from the list of selectable characteristics.
[0013] The present invention additionally relates to a system for designing and ordering printed promotional items. The system includes processing means for executing a web server application program, storing a set of web pages, and communicating with user customer computers via the Internet. The processing means is capable of sending web page information onto the Internet and is capable of receiving user customer-provided information off of the Internet. The set of web pages includes a web page having information concerning a plurality of possible characteristics of at least one printed promotional item, and another web page including an order form.
[0014] In the description, reference is made to the accompanying drawings, which form a part hereof, and which illustrate examples of the invention. Such examples, however, are not exhaustive of the various embodiments of the invention, and therefore, reference is made to the claims, which follow the description, for determining the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a schematic diagram of a computer network organization, and in particular shows a server providing a site on the World Wide Web (Internet) according to one embodiment of the present invention;
[0016] FIGS. 2 - 8 are exemplary screen displays seen on a user customer's computer in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Referring to FIG. 1, the system of the present invention includes a server computer 10 which is capable of hosting a web site on the World Wide Web of networks (also known as the Internet) and running Sun Solaris, Windows NT, Linux or another compatible operating system 11 . The server computer 10 is owned and operated by, or otherwise hosts the web site on behalf of, a provider (e.g., printer or manufacturer) of printed promotional items. In addition to a stand-alone web site, the invention can be hosted in a larger operation with other web sites, as is well known in the art. Firewalls and other security measures of a type known in the art can be incorporated in the web site, but are not shown.
[0018] Also shown in FIG. 1 are three user customer computers 14 , 15 and 16 , which connect to the server computer 10 through the Internet 13 represented as a group of connected nodes. The user customer computers 14 - 16 are operated by user customers, who are employees of or otherwise represent promoters that wish to work with the provider to design and order printed promotional items. Each of the user customer computers 14 - 16 includes at least one user customer interface such as a keyboard 5 or a mouse 6 , and also includes a display or other output device. The user customer computers 14 - 16 connect to the Internet 13 through modems 7 - 9 , respectively, or other suitable Internet connections of a type known in the art. The user customer computers 14 - 16 use well known browser software such as Microsoft Explorer or Netscape Navigator.
[0019] The server computer 10 runs a web server application program 12 for communicating with the user customer computers 14 - 16 . The web server application program 12 manages application requests, and transmits requested information to the user customer computers 14 - 16 . The web server application program 12 enables the server computer 10 to keep track of which of the user customer computers 14 - 16 is associated with each specific information request, and ensures that the information is properly transmitted.
[0020] The server computer 10 also manages a database 17 , stored in a memory storage device of suitable capacity. The database is managed by a database management program 18 , such as MY SQL or Oracle. In a MY SQL application, the application is configured and characterized by scripts written in PERL to define the database organization and execute database management functions. The MY SQL application also includes certain utility routines. The basic architecture provides a collection of web pages, which are called up and transmitted to the user customer computers 14 - 16 as the computers access the web site. Although a computer network employing a server computer, user customer computers and the Internet is described above, the present invention is also applicable to other types of computer networks, including networks employing wireless communications. It should also be noted that as used herein, a local computer network could be a single computer, or multiple computers.
[0021] Turning to FIGS. 2 - 8 , exemplary web pages or screens 20 , 30 , 40 , 50 , 60 , 70 and 80 are respectively shown, which are downloadable from the server computer 10 at the user customer computers 14 - 16 via the Internet 13 . The web pages 20 - 80 allow user customers representing promoters to design and order printed promotional items from the provider. More specifically, the web pages 20 - 80 provide an interface by which the user customers are able to provide information to the provider concerning the desired features for their printed promotional items, and to submit orders to the provider. The downloading of the web pages 20 - 80 , submission of information to the server computer 10 by user customers interacting with the web pages and other interaction of the user customer computers 14 - 16 with respect to the server computer and the web pages 20 - 80 form steps of a process for designing and ordering the printed promotional items.
[0022] Referring to FIG. 2, one of the user customer computers 14 , 16 is directed by a user customer to download a first web page 20 of the provider's website. The web page 20 provides two fields 22 , 24 into which the user customer can input a user customer name and a password, respectively, in order to log in to the web site operated by the server computer 10 . In an alternate embodiment, another added box is provided that can be checked by new user customers to indicate that they have not previously logged in. Depending upon the embodiment, the web page 20 can also provide various information concerning the provider, other information of interest to promoters, as well as advertisements such as banner ads.
[0023] Upon logging in, a home web page 30 appears, in which the user customer can begin creating a promotion. The home web page 30 , as well as subsequent web pages discussed below, can be tailored in terms of their organization and design to a particular customer as identified by the particular user customer's login and password. Indeed, the available categories, types and formats for promotional items can vary depending upon the customer's needs; that is, a user customer from company A would have a certain set of templates, colors, logos, trademarks, layouts, promotion terms, discounts, type styles and other design elements, which would be different from the set provided to a user customer from company B.
[0024] As shown, the home web page 30 includes a button 32 . Selection of the button 32 by a user customer causes an additional web page 40 (see FIG. 4A) to appear, on which are displayed different possible categories of promotional items that the user customer can design. Also, the home web page 30 includes other buttons such as a Promotional Planning Guide button 34 . The button 34 allows user customers who are not familiar with the system, or who are not familiar with the offerings of the provider that is operating the system, to learn about the various categories of promotional items that are available from the provider. A further set of buttons/links 35 on the web page 30 allows for a user customer to obtain software plug-ins that are useful in interacting with the system. The desired promotional item can be selected by the user customer using the user customer interface devices 5 , 6 .
[0025] Referring to FIG. 4A, upon selection of button 32 , different possible categories of promotional items are listed in a further web page 40 . As noted, the categories of promotional items can be tailored to different customers. In the embodiment shown in FIG. 4A, two available categories of promotional items are available, namely On-Pack promotional items (which are labels) and Off the Shelf promotional items (which are loose sheet items). Typically, these items are used as coupons. Additionally, the web page 40 also provides additional information concerning why a promoter would wish to select a particular type of coupon, as well as some of the common applications for that type of coupon and the common competitive advantages and disadvantages of using that type of coupon.
[0026] In alternate embodiments, other or different categories of promotional items can be available than those shown in FIG. 4A. Such items can include other types of labels or sheet items, game pieces, pop materials (“pop” stands for “point of purchase”), coupons, packaging and regional promotions, recipes, rebates, sweepstakes, or specialized product information. Depending upon the embodiment, the different categories of promotional items can be listed based upon their structural characteristics, the intended purposes of the promotional items, or along other lines. Regardless of the particular manner in which different categories of promotional items are listed, all possible printed promotional items that may be of interest to a given promoter and that are available from the provider should be available upon selecting button 32 .
[0027] Clicking on a button 42 in the web page 40 or on the hyperlinked phrase “Click here to view all of the On-Pack Promotions” causes a subsequent web page 50 to appear, as shown in FIG. 4B. The web page 50 shows specific information concerning the types of On-Pack coupons available to (tailored for) the specific user customer, or such information in a more generic format for all user customers. At least some of these templates preferably include colors, backgrounds, designs, graphics, trademarks, logos, terms and conditions, discounts, typefaces, logos and other design elements which are tailored for the specific user customer, and perhaps provided by the user customer and not accessible by other user customers or user customers of other companies. As shown in FIG. 4B, the On-Pack promotional items category includes, but is not limited to, three different coupon types 44 , 46 , and 48 .
[0028] The web page 50 also provides thumbnail images 45 , 47 and 49 of the different coupon types, as well as information concerning each coupon type's category, description, size, and construction methods (in an alternate embodiment, pricing information is also listed). Further, the web pages 40 and 50 of FIGS. 4A and 4B. respectively, continue to include selectable options 43 (also provided on the home web page 30 ). These include buttons to return to the home web page 30 , the Promotional Planning Guide button 34 , the button 32 (to return to the web page 40 ), and a My Promotions button 41 . The My Promotions button 41 in particular can be selected by a user customer to provide the customer with historical information regarding previous promotional items created by the user customer. In alternate embodiments, additional or different information can be provided on the web pages 40 and 50 other than that shown.
[0029] A user customer chooses to design a particular coupon having one of the available types 44 , 46 or 48 by selecting that coupon type, e.g., by clicking on one of the thumbnail images 45 , 47 , or 49 . Turning to FIG. 5, now that the user customer has selected a particular category and type of promotional item that it wishes to design and presumably order, the web page 60 appears allowing for the input of various specific design features/formats which may be keyed to the specific user. In the embodiment of FIG. 5, the user customer can input information concerning five specific attributes of the particular coupon. In particular, the user customer can input the promotional price or coupon offer in a first field 61 and pre-approved verbiage for the back copy of the coupon in a second field 63 .
[0030] In addition, a company name or a particular design of that name indicative of the promoter or a corporate sponsor of the coupon can be entered in a third field 65 . In addition, for any of these design elements, the user customer may be permitted an option whereby the user customer can import from his local computer network new design features which previously were not stored on the provider's network. More or fewer attributes may be selectable by the user in practicing the invention. These attributes are preferably keyed to the user, or at least some of them are, such as the corporate name, logos, type style, colors, promotion terms and other variables in the design of the promotional items.
[0031] Also, the user customer can specify a desired product image by selecting one of the images provided in a list 67 . The product images that can be selected by the user customer can be any of a number of standardized and pre-defined images showing boxes, bottles, cans, or other common products. In alternate embodiments, the product images in the list 67 are a standard set of graphic images that have been provided by the user customer (or another representative of the promoter) at an earlier time and may be keyed to the user customers, so that other unauthorized users do not have access to them. Tn such embodiments, it is envisioned that some promoters will have an ongoing relationship with the provider and will frequently return to the presently-described website to design and order new or updated coupons. Such promoters would be highly likely to have particular preferences for their coupons that would be repeatedly applicable to successive coupon designs. Providing special lists for these promoters, accessible by them and not by other users, would enable the provider to better satisfy these particular preferences of such promoters.
[0032] Referring still to FIG. 5, a fifth field 69 is provided into which the user customer can input an expiration date of the coupon. Additionally, in an alternate embodiment, it is envisioned that another field is provided into which the user customer can input specific bar code information. Further as shown in FIG. 5, exemplary front and back side views 62 and 64 , respectively, of the coupon are also provided on the web page 60 to show where the information specified by way of the fields 61 , 63 , 65 , 67 and 69 will be positioned on the coupons. Once all of the necessary information has been provided by the user customer, the user customer can submit the information to the server computer 10 by clicking on an Update button 66 . Also, a reset button 68 is provided in case the user customer wishes to delete previous entries in the fields 61 , 63 , 65 , 67 and 69 and begin again. Depending upon the embodiment as well as the category/type/format of promotional item that is being designed, the exact types of information that can be specified by a user customer by way of the fields and list 61 - 69 (or other similar elements For entering information) will differ from that shown in FIG. 5. Also, depending upon the embodiment, as well as upon the category/type/format of the promotional item being designed, certain information can be required, while other information can be optional.
[0033] Referring to FIG. 6, after submission of the information concerning the design of the coupon, the web screen 70 is displayed. The web screen 70 provides a view of how the coupon will appear when printed. Both a front side 72 and a back side 74 of the coupon are provided for proofing by the user customer. If the user customer does not approve of the design of the coupon as shown in the web page 70 , the user customer can return to the web screen 60 to modify the information that was previously input, either by pressing a back button on the Internet browser program or an edit button 76 . Assuming that the user customer approves of the current design of the coupon, the user customer can indicate approval by pressing an accept button 78 in FIG. 6.
[0034] Once the design of the coupon is approved, the web page 80 of FIG. 7 appears, in which the user customer is presented with an order form 82 by which the user customer can order copies of the coupon to be made by the provider. In the embodiment shown, the order form 82 includes a group of ten fields, 84 , for entering information that is necessary for processing the order. Much of this data is pre-populated based on the user customer's data that is captured at the time of login. Specifically, the user customer is requested to make any necessary changes to contact information fields such as the user customer's personal name, the promoter's corporate street address, city, state, zip code, telephone number, fax number, and email address. In addition, file name and department number information is obtained, for identification purposes.
[0035] [0035]FIG. 8 continues web page 80 with specific groups of fields necessary for processing the order. In FIG. 8, fields pertaining to order information 85 , finishing information 86 , and shipping information 87 , are necessary for the production process to begin. Once the information is properly entered, the user customer can submit the order by way of a submit button 89 . If various information must be changed, the user customer can instead select a cancel button 88 . In alternate embodiments, less than all of the information shown in the exemplary order form 82 is required for processing orders and so the order forms in those embodiments do not require as much information as is required by the order form that is shown. Also, in alternate embodiments, additional or different information is required in addition to that shown in FIGS. 7 and 8, such as date needed, and fields for submitting required authorizations, such as for indicating a purchase order number from the customer. In addition, a screen showing terms and conditions of the sale of the promotional items to the user customer may be shown at this time, to which the user customer must agree, by clicking through, before the order is acknowledged. After submitting screen 80 or any required subsequent screens, a screen may be provided by the system which tells the user customer that her/his order has been accepted, or that he/she will be contacted regarding the order.
[0036] The present embodiment of the invention shown in FIGS. 1 - 8 is an exemplary embodiment of the invention as it pertains to certain printed promotional items. The exact number, structure, and relative ordering of the different web pages will vary depending upon the embodiment, and also will vary depending upon the categories, types, and formats of printed promotional items that are available for design and ordering. For example, the information provided on some of the web pages 30 , 40 , 50 , 60 , 70 , or 80 could potentially appear in one or more web pages that appeared prior to the logging in of a customer via the web page 20 , so that prospective customers could get a better sense of how the present system operated. Also, for example, the web pages used in the present system will vary from the web pages 20 - 80 in the case where the printed promotional items being designed or ordered are bumper stickers or hang tags as opposed to On-Pack promotional items.
[0037] Also, depending upon the embodiment, the web pages will allow additional or different functionality than that discussed with respect to FIGS. 2 - 8 . For example, in embodiments where it is not required that user customers log in in order to design and order promotional items, the order form provided in the web page 80 could include an additional field for a credit card number, as well as fields for the name on the credit card and the expiration date of the credit card. Additionally, designs that have been developed by user customers can be saved to disk or other storage devices for later retrieval by the user customers, in addition to being stored by the server computer 10 . In certain embodiments, promoters themselves can have printing devices by which the promoters are able to print promotional items that have been designed using the system. Not all of the steps listed above need to be performed in every case; for example, in a case where a particular promoter has a long-term course of dealings with the provider, it may not be necessary for the promoter to complete an order form.
[0038] Additionally, the information that can be provided in the fields such as those shown in FIG. 5 will vary depending upon the type of promotional item, and can include different or additional information from that shown. For example, the information that can be provided by a user customer can include structural information concerning the number or types of layers of the promotional item, the surface area of the item, and whether the item has a particular scent (e.g., in the case of coupons for fragrances). Also, the information provided by a user customer can include additional substantive information, such as disclaimer information. In most embodiments, templates for standard types of printed promotional items will be available for selection by the user customer, and the user customer will in turn be allowed to specify certain standard design characteristics. These templates and design elements or characteristics can be keyed (i.e., “keyed” meaning that they have access to certain templates, design elements or characteristics which are germain to their product and not ones of other users) into the specific user or a particular group of users, e.g., all of the promotional marketing employees of a particular company who is sponsoring the promotion, who will then be able to design, proof and order printed promotional items for the company's products.
[0039] This has been a description of the preferred embodiments of the method and apparatus of the present invention. Those of ordinary skill in this art will recognize that modifications might be made while still coming within the spirit and scope of the invention and, therefore, to define the scope of the various embodiments of the invention, the following claims are made: | A method and system for designing printed promotional items are disclosed. The method includes providing onto a computer network first information concerning a plurality of possible characteristics of a printed promotional item. The method further includes receiving from the computer network second information submitted by a user customer and concerning a desired characteristic of the printed promotional item. The method additionally includes providing onto the computer network third information concerning a proposed design for the printed promotional item for review by the user customer. | 6 |
This application claims priority from U.S. Provisional Application No. 60/562,844, filed Apr. 16, 2004, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention is directed to garden string trimmers and, more particularly, to a cutting head for string trimmers which can be easily re-strung, and which is designed to minimize breakage of the strings when encountering solid objects.
String trimmers are most often used to cut vegetation along a border of a flower bed or plot of grass which is adjacent to a sidewalk, driveway or other solid structure. Since the cutting head rotates at a speed that makes the strings nearly imperceptible, an operator of the string trimmer is not always able to see that the strings may come into contact with a hard surface and react accordingly. As a result, strings on a string trimmer are commonly broken. Prior art designs of string trimmer cutting heads have attempted to ease the re-stringing process which may be quite time consuming.
One type of prior art cutter head design is generally known as a weave-type head. The latter usually includes an array of grooves and cut-outs in the hub of the cutting head which act to anchor a string therein. An example of this type of cutter head design is disclosed in U.S. Pat. No. 4,190,954 to Walto entitled “Cutting Head” which issued Mar. 4, 1980. This type of cutting head has several drawbacks. First, the grooves and cut-outs include a number of sharp corners which, in time, fray, weaken and break the string disposed therein. Second, a relatively thin string can only be used due to the numerous twists and turns the string must pass through to anchor the string to the cutter head. Third, disassembly of the weave-type cutting head is required to re-string the cutter head with subsequent bending and manipulation of the strings to conform with the grooves and cut-outs formed therein.
A second type of string trimmer cutting head design is generally known as a tap-and-go head. The latter includes a spool of string enclosed within the cutting head, where the string is paid out through peripheral apertures formed in the circumference of the cutting head as required, when the head is tapped against the ground. An example of this type of string trimmer cutting head design is disclosed in U.S. Pat. No. 3,708,967 to Geist, et al. entitled “Rotary Cutting Assembly” which issued on Jan. 9, 1973. This cutting head design also has several drawbacks. A failure near an aperture may cause the end of the string to retract within the cutting head, thus requiring disassembly of the cutter head and re-threading of the string through the aperture. Also, the operator of the string trimmer must carry the weight of an entire spool, including about twenty feet of string, during the course of operation, which for a commercial gardener may be a substantial time and even an entire work day, resulting in a strenuous effort.
The shortcomings of the prior art string trimmer cutting head designs have been overcome by the inventor of the subject invention in a new and improved head for string trimmer which is disclosed in the subject inventor's prior U.S. Pat. No. 5,758,424 which issued on Aug. 23, 1996 and U.S. Pat. No. 5,896,666 which issued on Apr. 27, 1999, both of which patents are entitled “Head for String Trimmer”.
In applicant's above-mentioned U.S. patents, a cutting head for a string trimmer is provided which accommodates discrete lengths of string of any gauge thickness and which may be easily and quickly re-threaded upon failure of a string previously disposed therein. Spring-biased clamping members are provided to clamp the strings within the cutter head, with the clamping force being provided by the springs and possibly supplemented by centrifugally generated force moments. The teachings of applicant's U.S. Pat. Nos. 5,758,424 and 5,896,666 are incorporated in their entirety herein by reference.
As illustrated in FIGS. 1-3 of U.S. Pat. No. 5,896,666, applicant's cutting head design includes a substantially cylindrical body having a disc-shaped base plate formed to define a central drive shaft aperture and a surrounding side wall. A plurality of slots are formed in the side wall with a radially inward extending pressing wall forming one edge of each of the slots. A spring-biased clamping member is pivotally mounted adjacent each aperture, opposite the corresponding pressing wall so that its center of gravity is disposed between the pivotal mounting and the corresponding pressing wall.
The spring-biased clamping members of U.S. Pat. No. 5,896,666 are adapted and formed to generate two degrees of clamping force in cooperation with the corresponding pressing walls. Each spring is provided to generate one degree of clamping force, wherein the clamping force is sufficient to grippingly engage and maintain strings within the cutting head. A second supplemental clamping force is generated with the clamping head being in use in that the rotation of the cutting head creates centrifugal force that acts on the center of gravity of the clamping members and enhances the gripping force thereof.
The spring-biased clamping force of the cutter head of U.S. Pat. No. 5,896,666 is overcome by a string being forcibly introduced from a location outside the cutting head, through the aperture and between the clamping member and the pressing wall, and into the central volume of the head. During operation, the clamping members are rigidly locked into a clamping position from which the supplemental clamping force is generated. Since the discrete strings are threaded through the apertures from a location outside the cutting head, no time-consuming disassembly of the cutting head is required to re-string the cutting head upon failure of a string. An operator of the cutting device, as disclosed in U.S. Pat. Nos. 5,758,424 and 5,896,666, may carry a bundle of strings pre-cut to a pre-determined length which can be easily threaded into the cutting head as needed.
Notwithstanding the outstanding results and efficiencies obtained using the cutting head of U.S. Pat. Nos. 5,758,424 and 5,896,666, depending on the physical characteristics of the string used with the cutting head, stress concentrations may develop at the point where the string is captured within the cutting head (i.e., where the spring-biased clamping member engages the string) as the string contacts a solid object. Repeated stress concentrations could result in the premature breaking of the string.
It is an object of the subject invention to provide a new and improved cutter head which includes means for minimizing or obviating the development of stress concentrations in the vicinity at which the clamping member engages the string when the string contacts a solid object.
It is also an object of this invention to provide a string trimmer cutter head which can be easily and quickly strung with any gauge string of discrete length.
It is yet another object of this invention to provide a lightweight string trimmer cutter head which contains an amount of string needed only for operation.
It is a further object of this invention to provide a string trimmer cutter head which can be re-strung without disassembly or bending and twisting of the string within the cutting head.
SUMMARY OF THE INVENTION
The above-stated objects are met by a new and improved string trimmer cutting head which can be easily and quickly re-strung and is capable of using thin, as well as thick, gauge string.
The subject invention achieves the above objectives by providing, as in the case of applicant's prior U.S. Pat. Nos. 5,758,424 and 5,896,666, a cutting head with spring-biased clamping members which are each mounted within a rotatable housing within the head, such that, as the string encounters a solid object, the clamping member and its associated rotatable housing are rotated about a generally vertical axis so as to obviate or minimize the development of a stress concentration in the string in the vicinity at which it is engaged by the clamping member. The spring-biased clamping members may be pivotally or slidably mounted within the associated rotatable housings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the cutting head of the subject invention with four cutting lines inserted into the cutting head;
FIG. 2 is a top plan view of the cutting head of FIG. 1 ;
FIG. 3 is a side elevational view of the cutting head and strings of FIG. 1 ;
FIG. 4 is a cross-sectional view taken along lines 4 - 4 in FIG. 3 ;
FIG. 5 is a perspective view of a rotatable housing which forms a part of the cutting head of the subject invention;
FIG. 6 is a perspective view of the rotatable housing of FIG. 5 taken from the opposite side thereof;
FIG. 7 is a top plan view of the rotatable housing of FIG. 5 ;
FIG. 8 is a side elevational view of the rotatable housing of FIG. 5 ;
FIG. 9 is a front elevational view of the rotatable housing of FIG. 5 ;
FIG. 10 is a cross-sectional view of the rotatable housing taken along lines 10 - 10 in FIG. 9 ;
FIG. 11 is a front elevational view of a second embodiment of the rotatable housing of the subject invention; and
FIG. 12 is a cross-sectional view of the second embodiment of the rotatable housing of the subject invention taken along lines 12 - 12 in FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-4 , the cutter head of the subject invention is generally designated by the numeral 10 , and is shown with cutting lines or strings 12 extending from the cutter head. Cutting string 12 usually is made of a plastic material, while the cutter head 10 may be made of metal or plastic.
As shown in FIGS. 1 and 2 , each string 12 is of a discrete length, on the order of eight inches, and is generally diamond-shaped in cross-section and includes ridges 14 extending along the length thereof. Each diamond-shaped string 12 is mounted within the cutter head 10 so that a ridged edge 14 of the string engages the vegetation to be trimmed and effectively saws the vegetation. Alternatively, the string 12 may be of circular cross-section and may be various diameters, depending upon the type of vegetation to be cut.
As shown in FIGS. 1-3 , the cutter head 10 includes upper cover 16 , lower cover 18 , and a plurality of posts 20 which are fixedly connected to and maintain the spacing between the upper and lower covers 16 , 18 .
Each discrete length of string 12 is selectively fixedly connected to the cutter head 10 by a rotatable clamp housing 22 . As illustrated in FIG. 1 , each rotatable clamping structure 22 is uniformly spaced about the periphery of the cutting head 10 , intermediate the posts 20 .
Each rotatable clamp housing 22 is rotatable about an axis, designated “a”, extending perpendicular to or generally vertical to the upper and lower covers 16 , 18 . By virtue of the rotation of the clamp housings 22 , should a string 12 contact a rigid structure during the operation of the cutting head, the respective clamp housing 22 will rotate about axis “a”, thereby obviating or minimizing the development of a stress concentration in the cutting string adjacent the connection of the cutting string 12 to the respective clamp housing 22 . When the cutting head 10 is rotating at operational speed, the centrifugal force action on each string 12 will maintain the string in the positions as shown in FIGS. 1 and 2 , until such time as the string encounters a rigid object, at which time the clamp housing 22 will rotate.
As more fully described hereinafter, disposed within each rotatable clamp housing 22 is a spring-biased clamping member of the type disclosed in applicant's U.S. Pat. Nos. 5,758,424 and 5,896,666. Each spring-biased clamping member disposed within a clamp housing 22 is adapted and formed to generate two degrees of clamping force. First, the cam of the clamping member is spring-biased to generate a clamping force which is sufficient to grippingly engage and maintain the string 12 within the rotatable clamp housing 22 . Depending on the design of the cam of the clamping member, a supplemental clamping force may be generated when the cutting head is rotated at operational speed. More particularly, rotation of the cutting head 10 may create a centrifugal force that acts on the center of gravity of the respective cam of the clamping member and thus enhances the gripping force of the clamping member on the string. The cam structure within the clamping member may be pivotally mounted or slidably mounted within the clamp housing 22 , as more fully described hereinafter.
FIGS. 5-10 illustrate various views of a rotatable clamp housing 22 , with FIG. 10 being a cross-sectional view of the rotatable clamp housing 22 . The latter includes a generally cylindrically shaped housing 24 , the lower end of which includes a circular support portion 26 of smaller diameter than the cylindrically shaped housing 24 . Extending from the upper end of the cylindrically shaped housing 24 is a curved tang 28 which provides a stop for limiting the amount of angular rotation of the rotatable clamp housing 22 about the axis “a” within the cutter head 10 .
At the front portion of each rotatable clamp housing 22 is a protrusion 30 including a diamond-shaped opening 32 leading to a passageway 34 which extends completely through the housing 24 for receiving a string 12 .
As illustrated in FIG. 10 , the passageway 34 extends through the housing 24 to the rear opening 36 in order to allow the through passage of the string 12 .
Referring to FIGS. 7 and 10 , disposed within each rotatable clamp housing 22 is a clamping member 40 of the type disclosed in applicant's U.S. Pat. Nos. 5,758,424 and 5,896,666, with the cam 42 of said clamping member 40 being spring-biased by torsion spring 44 and being disposed within the rotatable clamp housing 22 . As shown in FIG. 10 , the pivot axis 46 of the cam 42 is orthogonal to the rotatable axis “a” of the rotatable clamp housing 22 . As shown in FIGS. 7 and 10 , the spring 44 is of the torsion type, although various other types of springs may be utilized in order to provide the spring-biased force of the cam 42 against the string 12 .
During operation of the cutter head, as the cutter head 10 is rotating at high speed, the spring-biased cam 42 clamps the cutting line 12 to the cutter head 10 .
As illustrated in FIG. 4 , each rotatable clamp housing 22 is mounted within the cutting head 10 with the circular support portion 26 being rotatably supported within circular opening 50 provided in the lower cover 18 . The curved tang 28 of each rotatable clamp housing 22 is accommodated in a curved recess 52 within the upper cover 16 , with the curved recess 52 extending about 180 degrees, thus enabling the rotatable clamp housing 22 to be rotated 90 degrees about axis “a” in either direction from the neutral position as shown in FIG. 1 .
As in the case of applicant's trimmer head as disclosed in U.S. Pat. Nos. 5,758,424 and 5,896,666, the passageway 34 extends completely through the cylindrically shaped housing 24 . Hence, should a string 12 be broken during operation of the cutter head 10 , it can be readily pushed radially inwardly and through rear opening 36 to the central volume 60 within the cutter head 10 in order to extract the string 12 from the cutter head, and enable a new string 12 to be loaded into the trimmer head via opening 32 .
The volume 60 which is radially inward of the rotatable clamp housings 22 enable the latter to be rotated through a range of 180 degrees, without the string 12 contacting the inner surface of the cutting head 10 .
As illustrated in FIG. 4 , the upper cover 16 includes drive shaft aperture 70 for receiving the drive shaft of a motor (not shown) for powering the cutter head.
During operation of the cutter head 10 , a string 12 is inserted through opening 32 and through the passageway 34 and out of the rear opening 36 . At such time, one end of the string 12 is engaged by the spring-biased clamping member 40 and is maintained in that position during rotation of the cutting head. The distal end of the string 12 which extends out of the rear opening 36 of the rotatable clamp housing 22 is disposed in the central volume 60 of the rotatable clamp housing 22 . Hence, if a string 12 breaks during operation of the trimmer head, the operator turns off the machine and pulls on the radially inner distal end of the string 12 through volume 60 in order to remove the broken string preparatory to insertion of a new string 12 through the opening 32 in the protrusion 30 .
As illustrated in FIGS. 4 and 10 , spring-biased cam 42 is pivotally mounted about axis 46 that extends generally parallel to the planes of the upper and lower covers 16 , 18 . Cam 42 includes teeth 48 for gripping the cutting line 12 , and for preventing the cutting line or string 12 from being pulled out of the rotatable clamping structure 22 through the diamond-shaped opening 32 . The cam 42 is spring-biased and cooperates with the opposing pressing wall 34 A (see FIG. 10 ) within the passageway 34 of the rotatable clamp housing 22 to clamp the string 12 within the clamp housing 22 . Preferably, each cam 42 is pivotally mounted about generally horizontal axis 46 such that the center of gravity of the cam 42 is disposed between the pivot axis 46 and the pressing wall 34 A. The construction and operation of cams 42 generally correspond to the operation of the cam structure in applicant's prior U.S. Pat. Nos. 5,758,424 and 5,896,666.
In operation, if a cutting string 12 should contact a rigid object, the rotatable clamp housing 22 would react by rotating about the circular support portion 26 within the circular opening 50 , and the tang 28 would slide within the curved recessed opening 52 in the upper cover 16 , with the rotation of the rotatable clamp housing 22 thereby minimizing the development of a stress concentration in or breaking of the string 12 in the region where the string engages the rotatable clamp housing 22 .
Should a cutting line 12 be broken, it is merely necessary for the user to turn off the trimmer and rotate the rotatable clamp housing 22 in order to pull the broken string through the rear opening 36 and out through the volume 60 .
FIGS. 11 and 12 illustrate an alternate embodiment of a clamping member disposed within the rotatable clamp housing 22 . Instead of being pivotally mounted, the cam 80 is slidably mounted in a guide structure 82 and is biased by a compression spring 84 into engagement with the string 12 .
Although the cutting head illustrated in FIGS. 1-10 includes four cutting strings 12 , the subject cutting head may also be operated with only two diametrically opposed cutting strings.
As is readily apparent, numerous modifications and changes may readily occur to those skilled in the art and, hence, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modification equivalents may be resorted to falling within the scope of the invention as claimed. | A cutting head for a string trimmer is provided which accommodates any string gauge thickness and may be easily and quickly re-threaded upon failure of a string previously disposed therein. The cutting head has spring-biased clamping members which are each mounted within a rotatable clamp housing within the head, such that, as a string encounters a solid object, the clamping member and its associated housing are rotated about a generally vertical axis so as to obviate or minimize the development of a stress concentration in the string in the vicinity at which it is engaged by the clamp housing. | 0 |
FIELD OF INVENTION
The present invention concerns a method for the renewal of a railroad switch or crossing as well as a train for carrying out the method.
PRIOR ART
When renewing a railroad track, renewal of the railroad devices, for example switches or crossing, represents a quite considerable and relatively complicated job, for the railroad devices are very bulky components in respect of their width, and handling them poses problems. At the present time, the work of laying/removal and shifting of the railroad switches or crossings is carried out mainly in two ways.
(1) By cranes moving along the parallel track.
(2) By gantries running on a service track placed under the railroad switch or crossing which has been lifted beforehand.
In both cases, displacement of the switch or crossing is performed in a plane parallel to the plane of the track, and the track alignment gauge is exceeded considerably. Further, in the first case the cranes block the parallel track to traffic, and in the second case a large crew is needed to lay the service track under the lifted switch or crossing and to operate several gantries.
SUMMARY OF THE INVENTION
It is the object of the present invention to eliminate these disadvantages by proposing a method and a train for carrying out the method allowing a railroad switch or crossing or a part thereof to be laid or removed without blocking the parallel track to traffic by moving machines such as cranes along it, and offering the possibility of keeping within the track alignment gauge during displacement of the railroad switch or crossing which has been removed or is to be laid.
The method according to the invention is characterised by the fact that side rails are disposed on both sides of the railroad switch or crossing, said switch or crossing or a part thereof is raised by means of a girder suspended by its ends from two cranes, at least one of which is provided with means for running along the side rails and which are disposed on the ends of two track sections connected by said switch or crossing, the switch or crossing is moved to the site of dismounting, and the new railroad switch or crossing is supplied and laid by means of the girder and two cranes.
The advantages of the method which is the subject of the present invention are connected on the one hand with the fact that the cranes are located on the track containing the railraod switch or crossing, thus leaving the parallel track free for traffic, and on the other hand with the fact that the side rails which are installed on both sides of the railroad switch or crossing and the adjacent sections of the ordinary track facilitate renewal end ensure good stability on account of their gauge.
Preferably, according to one variant of the method, before transporting the lifted switch or crossing it is tilted about an axis at least approximately parallel to the longitudinal axis of the track in such a way that the track alignment gauge is observed and the parallel track or tracks are free for traffic.
Of course, the new switch or crossing is transported in the same way from the depot site to the site of laying.
According to one variant, after removal of the switch or crossing the side rails are joined together by spacer bars at normal gauge in order to allow cleansing of the ballast and/or road bed by maintenance machines known in the art.
The invention likewise concerns a train for carrying out the method characterized by the fact that it includes two cranes mounted on running gear suitable for running along the railroad, and a girder provided with gripping means for the railroad switch or crossing and suspended by its ends from the two cranes, and at least one of the cranes is provided with means for moving along side rails disposed on both sides of the railroad switch or crossing. Preferably, the two cranes are provided with means for tilting the lifted switch or crossing by rotating it about a longitudinal axis approximately parallel to the plane of the track.
According to one variant, the same means which are used for movement along the side rails and which are preferably supported orientable in the plane of the chassis and provided with bogies, are also provided with track lifters for laying side rails.
Apart from the above-mentioned advantages, the method and the train for carrying out the method also allow the number of persons in the crew entrusted with the operations of renewal of the railroad switch or crossing to be restricted to a minimum, most of the operations being performed by mechanical means.
Furthermore, the bogies for running along the side rails are also adaptable to run along the ordinary track, which allows stability of the cranes to be increased when transporting a railroad switch or crossing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail with the aid of attached drawings concerning a preferred embodiment of the invention.
FIG. 1 is a schematic side view of a renewal train.
FIG. 2 is a plan view of a track with a switch or crossing and the side rails.
FIG. 3 is a view similar to the preceding one, with the switch or crossing removed and the side rails assembled at normal gauge.
FIG. 4 is a side view showing in greater detail the crane provided with the means for moving along the side rails and part of the girder.
FIG. 5 is a plan view of the preceding figure.
FIG. 6 is a view parallel to the axis of the track, showing a lifted and tilted switch or crossing.
FIG. 7 is a side view of part of one of the bogies of one of the supports.
FIG. 8 is a front view of the part shown in the preceding figure.
FIG. 9 shows from the front the girder and the means for gripping the switch or crossing.
FIG. 10 is a side view of the view according to FIG. 9,
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The renewal train illustrated in FIG. 1 includes a first crane 1 mounted on a chassis 2 provided with the gear 3 for running on the track 4, a second crane 5 mounted on a chassis 6 and provided firstly with gear 7 for running on the track 4 and secondly with bogies 8 for running on the side rails 9, and lastly a girder 13 suspended by its ends from the two cranes 1 and 5. The side rails 9 are disposed on both sides of the switch or crossing 10 and adjacent sections of the track 4, that is, those connected by the switch or crossing 10 (FIG. 2). The bogies 8 are fixed to the ends of supports 11 articulated to the chassis 6 of the crane 5. The girder 13 is provided with gripping means 14 in the form of lifting beams for gripping the switch or crossing 10 to be lifted.
FIG. 3 shows the track 4 without the switch or crossing 10, and the side rails 9 at the site of the switch or crossing being shifted to normal gauge 9' and joined together by spacer bars 9" to ensure continuity of the track and allow cleansing of the ballast and/or road bed by known machines.
The cranes 1 and 5 are each provided with a telescopic jib 15 equipped with an auxiliary winch 16 and a cable 17, as shown only for crane 5 (FIGS. 4 and 5), allowing tilting of the lifted switch of crossing as will be described below. The crane 1 or 5 is mounted on a 360° turntable 12. At least one of the two sets of running gear 3 and 7 is provided with drive means to allow movement of the train along the track 4.
In the example under consideration, only crane 5 is intended and equipped to run on the side rails 9 and will therefore be described in detail.
The chassis 6 of the crane 5 is provided at its ends with four supports 11 and 11' articulated to the chassis 6 by spindles 18 perpendicular to the plane of the chassis 6. The angular position of the supports 11, 11' in the plane of the chassis 6 is provided by hydraulic actuators 20 (FIG. 5), one actuator 20 being provided per support. From the free ends of the four supports 11, 11' are suspended by actuators 19, bogies 8 suitable for running on the side rails 9, at least one of these bogies being provided with drive means M (FIG. 7).
When the crane 5 moves along the side rails 9, the supports 11 and 11' are opened out, the bogies 8 come into contact with the side rails 9 by means of suspension-type actuators 19 simultaneously allowing lifting, if necessary, of the running gear 7 relative to the track 4. Basically, a pair of supports located on the same lateral side of the chassis 6, for example 11', are locked in a set angular position, while the other pair 11 remains free in order to be able to follow the variations in gauge of the side rails 9, particularly at the location of the switch or crossing 10.
The gripping means 14 of the girder 13 formed by lifting beams are provided with hooks 21 for gripping the switch or crossing 10, as shown in FIGS. 6, 9 and 10. In FIG. 6 is shown a railraod switch or crossing 10 lifted and tilted in such a way that it remains within the track alignment gauge G.
The girder 13 is suspended from the loose pulleys 22 of the cranes 1 and 5 by joints 23 (FIGS. 9 and 10) allowing tilting of the girder 13 about an axis parallel to the plane of the track 4. Tilting is obtained by the action of the cable 17 of each crane 1, 5 attached to a point 24 of a lifting beam 14, offset from the axis defined by the two suspension joints 23 of the girder 13, and driven by the auxiliary winch 16. This same cable 17 allows, during lifting of the switch or crossing 10, balancing of the load in a plane approximately parallel to that of the track 4.
In order to avoid deformation of the switch or crossing 10, several extensible lifting beams 14 are provided, with adjustable width for adaptation to the gauge of two non-parallel rails. The hooks 21 (FIG. 9) are positioned at the desired gauge by worms 27, to allow gripping of the switch or crossing 10 or the release thereof.
To allow laying of side rails 9 (FIGS. 7 and 8) the bogies 8 of the supports 11, 11' are provided with track lifters 25 driven by a double-acting cylinder 26. These lifters allow laying of the side rails on both sides of the railroad track as well the removal thereof on completion of the work.
In FIG. 7 is shown a bogie 8 provided with a motor M ensuring drive of the crane over the side rails 9.
Operation of the train according to the method is as follows: the train arrives along the track 4 at the site of the switch or crossing 10, laying the side rails 9 on both sides as it proceeds. In the example illustrated in FIG. 2, the train approaches from the left (in the direction of the arrow F), and during this time the two cranes 1 and 5 run over the ordinary track 4. When the girder 13 is above the railraod switch or crossing 10, the bogies 8 are lowered by the suspension type actuators 19 so that they are supported on the side rails 9 and so as to lift simultaneously the chasis 6 with its running gear 7; then the switch or crossing 10 is dismounted from the rest of the track 4, raised with the girder 13 and two cranes (FIGS. 4 and 5), and tilted by means of the winches 16 (FIG. 6). The train leaves in the direction in which it arrived (to the left in FIG. 2) and the crane 5 traverses the region of the switch or crossing which has been removed by running exclusively along the side rails 9 by means of supports 11, 11' provided with bogies 8 until the region from which the switch or crossing 10 has been removed has been crossed, then the crane 5 can be lowered in such a way that its running gear 7 is in contact with the ordinary track 4, and the supports 11, 11' and bogies 8 return to their rest position. The supension-type actuators 19 allow accommodation of the variations in height of the service track formed by the side rails.
In theory, the switch or crossing 10 can be dismounted or lifted while the crane 5 is resting on the ordinary track 4 by its running gear 7, and after the switch or crossing 10 has been lifted and is ready to be transported the bogies 8 are placed in contact with the side rails 9. Naturally, if this last operation is performed before dismounting of the switch or crossing 10, it allows the stability of the crane 5 to be increased.
The new switch or crossing is supplied to the site of the old one in the opposite direction and by the reverse operations. In the meantime, the ballast and/or road bed has been cleansed by maintenance machines known in the art. To do this, the side rails 9 can be joined together (FIG. 3) at normal gauge 9' to allow movement of the cleansing machines. After the cleansing work, the side rails 9 are moved apart to allow the train with the new switch or crossing 10 to travel over the region from which the switch or crossing has been removed, by means of supports 11, 11' and bogies 8, and to stop above said region. In fact, since it is genrally prohibited, for obvious reasons of safety, to work under the suspended switch or crossing 10, the side rails 9' ought to have been moved apart before the arrival of the new switch or crossing 10, so the service track cannot be used at normal gauge 9' to allow traversing of the region from which the switch or crossing 10 has been removed.
Of course, the other crane 1 or both cranes 1 and 5 may be provided with supports 11, 11' to carry out this work.
If both cranes 1, 5 of the train are provided with means 8, 11, 11' for moving along the side rails 9, the arrival and departure of the train may take place in any direction. On the other hand, if only one crane is provided with these means, as in the embodiment described above, departure of the train with the swtich or crossing 10 must take place in such a way that the crane 1, which is not equipped to run along the side rails 9, is at the front, for it cannot traverse the track region in which was located the lifted switch or crossing 10.
Obviously, if the switch or crossing 10 is very long, it can be removed and the new one supplied by dismantling it into two or more parts. In this case, it is necessary for both cranes 1,5 to be adapted to run along the side rails 9 in order to be able first of all to remove all the parts of the switch or crossing 10 before supplying the parts of the new switch or crossing, for in this case the distance between the two cranes 1 and 5 is less than the total length of the switch or crossing 10.
To allow the stability of the train to be increased when moving along the ordinary track with the lifted switch or crossing, the bogies 8 may be constructed in such a way that they can also run on the rails of the ordinary track 4. For this, the angle of the supports 11, 11' is modified by the actuators 20 in such a way that the bogies 8 are perpendicular to the rails of the track 4, and by the suspension-type actuators 19 they are lowered onto the rails of the ordinary track 4. | A train for carrying out the renewal of a railroad switch or crossing in a track comprises two chassis with a girder between them supported by two cranes on the respective chassis. Cross beams on the girder have hooks for gripping the switch or crossing. The girder is suspended from the cranes by rotary joints and an auxiliary winch has a cable connected to the switch or crossing off-center to provide for tilting the switch or crossing. At least one of the chassis is provided at its four corners with articulated arms and extensible columns provided with bogies for running on side rails. The arms can be swung in so that the bogies can run on standard gauge track. | 4 |
FIELD OF THE INVENTION
The present invention relates to sprinklers for irrigation purposes and more particularly to robotic sprinklers programmable to accurately cover irregular shaped areas.
BACKGROUND OF THE INVENTION
In the past, water has been a plentiful and inexpensive commodity; however, it is becoming increasingly scarce and more expensive. Accordingly, past sprinklers utilized techniques to approximate uniform coverage by overlapping circles and sectors of circles, rectangular shapes and more recently irregular shapes; however, the previous art until the present invention, has failed to address the shortcomings of the underlying approach in dispersing the water. Whether they are impact, rotary or oscillating sprinklers, all known sprinklers attempt to produce a more or less uniform linear cord of spray and to advance this linear cord in a straight or circular path generally perpendicular to this cord. Furthermore, to generate these uniform cords of spray, water streams are impinged upon objects or forced through small openings to generate small droplets and mist uniformly distributed along the length of the cord.
This method creates a wide range of droplets sizes ranging from large drops to a fine mist with the larger drops traveling the greatest distance and the smaller drops decelerating quickly and falling short as a result of their respective aerodynamics. Even recent sprinklers which claim to cover irregular shapes still use a uniform cord of water adjusted in length by changing the elevation angle (range) or lowering a shield in front of the stream thereby breaking the entire stream into mist. The mist is generally lost by drifting in winds and evaporating.
Furthermore, with these small droplets, it is necessary to thoroughly saturate the organic lawn material until water can agglomerate into large droplets which make their way down to the soil. All the while, the organic matter is maintained in a saturated condition over essentially the total area which further increases evaporation. Ultimately, most water left in surface vegetation is lost to evaporation instead of being taken in by the roots. Losses are further increased because particles of small aerodynamic diameters drift and are difficult to accurately direct to the lawn.
The second aspect of efficiency which the present invention resolves is precise pointing. It is this precision which is most obvious to the user and consequently represents his main advantage. Perhaps the most undesirable characteristic of a watering system is for water to strike a building, walk, street or other unwanted area. For irregular shaped lawns, to avoid striking unwanted areas the water source must be located at many locations. For buried systems this means many separate heads and consequently more cost. For portable systems, this means moving the sprinkler many times and consequently more wasted user time and more inconvenience.
As an example of control difficulties, a commercial embodiment of U.S. Pat. No. 4,637,549 utilizes the lowered screen to prevent excessive range by disintegrating large droplets. In addition to the increased evaporation as previously described, the stream is diverted into a 30 or 40 degree wide wedge which by the manufacturer's own admission makes tight control impossible. Other patents cite controlled coverage as their advantage; however, it is the failure of these devices to address the fundamental deficiencies of the control method which defeats these attempts.
U.S. Pat. No. 2,757,956 which departs considerably from the other references falls far short of the performance of the present invention. While Salminen teaches improved efficiency by providing rectangular patterns to prevent the required overlapping of circles, he specifies a device which is inherently inefficient. To obtain zero range, his device discharges water vertically upwards. This produces maximum evaporation, dispersion and potential for aiming error. Only a slight breeze or aiming error will cause the trajectory to vary greatly from the desired target. He addresses only the inefficiency of overlapping circular areas but fails to observe the need to follow irregular boundaries while eliminating multiple sprinklers and providing precise aiming. The complex needs of the field of this invention are not obvious and until the present invention have evaded a solution.
It is precision in range and precision in azimuth which the present invention provides to overcome these problems. Precision is provided in azimuth by the radial, non-rotary, action of the present invention. By indexing azimuth in narrow bands of approximately 3 to 6 degrees, and using a "power nozzle" with a comparable angle of dispersion, the present invention produces sharp cuts in azimuth. And due to the discrete stationary azimuth positions, the device can go from minimum range to maximum range and, vice versa within one azimuth increment. By the use of variable range angle and/or variable water pressure, the present invention provides a maximum to minimum radius (or "turn down ratio") of 5:1 or greater. In actuality, by varying the water pressure to a bubble tight shut off in several embodiments of the invention, the device can completely eliminate water coverage to any desired azimuth positions.
A valve linked to the range setting within the present invention decreases pressure at close in ranges. This has the combined effect of eliminating the damaging water blasting of close-in vegetation, decreasing the total water applied to the proportionally smaller close in areas, and decreasing the range simultaneously. This produces tight radial control and uniform watering.
A further embodiment of the present invention is provided by the addition of a second site specific data base. This data base contains information regulating the minimum desired range. The combination of the maximum range and this minimum range at site specific azimuth angles and a tight shut-off valve provides a discontinuous, point watering, system. This point watering system waters discrete trees, shrubs gardens and architectural landscapes. While existing drip watering and root watering systems provide this precision, they do it at extensive cost and extreme inflexibility to change the pattern of water distribution.
This apparatus and control system lends itself equally to above ground or buried, "pop-up" sprinkler systems. Within the latter version, the base is designed to be buried and a piston device is interstitially configured between the base and the azimuth rotor.
The embodiments of the present invention thereby provide a water powered, articulated, actuation and control system which aims a precision, power jet, consolidated water stream to all coordinates within a polar coordinate system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top plan view of the present invention and its operative relationship to an irregular area and a building structure;
FIG. 2 is a part sectional elevation of a water sprinkler according to the present invention with portions rotated and spaced apart for clarity;
FIG. 3 is a side elevation of an embodiment of the invention with parts broken away;
FIG. 4 is a schematic top plan view of an embodiment of the present invention in accordance with the spot watering embodiment and its operative relationship to an irregular area and a building structure;
FIG. 5 is a part sectional view of the embodiment of the present invention in accordance with the spot watering embodiment;
FIG. 6 is a part sectional detail of an embodiment of the range rotor assembly incorporating a slide valve into said assembly;
FIG. 7A is a side view detail of an embodiment of the range rotor assembly incorporating a pinch valve into said assembly, showing the apparatus in a maximum range position;
FIG. 7B is a side view detail of an embodiment of the range rotor assembly incorporating a pinch valve into said assembly, showing the apparatus in a minimum range position; and,
FIG. 8 is a part sectional detail of the azimuth rotor assembly in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 there is illustrated a robotic sprinkler apparatus 10 for watering irregular shaped lawns 100 shown bordered on the sides by residence 101, drive way 102, street 103, and area of low water consuming plants 104. The structure, actuation means and controls combine to define a polar coordinate system with the apparatus 10 forming the pole, the nozzle direction defining the azimuthal coordinate 105 and the variable trajectory of the water defining the range coordinate 106.
The preferred embodiment establishes uniform water coverage by indexing uniformly in azimuth by the indexing angle 107 and directing the trajectory of a stream of water emitting from the nozzle to advance uniformly from one radial extreme to the other at that azimuth. Zero range is at apparatus 10 and the azimuth specific maximum range 106 is defined by the intersection of the radial path of the water and the irregular boundary of the watered area. Thus, lawn 100 is uniformly covered by wedges of water, azimuth indexing angle 107 wide by azimuth specific maximum range 106 long.
It is appreciated that for uniform water coverage, the dispersion angle of the nozzle must correspond to the azimuth indexing angle 107 of the apparatus. And further, to maintain uniform water coverage, watering time and/or watering flow rate must increase proportionally as range increases. The present invention is shown later to do this.
The maximum range of radial path 108 varies as a function of azimuth orientation and the preset, site specific data stored within apparatus 10 for the respective azimuth direction, as will be later shown. Azimuth extremes 109, 110, 111 and 112 likewise are site specific and defined by various control means as will be later shown. In that there is no preset zero azimuth stored within the device, this setting is site specific and to be set by the user or the unit is left to index in the same direction through 360 degrees and repeat continuously.
An alternate embodiment which is not shown in the present patent is the rearrangement of elements to establish uniform water coverage by uniformly indexing range while advancing azimuth to form uniform arcs with site specific extremes. This embodiment can produce equally desirable operation but is not preferred due to increased data storage.
Reference is now made to FIG. 2 which schematically illustrates an embodiment of the present invention generally identified at 10 and operating in accordance with FIG. 1. The embodiment is comprised generally of a nozzle assembly 11 rotatably mounted in a vertical, range, plane upon azimuth rotor assembly 13 which is rotatably mounted in a horizontal azimuth plane upon base assembly 12.
Base assembly 12 is comprised of water connection means 43, water communication means 44, anchors 42, azimuth indexing pins 45 and programmable range stops 46. Said base assembly is typically, though not necessarily molded of plastic with azimuth indexing pins 45 and anchors 42 an integral part of the assembly. However, by definition, said programmable range stops 46 are mounted within holes formed within the base and having adjustable heights relative thereto. It is this variable height relative to the base that forms a mechanical, erasable, programmable, read only memory which is analogous to an "EPROM" within electrical programmable controllers. This user stored site specific data provides range information to the control system which controls the maximum boundary outline of the area to be watered.
Azimuth rotor 13 is rotatably mounted to base 12 on azimuth bearing 15 which is comprised, generally, of two hollow cylindrical members concentrically related and provided with thrust resistant sealing means. These bearings are typical of all known rotary sprinklers and can be constructed of plastic or metal or a combination of both. Water communication means 27 A and B connect index bearing 15 with range bearing 14 for the communication of pressurized water there between. Range bearing 14 is identical to index bearing 15.
Valve 18 is interstitially located between high pressure water communication means 27A and controlled pressure water communication means 27B to control the discharge pressure of nozzle 19 while maintaining high pressure control water to needle valve 47 with its inlet positioned to communicate with high pressure water communication means 27A, and its discharge communicating with hydraulic passage 36. Hydraulic passage 36 thereafter, communicates with range control actuation means 22, cycle reset actuation means 33, and azimuth control actuation means 29, each with their respective return springs 16, 35, and 30. Venting valve 23 is also in communication with hydraulic passage 36. Venting valve 23 is similar to a typical Schrader valve common in tire and inner tube valve stems. This valve is shown without its typical closure spring for clarity. Advantage is taken of the plurality of actuation means to closely sequence operations as will be described later; however, in consideration of the practical need to limit wetted parts, subsequent embodiments illustrate the limiting of the number of actuation means to a single member. Obviously, then, the total number of actuation means is not critical.
Linkage 28 is a lever fixed at one end to valve 18 and rotatably pinned at one end of compressive linkage 20 which is slidably engaged to cam 38. Linkage 20 is rotatably pinned at a central location to linkage 34 also rotatably pinned to to azimuth rotor assembly 13 to form a four bar linkage in order to control the rotational position of linkage 20. Linkage 21 is rotatably pinned to range rotor assembly 11 at its upper end and to range control actuator means 22 at its lower end. Linkage means 31 is fixedly connected to range rotor assembly 11 at its shown left end and rotatably pinned to one end of linkage 39 which is rotatably pinned to the upper end of linkage 48 which slidably engages linkage guide 57A which is aligned to direct linkage 48 to strike range stop 46.
Pawl 17 is rotatably pinned to azimuth rotor assembly 13 and driven by compression spring 49 to rotate clockwise into engagement with azimuth indexing pins 45 in a manner to override said pins as rotor assembly 13 rotates clockwise as viewed from above and to bind on said pins as rotor assembly 13 attempts to rotate counterclockwise. In like manner pawl 26 is rotatably pinned to azimuth control actuator means 29 and driven by compression spring 31 to engage said pins 45 when actuator means 29 extends and override pins 45 when actuator means 29 withdraws. Said elements combine to form a ratcheting mechanism for indexing azimuth.
Linkage 20 is rotatably pinned at its upper end to actuator means 29 and at its lower end to sear 24 in such a manner to cause clockwise rotation of sear around pin 40 as actuator means 29 extends. This brings sear 24 into interference with the path of the linkage lower extreme. It is appreciated that sear 24 must be suitably flexible to override as linkage 25 passes but rigid enough to sustain engagement of hooked end until actuator means 29 withdraws.
Compression spring 32 is rotatably pinned at one end to cycle reset actuator means 33 and at the other to linkage 25 which is rotatably pinned at its upper end to rotor assembly 13. Said linkages and spring comprise an "over center", "snap action" device such that as actuator means 33 extends, the upper extremity of spring 32 passes through the center line projected through spring 32 connection point to linkage 25 and pivot point 37. The lower end of linkage 25 is designed in barb fashion to override sear 24 as linkage 25 rotates counterclockwise and to engage sear 24 as it attempts to rotate clockwise. Linkage 25 thus engages vent valve 23 to open the valve and maintain it open until actuator means 29 withdraws, disengaging sear 24 from linkage 25.
Generally these linkages, pins, pawls, sear and cam elements are typically plastic or metal in construction and designed to suit the application and function.
Range rotor 11 is comprised of range bearing 14, elbow and water straightener 41 and nozzle 19. Range bearing 14 is identical to azimuth rotor bearing 15. Water straightener 41 and nozzle 19 form a power nozzle which issues a smooth stream of water of maximum range, with the most concise impact area.
In FIG. 2 automatic sprinkler apparatus 10 operates in the following manner. Azimuth rotor 13 is rotatably mounted to base 12 on azimuth bearing 15 and indexed in rotation by azimuth control actuator means 29. This actuator means as all other actuator means herein described are represented as piston and cylinder actuators although other compression actuators like the bellows or diaphragm and tension actuators as described in U.S. Pat. No. 2,844,126 are equally applicable and may be substituted. Azimuth control actuator means 29 is in hydraulic communication with range control actuator means 22 and cycle reset actuator means 33 by means of hydraulic passage 36.
High pressure water is allowed to flow from water communication means 27 within rotor assembly 13 to hydraulic passage 36 at an adjustable flow rate through needle valve 47.
As water enters passage 36, its pressure is exerted equally on all three actuator means (29, 33 and 22). Each actuator means has an individual return spring (30, 35 and 16 respectively) each with differing spring preloads and spring rates such that the actuators operate in the following sequence. As water flows into passage 36, actuator 29 begins extending first because its spring is the softest and has the least preload. As actuator means 29 extends, pawl 26 presses against azimuth indexing pin 45 causing azimuth rotor to index clockwise when viewed from above apparatus 10. Pawl 17 rides over its respective pin 45 to prevent counter rotation as described later. As actuator means 29 bottoms out at its full travel, pressure in passage 36 increases until spring 16 and friction of valve and range bearing are overcome by the force of range control actuator means 22. As actuator means 22 extends, valve 18 is opened by the action of linkages 28 and articulated linkage 20A and cam 38 while linkage 21 causes range rotor assembly 11 to rotate about range bearing 14, increasing its superelevation until range stop 46 is struck by linkage 48.
Range stop 46 is adjustable to its lowest setting which allows nozzle assembly 11 to assume its maximum theoretical range angle of 45 degrees superelevation. In actuality, however, a practical range angle extreme of about 38 degrees provides a range immeasurably close to that of 45 degrees while conserving linkage sizing. At this maximum range position, valve 18 is full open and the device is producing the maximum range possible given the site specific water flow and pressure conditions.
Range stops 46 are adjustable to their highest setting which prevents valve 18 from opening. At this position, the device cycles in azimuth without discharging water from nozzle 19. Thereby, sections of area are left completely omitted from watering. These sections may correspond to buildings, pavement or other areas which are desired to receive no water.
At most times, however, range stops 46 are set between their highest and lowest positions to correspond to the exact range desired at each specific azimuth positions. Basically there is a single range stop provided for each respective azimuth increment. (i.e., there are the same number of equally spaced range stops 46 as there are azimuth indexing pins 45). The particular setting of range stop 46 provides the combined valve 18 position and nozzle 19 superelevation to result in the desired range.
When linkage 48 strikes stop 46, actuator means 22 is prevented from extending further. Pressure within passage 36 increases until spring 35 is overcome and reset actuator means 33 extends. Actuator means 33, compression spring 32 and linkage 25 combine to form a "snap action" or "over center" device to open valve 23. As actuator 33 extends, compression spring is further compressed until it passes over pivot point 37 of linkage 25 at which point linkage 25 reverses position engaging sear 24 and opening valve 23. Valve 23 is similar to a standard Schrader valve and is retained open until each piston returns to its initial position, in reversed order, discharging the working volume of water from passage 36. Actuation means 33 is first to return to its initial position followed by 22 and then 29. As pawl 17 engages azimuth indexing pin 45 to prevent counter rotation, actuator means 29 reaches its initial position causing sear linkage 24 to rotate counterclockwise disengaging linkage 25. As linkage 25 rotates clockwise, valve 23 closes building up pressure to repeat the control sequence.
The specific configuration of linkages 31, 18, 28 and 20 plus cam 38 are designed appropriately to control range rate and water discharge rate to produce uniform water coverage. In like manner, advantage is taken of the fact that as the diameter of the actuator means decreases, the area decreases by the square of this decrease and consequently, the speed of actuation of the respective actuation means increases by this squared ratio. Thereby, the diameters of actuation means 29 and 33 are reduced to the minimum required for their respective operations, thus maintaining azimuth indexing at a minimum elapsed time.
In FIG. 3 is schematically illustrated an alternate embodiment of robotic sprinkle apparatus 10 which has been modified to use only one actuator means and to accomplish all sequential operations by altered linkages, having the advantage of less wetted parts. Base 12 and range rotor assembly 11 are identical to those illustrated in FIG. 2 with the exception of the location of linkage connection points. Within this embodiment the raised, maximum range, position of range rotor 11 is achieved during the vented condition of water passage 36 and the horizontal position, at the end of the pressurizing cycle of passage 36.
Ratchet wheel 59 has been added to provide compact indexing and to facilitate a later described reversing embodiment of the present invention. Ratchet pins 60 are integrally molded to or attached to wheel 59. The lower end of compression linkage 64 provides the function of azimuth control actuator means and pawl 26. Pawl 17 and spring 49 are modified slightly as are the "over center" device comprising tension spring 32A, linkage 25A and pivot point 37 of linkage 25A on azimuth rotor assembly 13. Linkage 64 is rotatably pinned to linkage 63 which is rotatably pinned to range rotor assembly 11 at pin 62. Thereby the rotation of range rotor assembly 11 provides the motive force for azimuth indexing.
New linkages 52, 55 and 56 are added to release sear 24. Linkage 52 is fixedly connected to range rotor assembly 11 at one end and rotatably pinned at pin 61 to spring 16, linkage 55 and linkage 21. Linkage 55 is rotatably pinned at upper end of linkage 39.
The operation of the embodiment illustrated within FIG. 3 is described within the following sequence. Water enters sprinkler 10 at inlet 43 and is discharged through main nozzle 19 or through control needle valve 47 in identical manner as described for FIG. 2. As water passes through needle valve 42 and enters water passage 36 it operates a single actuation means 22. As actuation means 22 moves upward, cam 38 moves linkage 20 to the right, rotating valve control linkage 28 clockwise, closing the valve (not shown) which is inside rotor assembly 13 in like manner to the description of FIG. 2. Linkage 34 has been provided within this embodiment to create a "four bar linkage" controlling the rotation of linkage 20 as it translates.
As linkage 21 moves upward, with actuation means 22, pin 61 travels upward in an arc around range bearing 14 at the end of linkage 52 rotating range rotor 11 toward horizontal. Linkage 55 rotates counter clockwise while pin 54 and linkage 39 travel upward, and linkage 48 slides within guide 57. In similar manner to the description of FIG. 2, valve 18 position, nozzle 19 direction, and range rate are coordinated to provide uniform radial water distribution.
Counterclockwise rotation of range rotor 11 forces pin 62 and linkages 63 and 64 downward. Linkage 64 lowers without rotation through linkage guides 57. The lower end of linkage 64 strikes pin 60 which rotates ratchet wheel 59 counter clockwise. As pawl 17 under the force of spring 49 overrides and secures another pin 67 on ratchet wheel 59, azimuth rotor 13 advances one azimuth index 107 as described in FIG. 2. As indexing occurs, spring pin 65 at the end of tension spring 66 moves through the center between pin 37 and spring pin 65A which results in rapid counter clockwise rotation of linkage 25 about pin 37. The lower end of linkage 25 engages sear 24 while depressing the stem of valve 23 (valve spring not shown). Spring 53 maintains sear 24 engages with linkage 25 until 63A is released as described later. Since water discharges more rapidly out of valve 23 then it enters through needle valve 47, passage 36 is vented, allowing spring 16 to return all linkage to their original positions.
When linkage 48 strikes range stop 46 pin 54 becomes stationary and the instant center of rotation of linkage 55. This is to say that pin 61 continues to move down while pin 54 is stationary in this manner, the left hand end of linkage 55 forces linkage 56 down, sliding within guide 57C. The bottom end of linkage 56 forces sear 24 down thus disengaging linkage 25 which releases valve 23 to close (valve spring not shown). Thus the cycle starts over.
Since there are portions of lawn and surrounding features which are desired to remain dry, the apparatus is featured with a by pass operating mode for these areas. Within this mode, valve 18 is held tight closed while sear 24 is restrained from contacting linkage 25 thus allowing rapid dithering of linkage 25 sufficient to operate azimuth indexing without opening valve 18. Specifically, range stop 46 is set to its highest position. At this position range rotor is driven to minimum range stop 90 and the action of ratchet wheel 59 indexes azimuth rotor assembly 13 thus driving linkage 48 against stop 46. The curvature of the contact surfaces of linkage 48 and stop 46 are sufficient to ramp 48 up over 46. With range rotor fixed against range stop 90 and consequently pin 61 stationary at its highest position, linkage 55 is forced to rotate ccw about pin 61 causing its left hand end 55A to depress linkage 56 holding seat 24 out of contact with linkage 25.
In this position, linkage 25 rotates into contact with valve 23 discharging water which allows spring 16 to start range rotor rotating clockwise. However with linkage 48 held stationary. linkage 56 is further depressed as pin 61 lowers under the rotation of linkage 52, thus holding sear 24 open. As soon as pin 65 passes above the center line between 65A and 37, linkage 25 snaps out of contact with valve 23 causing apparatus to cycle without the opening of valve 18 because cam 38 is flat in a vertical position which does not start the opening of valve 18. Pressure starts increasing in fluid 36 which rotates range rotor 11 ccw depressing linkage 64 to index ratchet wheel 59 and rotate linkage 25 ccw depressing valve 23. In this manner azimuth is indexed while valve 18 is held closed. As an azimuth position is reached where setting is lower than the by pass position, operation continues in the normal watering mode.
In FIG. 4 there is schematically illustrated a robotic sprinkler apparatus 10A for watering irregular shaped lawns 100 shown bordered on the sides by residence 101, drive way 102, and street 103, which is similar to FIG. 1 except the embodiment shown at 10A is designed as illustrated later in FIG. 5 for spot watering. Within this embodiment, the structure, actuation and control means coordinate to form a polar coordinate system with the apparatus 10A forming the pole, the nozzle direction defining the azimuthal coordinate 105 and the variable trajectory of the water defining the range coordinate 106 as in FIG. 1. Except, within this embodiment, is included the control means to store minimum range data to enable the coverage of discrete areas which are not in contact with the sprinkler apparatus.
Within the preferred embodiment, uniform water coverage is established by indexing uniformly in azimuth by the angle 107 while range is controlled to define a uniform locus of points which form a radial path of water impact 108. The maximum range of radial path 108 (farthermost extreme of radial path from apparatus 10A) varies as a function of azimuthal orientation and the preset, site specific data stored within the base of apparatus 10A for the respective azimuth direction. Within the embodiment illustrated at 10A is included also the means of limiting the minimum range of 110. The azimuth extremes (108, 109 and 108', 109' likewise are site specific and defined by various control means as will be later shown. In that there is no preset zero azimuth stored within the device, this setting is site specific and to be set by the user or the unit is left to index continuously 360 degrees and repeat.
In FIG. 5 is schematically illustrated an alternate embodiment at robotic sprinkler apparatus 10A which has been modified for spot watering as was illustrated in FIG. 4. This operation is provided by the addition of an adjustable minimum range stop 69 and linkages 67 and 68 and elimination of linkage 63 to recycle the actuation means at site specific minimum ranges in a similar manner to the maximum range components.
In operation, 10A initiates it's cycle at maximum range with linkage 48 stationarily obstructed by stop 46, forcing sear 24 from engagement with linkage 25, and proceeds toward minimum range in identical fashion to apparatus 10. However, within apparatus 10A, range stop 69 is field adjusted by the user to cause the mechanism to recycle at the desired site specific minimum range instead of zero range as in apparatus 10. As range rotor 11 moves counter clockwise linkage 67 lowers, causes linkage 68 to lower until it contacts stop 69. The left end of linkage 68 is fixedly in contact with stop 69 at 68', and 67 continues downward, moving pin 92 downward with it. Correspondingly pin 91 moves linkage 64 down. As pin 65 on linkage 64 moves down through the center line between pins 37 and 65A, linkage 25 "snaps" ccw opening valve 23 and engages sear 24 while the bottom end of 64 rotates ratchet wheel 59 indexing azimuth incrementally. Valve 23 continues venting control water allowing spring 16 to return device to deenergized condition. The contact of linkage 48 and 46 starts the cycle again as described earlier.
FIG. 6 and FIGS. 7A and 7B illustrate embodiments of the present invention which combine valve 18 and range rotor assembly 11 thus eliminating linkages. FIG. 6 illustrates a slide valve assembly which is not necessarily water tight while the pinch valve of FIG. 7A and 7B is water tight.
In FIG. 6 is illustrated upper portion of azimuth rotor 13 and range rotor assembly 11 modified to incorporate slide valve 71. Slide valve 71 is comprised of orifice plate 51A which is fixedly attached to outer race of range bearing 14 which, in turn, is fixedly secured to azimuth rotor 13, and orifice plate 51B which is fixedly attached to inner race of bearing 14 which is free to rotate with range rotor assembly 11. Orifice plates 51 A and B are comprised of circular disks with orifices 70 radially disposed at equal radii and circumferentially disposed at 90 degree increments. The size of orifices 70 are such that the land between adjacent orifices is larger than the orifice. Thus at minimum range which is illustrated within FIG. 6, the lands of orifice plate 51A are covering the orifices of 51B and conversely 51B covers 51A. As 51B rotates clockwise as range rotor moves to maximum range at 45 Degrees, orifices 70 on both orifice plates 51A and 51B continually move toward alignment which occurs at 45 degrees. Thereby the flow area varies from zero at zero range and maximum at 45 degrees. All other functions of this embodiment are as previously described according to the desired operation.
FIGS. 7A and 7B illustrate a final embodiment combining range rotor assembly 11 and valve 18. FIG. 7A illustrates the assembly at maximum range and full flow and FIG. 7B illustrates the assembly at zero range and zero flow rate. Range rotor assembly 11A is comprised of flexible pressure conduit 40, anvils 50 and 50A, and linkage 52A which cooperate to form a pinch valve. In operation within FIGS. 7A water flows freely within flexible pressure conduit 40 from inlet end attached to azimuth rotor 13A and discharges through nozzle 19 which is connected to the discharge of flexible pressure conduit 40. Within FIG. 7B water flow is illustrated as restricted and ultimately pinched off by the movement of anvil 50 downward and against anvil 50A as linkage rotates counterclockwise about pivot point 72. The pressure exerted by 50 on 50A pinches off the water flow. Again, the other operating parameters are unchanged from previous embodiments.
FIG. 8 illustrates an embodiment of the present invention which perhaps sacrifices performance somewhat for the obvious economic advantage of eliminating range rotor assembly 11. Within this embodiment, a plurality of nozzles 19 are fixedly mounted in range angle to azimuth rotor 13B eliminating range rotor assembly 11. Each of the plurality of nozzles 19 are provided with hydraulic passages 36A designed to dissipate water pressure while producing desired turbulence and rotation of water to cooperate with its respective range angle to provide the desired range and water dispersion. To gain the maximum range and accuracy, the top nozzle 19 is superelevated 45 degrees above the horizon and provided full pressure with minimum turbulence. The pattern produced by each nozzle is designed to overlap that of other nozzles to create a continuous pattern which can be progressed uniformly from minimum to maximum range at each specific azimuth angle.
In operation, this device exhibits the same accuracy of control and turn down which is typical of the previous embodiments. The apparatus sits stationary in azimuth while valve 18 operates over its pre-set site specific range until its maximum range is reached. In this case, maximum range is coincident with maximum pressure associated with the maximum open position of valve 18. In this case range operation is accomplished by range actuation means 22, not shown, operating in identical manner to previous embodiments with the exception that there is no range rotor assembly to operate. Azimuth is operated identically to other embodiments, thus providing the typical radial operation of the apparatus which distinguishes it from all other known devices.
This apparatus and control system lends itself equally to above ground or buried, "pop-up" sprinkler systems. Within the latter version, the base is designed to be buried and a typical water actuated piston device is interstitially configured between the base and the azimuth rotor to pop the rotor up when in operation. While this style is not illustrated, a typically conical shape is anticipated with a lid and openings for setting range spaced around the upper rim of the base. A cap ring with inserts to snap into the said openings would prevent plugging of range data settings.
One final embodiment which is incorporated by description but not illustrated is a spring returned version which does not rotate continuously in a single direction; but, is returned by counter-rotating in azimuth to an original position. Within this embodiment, the azimuth rotor is advanced in a fashion identical to the previous descriptions; however, a clock spring connected at one end to the base and to the azimuth rotor at the other, resists the advancement of said rotor. The ratchet wheel 59 prevents counter-rotation. Within this embodiment, however, said ratchet wheel is split into an input ratchet plate and an output ratchet plate connected by a spring loaded clutch plate. This spring loading device is an over-center "snap-action" device which is normally engaged. As the azimuth rotor advances, a lever engages a tripping device mounted upon said base and disengages clutch at a user set location. Rotor rotates back to its initial orientation at which point another preset tripping device engages clutch to secure rotor and start cycle over. | An automatic robotic lawn sprinkler providing a water powered, articulated, actuation and control system aiming a continuous stream of water to all coordinates within a polar coordinate system comprising a manually programmable base assembly for anchoring to the ground and containing site specific range data, an azimuth rotor assembly rotatably mounted to the base in a horizontal plane, a range rotor assembly rotatably mounted in a vertical plane substantially perpendicular to the azimuth rotor, an azimuth actuation and control system, range actuation and control system, and a mechanism for variably controlling range rate and flow volume. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 10/902,959 filed Aug. 2, 2004 which is a continuation in part of application Ser. No. 10/118,079 filed Apr. 9, 2002, which claims priority on Canadian Application 2,342,970; 2,362,004; and 2,367,636 filed Apr. 12, 2001, Nov. 13, 2001 and Jan. 15, 2002, respectively. The entire content of these applications is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to conjugate or fusion type proteins (polypeptides) comprising, for example, C3-like fusion proteins, C3 chimeric fusion proteins. Although, in the following, fusion-type proteins of the present invention will be particularly discussed in relation to the use to facilitate regeneration of axons and neuroprotection, it is to be understood that the fusion proteins may be exploited in other contexts.
[0003] The present invention in particular pertains to the field of mammalian nervous system repair (e.g. repair of a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site), axon regeneration and axon sprouting, neurite growth and protection from neurodegeneration and ischemic damage.
[0004] The retina is part of the CNS, and this invention pertains to repair of the retina, neuroprotection in the retina, retinal trauma and disease, and ischemic damage to the retina. The invention in particular pertains to compositions and methods useful to treat diseases of the eye such as macular degeneration (such as wet macular degeneration and dry macular degeneration), Stargardt's Disease, Retinitis Pigmentosa, diabetic retinopathy, hypertensive retinopathy, occlusive retinopathy, and other diseases of the retina, including diseases comprising abnormal blood and fluid flow.
BACKGROUND OF THE INVENTION
[0005] Traumatic injury of the spinal cord results in permanent functional impairment. Most of the deficits associated with spinal cord injury result from the loss of axons that are damaged in the central nervous system (CNS). Similarly, other diseases of the CNS are associated with axonal loss and retraction, such as stroke, human immunodeficiency virus (HIV) dementia, prion diseases, Parkinson's disease, Alzheimer's disease, multiple sclerosis and glaucoma. Common to all of these diseases is the loss of axonal connections with their targets, and cell death. The ability to stimulate growth of axons from the affected or diseased neuronal population would improve recovery of lost neurological functions, and protection from cell death can limit the extent of damage. For example, following a white matter stroke, axons are damaged and lost, even though the neuronal cell bodies are alive, and stroke in grey matter kills many neurons and non-neuronal (glial) cells. Treatments that are effective in eliciting sprouting from injured axons are equally effective in treating some types of stroke (Boston life sciences, Sep. 6, 2000 Press release). Neuroprotective agents often tested as potential compounds that can limit damage after stroke. Compounds which show both growth-promotion and neuroprotection are especially good candidates for treatment of stroke and neurodegenerative diseases. Similarly, although the following discussion will generally relate to delivery of Rho antagonists, etc. to a traumatically damaged nervous system, this invention may also be applied to damage from unknown causes, such as during stroke, multiple sclerosis, HIV dementia, Parkinson's disease, Alzheimer's disease, prion diseases or other diseases of the CNS were axons are damaged in the CNS environment. Also, Rho is an important target for treatment of cancer and metastasis (Clark et al (2000) Nature 406:532-535), and hypertension (Uehata et al. (1997) Nature 389:990) and RhoA is reported to have a cardioprotective role (Lee et al. FASEB J. 15:1886-1884). Therefore, the new C3-like proteins are expected to be useful for a variety of diseases were inhibition of Rho activity is required.
[0006] It has been proposed to use various Rho antagonists as agents to stimulate regeneration of (cut) axons, i.e. nerve lesions; please see, for example, Canadian Patent application nos. 2,304,981 (McKerracher et al) and 2,300,878 (Strittmatter). These patent application documents propose the use of known Rho antagonists such as for example C3, chimeric C3 proteins, etc. (see blow) as well as substances selected from among known trans-4-amino (alkyl)-1-pyridylcarbamoylcyclohexane compounds (also see below) or Rho kinase inhibitors for use in the regeneration of axons. C3 inactivates Rho by ADP-ribosylation and is fairly non-toxic to cells (Dillon and Feig (1995) Methods in Enzymology: Small GTPases and their regulators Part. B.256:174-184).
[0007] While the following discussion will generally relate or be directed at repair in the CNS, the techniques described herein may be extended to use in many other diseases including, but not restricted to, cancer, metastasis, hypertension, cardiac disease, stroke, diabetic neuropathy, and neurodegenerative disorders such as stroke, Alzheimer's disease, Parkinson's disease, amyotrophic lateral sclerosis (ALS). Treatment with Rho antagonists would be used to enhance the rate of axon growth of peripheral nerves and thereby be effective for repair of peripheral nerves after surgery, for example after reattaching severed limbs. Also, treatment with our fusion compounds (proteins) is expected to be effective for the treatment of various peripheral neuropathies because of their axon growth promoting effects.
[0008] As mentioned above, traumatic injury of the spinal cord results in permanent functional impairment. Axon regeneration does not occur in the adult mammalian CNS because substrate-bound growth inhibitory proteins block axon growth. Many compounds, such as trophic factors, enhance neuronal differentiation and stimulate axon growth in tissue culture. However, most factors that enhance growth and differentiation are not able to promote axon regenerative growth on inhibitory substrates. To demonstrate that a compound known to stimulate axon growth in tissue culture most accurately reflects the potential for therapeutic use in axon regeneration in the CNS, it is important for the cell culture studies to include the demonstration that a compound can permit axon growth on growth inhibitory substrates. An example of trophic and differentiation factors that stimulate growth on permissive substrates in tissue culture, are neurotrophins such as nerve growth factor (NGF) and brain-derived growth factor. NGF, however, does not promote growth on inhibitory substrates (Lehmann, et al. (1999) 19: 7537-7547) and it has not been effective in promoting axon regeneration in vivo. Brain derived neurotrophic factor (BDNF) is not effective to promote regeneration in vivo either (Mansour-Robaey, et al. J. Neurosci. (1994) 91: 1632-1636). BDNF does not promote neurite growth on growth inhibitory substrates (Lehmann et al supra).
[0009] Targeting intracellular signaling mechanisms involving Rho and the Rho kinase for promoting axon regeneration has been proposed (see, for example, the above-mentioned Canadian Patent application nos. 2,304,981 (McKerracher et al)). For demonstration that inactivation of Rho promotes axon regeneration on growth inhibitory substrates, recombinant C3, a protein that inactivates Rho by ADP ribosylation of the effector domain was used. While such a C3 protein can effectively promote regeneration, it has been noted that such a C3 protein does not easily penetrate into cells, and high doses must therefore be applied for it to be effective. The high dose of recombinant C3 needed to promote functional recovery presents a practical constraint or limitation on the use of C3 in vivo to promote regeneration (Lehmann, et al. (1999) J. Neurosci. 19: 7537-7547; Morii, N and Narumiya, S. (1995) Methods in Enzymology, Vol 256 part B, pg. 196-206. In tissue culture studies, it has, for example, been determined that the minimum amount of C3 that can be used to induce growth on inhibitory substrates is 25 ug/ml (Lehmann, et al. (1999) J. Neurosci. 19: 7537-7547; Morii, N and Narumiya, S. (1995) Methods in Enzymology, Vol 256 part B, pg. 196-206. If the cells are not triturated, even this dose is ineffective. It has been estimated, for example, that at least 40 μg of C3 per 20 g mouse needs to be applied to injured mouse spinal cord or rat optic nerve (McKerracher, Canadian patent application No.: 2,325,842). Calculating doses that would be required to treat an adult human on an equivalent dose per weight scale up used for rat and mice experiments, it would be necessary to apply 120 mg/kg of C3 (i.e. alone) to the injured human spinal cord. The large amount of recombinant C3 protein needed creates significant problems for manufacturing, due to the large-scale protein purification and cost. It also limits the dose ranging that can be tested because of the large amount of protein needed for minimal effective doses.
[0010] Another related limitation with respect to the use of C3 to promote repair in the injured CNS is that it does not easily penetrate the plasma membrane of living cells. In tissue culture studies when C3 is applied to test biological effects it has been microinjected directly into the cell (Ridley and Hall (1992) Cell 70: 389-399), or applied by trituration of the cells to break the plasma membrane (Lehmann, et al. (1999) J. Neurosci. 19: 7537-7547, Jin and Strittmatter (1997) J. Neurosci. 17: 6256-6263). In the case of axon injury in vivo, the C3 protein is likely able to enter the cell because injured axons readily take up substances from their environment. However, C3-like proteins of the present invention are likely to act also on surrounding undamaged neurons and help them make new connections as well, thus facilitating recovery. After incomplete SCI, there is plasticity of motor systems attributed to cortical and subcortical levels, including spinal cord circuitry (Raineteau, O., and Schwab, M. E. (2001) Nat Rev Neurosci 2: 263-73). This plasticity may be attributed to axonal or dendritic sprouting of collaterals and synaptic strengthening or weakening. Additionally, it has been shown that sparing of a few ventrolateral fibers may translate into significant differences in locomotor performance since these fibers are important in the initiation and control of locomotor pattern through spinal central pattern generators (Brustein, E., and Rossignol, S. (1998) J Neurophysiol 80: 1245-67). It is well documented that reorganization of spared collateral cortical spinal fibers occurs after spinal cord injury and this contributes to functional recovery (Weidner et al, 2001 Proc. Natl. Acad. Sci. 98: 3513-3518). The process of reorganization and sprouting of spared fibers would be enhanced by treatment with C3-like proteins able to enter non-injured neurons. This would enhances spontaneous plasticity of axons and dendritic remodeling known to help functional recovery.
[0011] Other methods of delivery of C3 in vitro have been to make a recombinant protein that can be taken up by a receptor-mediated mechanism (Boquet, P. et al. (1995) Meth. Enzymol. 256: 297-306). The disadvantage of this method is that the cells needing treatment must express the necessary receptor. Lastly, addition of a C211 binding protein to the tissue culture medium, along with a C21N-C3 fusion toxin allows uptake of C3 by receptor-mediated endocytosis (Barthe et al. (1998) Infection and Immunity 66:1364). The disadvantage of this system is that much of the C3 in the cell will be restrained within a membrane compartment. More importantly, two different proteins must be added separately for transport to occur (Wahl et al. 2000. J. Cell Biol. 149:263), which make this system difficult to apply to for treatment of disease in vivo.
[0012] Retinitis pigmentosa is a retinal degeneration disease which manifests as night blindness, progressive loss of visual field and peripheral vision, eventually leading to total blindness; opthalmoscopic changes can consist in dark mosaic-like retinal pigmentation, attenuation of the retinal vessels, waxy pallor of the optic disc, and in the advanced forms, macular degeneration. In some cases there can be a lack of pigmentation. This disease is hereditary and the degeneration of retinal photoreceptor cell proceeds with increasingly narrower retinochoroidal blood vessel and circulatory disorders.
[0013] Diabetic retinopathy, a leading cause of blindness in type 1 and type 2 diabetics, is a complication of diabetes which produces damage to the blood vessels inside the retina. Diabetic retinopathy can have four stages: (1) mild nonproliferative retinopathy, wherein microaneurysms in the retina's blood vessels occur; (2) moderate nonproliferative retinopathy, wherein some blood vessels feeding the retina become blocked; (3) severe nonproliferative retinopathy, wherein many blood vessels to the retina are blocked, depriving several areas of the retina with their blood supply; and (4) proliferative retinopathy, wherein new, abnormal, thin- and fragile-walled blood vessels grow to supply blood to the retina, but which new blood vessels may leak blood to produce severe vision loss and blindness. Hemorrhages can occur more than once, often during sleep. Fluid can also leak into the center of the macula at any stage of diabetic retinopathy and cause macular edema and blurred vision. About 40 to 45 percent of Americans diagnosed with diabetes have some stage of diabetic retinopathy, and about half of the people with proliferative retinopathy also have macular edema.
[0014] Stargardt's disease, or fundus flavimaculatus, is a hereditary macular degenerative disorder. Most patients with the condition present in the teenage years with complaints of bilaterally reduced vision. Vision is commonly in the 20/40 range upon first presentation, but frequently falls to the 20/100 level within 4 or 5 years. Vision usually progressively, but gradually, declines beyond 20 years of age, perhaps to the 20/200 level, or worse. Patients will invariably have characteristic flecks in the retina, and these may occupy the macular area in early life. With progression of the disorder, the macula shows atrophy that is not unlike some cases of age related macular degeneration. However, this degree of atrophy is often present in the teens or early 20's. Some patients will develop choroidal neovascular membranes or vessels beneath the retina which may leak fluid or bleed. There is no known treatment that will delay or halt the progression of the disease.
[0000] Hypertensive retinopathy involves damage to the retina caused by high blood pressure which produces narrowing of and excess fluid oozing from blood vessels in the retina. The degree of retina damage (retinopathy) is graded on a scale of I to IV, wherein Group I comprises minimal narrowing of the retinal arteries; Group II comprises narrowing of the retinal arteries in conjunction with regions of focal narrowing and arteriovenous nicking; Group III comprises abnormalities seen in groups I and II, as well as retinal hemorrhages, hard exudation, and cotton-wool spots; and Group IV hypertensive retinopathy comprises abnormalities encountered in groups I through III, as well as swelling of the optic nerve head and macula, which can cause decreased vision. Control of high blood pressure (hypertension) is the only treatment for hypertensive retinopathy. Some patients with grade IV hypertensive retinopathy will have permanent damage to the optic nerve or macula. Hypertensive choroidopathy frequently accompanies hypertensive retinopathy when the changes of group IV, and sometimes those of group III, are present. In the acute phase, yellow spots are visible at the level of the retinal pigment epithelium. They are known as Elshnig Nodules. They are hyperfluorescent on fluorescein angiography and appear to occur secondary to fibrinoid necrosis within the choriocapillaris, leading to damage to the overlying retinal pigment epithelium. In severe cases, the intense leakage of plasma from these foci contributes to serous retinal detachment. Over a period of weeks, these spots become pigmented or depigmented. When the spots occur in a linear fashion, they are referred to as Siegrist's streaks.
[0015] Occlusive retinopathy or retinal vein occlusion, second only to diabetic retinopathy as a cause of visual loss due to retinal vascular disease, comprises both branch and central retinal vein occlusion in which a portion of the circulation that drains the retina of blood becomes blocked, causing back-up pressure in the capillaries, dilated blood vessels, hemorrhages, swelling (edema), and leakage of fluid and other constituents of blood in the distribution of the vein. An occlusion of the central retinal vein involves the entire retina. Complete vein blockage leads to intense hemorrhages and edema, and involved capillaries can cease to function and close off (ischemia or capillary non-perfusion). Complications of branch retinal vein occlusion include macular edema, macular ischemia (non-perfusion) and neovacularization (growth of new abnormal blood vessels). When the distribution of the vein involves the macula, bleeding and exudation or leakage occurs there to produce macular edema with blurred vision and loss of portions of the field of vision. Scar tissue may form on the surface of the retina to produce a macular pucker or an epiretinal membrane may result in distorted vision (metamorphopsia). With significant closure of capillaries, abnormal vessels may grow (neovascularization) and bleed into the overlying ocular cavity in the posterior part of the eye (vitreous hemorrhage) leading to retinal detachment. Central retinal vein occlusion is closure of the retinal vein located at the optic nerve; the occlusion can be non-ischemic or ischemic. Some central retinal vein occlusions are associated with a significant obstruction of capillaries or non-perfusion, and predisposition to neovascularization that occurs in front of the eye on the iris (rubeosis irides). These eyes may develop a very high pressure (neovascular glaucoma) due to obstruction of the fluid outflow channels, and experience severe vision loss, pain, and loss of the eye. Central retinal vein occlusion can produce macular edema and neovascularization in the back of the eye leading to vitreous hemorrhage and retinal detachment.
[0016] The Rho family GTPases regulates axon growth and regeneration. Inactivation of Rho with Clostridium botulinum C3 exotransferase (hereinafter simply referred to as C3) can stimulate regeneration and sprouting of injured axons; C3 is a toxin purified from Clostridium botulinum (see Saito et al., 1995, FEBS Lett 371:105-109; Wilde et al 2000. J. Biol. Chem. 275:16478). Compounds of the C3 family from Clostridium botulinum inactivate Rho by ADP-ribosylation and thus act as antagonists of Rho effect or function (Rho antagonists).
[0017] Degeneration of components of the retina can lead to partial or total blindness. Macular degeneration is a degeneration of the macular region of the retina in the eye. Degeneration of the macula causes a decrease in acute vision and can lead to eventual loss of acute vision. The wet form of macular degeneration is related to abnormal growth of blood vessels in the retina that can leak blood and can cause damage to photoreceptor cells.
[0018] Age-related macular degeneration (AMD) is a collection of clinically recognizable ocular findings that can lead to blindness.
[0019] Macular degeneration is a group of diseases that affect the central retina, or macula. There are two basic types of macular degeneration: “wet” and “dry”. In wet macular degeneration, there is an abnormal growth of new blood vessels. These new blood vessels break and leak fluid, causing damage to the central retina. This form of macular degeneration is often associated with aging. Approximately 90% of macular degeneration cases are dry macular degeneration. Vision loss can result from the accumulation of deposits in the retina called drusen, and from the death of photoreceptor cells. This process can lead to thinning and drying of the retina.
[0020] The findings of AMD include the presence of drusen, retinal pigment epithelial disturbance, including pigment clumping and/or dropout, retinal pigment epithelial detachment, geographic atrophy, subretinal neovascularization and disciform scar. Age-related macular degeneration is a leading cause of presently incurable blindness, particularly in persons over 55 years of age. Approximately one in four persons age 65 or over have signs of age-related maculopathy, and about 7% of persons age 75 or over have advanced macular degeneration with vision loss.
[0021] Drusen are opthalmoscopically visible, yellow-white hyaline excrescences or nodules of Bruch's membrane. Bruch's membrane lies beneath the retina and the adjacent retina pigment epithelium layer. Fat accumulates in Bruch's membrane with age and may contribute to the formation of drusen.
[0022] Drusen can occur in two forms. One form comprises hard, small (less than about 60 micrometers in diameter) drusen which do not increase with age and which do not predispose to macular degeneration. Another form comprises soft, large (more than about 63 micrometers in diameter) drusen which enlarge and become confluent with age. The soft, large drusen may predispose to macular degeneration, and are commonly seen in eyes of people with advanced macular degeneration in at least their other eye.
[0023] Drusen may be metabolic waste products from various layers of the retina such as from the retina, retina pigment epithelium, and choriocapillaris. Drusen may be yellow, white, gray, refractile, and/or pink. Drusen may be small, medium or large in size. Drusen may be regular or irregular, or symmetrical or asymmetrical in shape. A patient who has drusen and who suffers complications in one eye may suffer no complications in the other eye. Complications may comprise one or more conditions selected from the group consisting of retina pigment epithelium atrophy, choroid neovascularization, retina detachment serous, and retina detachment hemorrhagic. Drusen may affect contrast sensitivity, and may reduce the eye's ability to see adequately to allow a person to read in dim light or to see sufficient detail to permit a person to drive an automobile safely at night.
[0024] Not all these manifestations are needed for AMD to be considered present, and drusen alone are not directly associated with vision loss. The amount of opthalmoscopically or photographically identifiable drusen increases with age. Most definitions of AMD include drusen as a requisite because of the association of drusen with vision-threatening lesions of AMD such as geographic atrophy, retinal pigment epithelial detachment and subretinal neovascularization.
[0025] While the exact causes of macular degeneration are not known, contributing factors have been identified. The collective result of the contributing factors is a disturbance between the photoreceptor cells and the tissues under the retina which nourish the photoreceptor cells, including the retinal pigment epithelium, which directly underlies and supports the photoreceptor cells, and the choroid, which underlies and nourishes the retinal pigment epithelium.
[0026] The retina and macula may be subjected to oxidative damage by oxidants such as free-radicals and singlet oxygen, 1 O 2 . The macula contains polyunsaturated fatty acids and is exposed to light, including in the visible and near ultraviolet light spectrum high-energy blue light, which can photosensitize the conversion of triplet oxygen to singlet oxygen, an oxidizing agent capable of damaging the polyunsaturated fatty acids, DNA, proteins, lipids, and carbohydrates in the macula. Reaction products resulting from oxidative interactions between components of the retina and oxidizing agents may accumulate in the retinal pigment epithelium and contribute to macular degeneration. Certain antioxidant nutrients may reduce the risk of developing macular degeneration by reducing the formation of radicals and reactive oxygen by decomposition of hydrogen peroxide without generating radicals, by quenching active singlet oxygen, and by trapping and quenching radicals before they reach a cellular target.
[0027] Another factor which may be involved in the pathology of macular degeneration comprises an elevated serum concentration of low density cholesterol lipoprotein (LDL). Low density lipoprotein cholesterol can be oxidized by an oxidizing agent to form oxidized LDL, which is found in atherosclerotic plaques. These oxidized products may accumulate as deposits in healthy retinal pigment epithelium and cause necrosis or death of functioning tissue. LDL cholesterol may also form atherosclerotic plaques in the blood vessels of the retinal and subretinal tissue, inducing hypoxia in the tissue, resulting in neovascularization. Postmenopausal women given unopposed estrogen replacement therapy can have a reduced risk of neovascular age-related macular degeneration. Estrogen can increase the amount of high density lipoprotein cholesterol (HDL) in the blood, which may produce changes in the transport and metabolism of lipid-soluble antioxidants, and limit the accumulation of oxidized LDL cholesterol in the retinal and subretinal tissues and blood vessels.
[0028] A contributing and indicating factor of advanced macular degeneration is neovascularization of the choroid tissue underlying the photoreceptor cells in the macula. Healthy mature ocular vasculature is normally quiescent and exists in a state of homeostasis in which a balance is maintained between positive and negative mediators of angiogenisis in development of new vasculature. Macular degeneration, particularly in its advanced stages, is characterized by the pathological growth of new blood vessels in the choroid underlying the macula. Angiogenic blood vessels in the subretinal choroid can leak vision obscuring fluids, leading to blindness.
[0029] Angiogenisis in the choroid can be induced by the presence of cytokine growth factors such as basic fibroblast growth factor (bFGF). Hypoxia of retinal cells may induce the expression of such growth factors, wherein the hypoxia may be induced by cellular debris or drusen accumulated in the retinal pigment epithelium, by oxidative damage of retinal and subretinal tissue, or by deposits of oxidized LDL cholesterol.
[0030] Existing retinal and subretinal vascular endothelial cells can be activated by interaction of the cytokine growth factors, such as bFGF, with tyrosine kinase mediated receptors of the endothelial cells. The activated endothelial cells can increase in cellular proliferation and express several molecular agents, such as the integrin α v β 3 , adhesion molecules, and proteolytic enzymes, which enable newly developed endothelial cells to extend through the surrounding tissue. The newly extended endothelial cells can form into vascular cords and eventually differentiate into mature blood vessels.
[0031] Currently, no treatment has been shown to be of benefit to the majority of people who have AMD. There is no therapy that can significantly slow the degenerative progression of macular degeneration, or which can inhibit or substantially reduce the rate of subretinal neovascularization and proliferation of neovascular tissue in the choroids under the macula of the eye. Most experimental forms of treatment address the wet form of AMD, and target specifically neovascularization. Laser photocoagulation of the subretinal neovascular membranes that occur in 10-15% of affected patients can benefit individuals with macular degeneration who develop acute, extrafoveal choroidal neovascularization. For dry AMD, high daily doses of antioxidants such vitamin C (500 mg), vitamin E (400 IU), beta carotene (15 mg), as well as zinc oxide (80 mg; high concentrations of zinc occur in ocular tissues, particularly the retina, pigment epithelium and choroid) may modestly reduce risk of progression of those who have intermediate-sized drusen, large drusen, or non-central geographic atrophy, or advanced macular degeneration in one eye.
[0032] A number of techniques have been disclosed for administration of drugs to the eye including the posterior region of the eye. For example, U.S. Pat. No. 5,707,643 relates to a biodegradable scleral plug that is inserted through an incision in the sclera into the vitreous body. For administration of a drug to the eye, the plug releases a drug into the vitreous body for treating the retina by diffusion through the vitreous body.
[0033] Another technique for administration of a drug to the eye is disclosed in U.S. Pat. No. 5,443,505 which discloses implants which can be placed in the suprachoroidal space over an avascular region of the eye such as the pars plana or a surgically induced avascular region. Another embodiment involves forming a partial thickness scleral flap over an avascular region, inserting an implant onto the remaining scleral bed, optionally with holes therein, and suturing closed the flap. The drug can diffuse into the vitreous region and the intraocular structure.
[0034] Another delivery approach for administration of a drug to the eye is direct injection. For the posterior segment of the eye, an intravitreal injection has been used to deliver drugs into the vitreous body. In this regard, U.S. Pat. No. 5,632,984 relates to a treatment of macular degeneration with various drugs by intraocular injection. For administration of a drug to the eye, drugs are preferably injected as microcapsules. Intraocular injection into the posterior segment of the eye can allow diffusion of the drug throughout the vitreous, the entire retina, the choroid and the opposing sclera. Additionally, U.S. Pat. No. 5,770,589 relates to treating macular degeneration by intravitreally injecting an anti-inflammatory into the vitreous humor for administration of a drug to the eye. Injections can be administered through the pars plana in order to minimize the damage to the eye while drug is delivered to the posterior segment.
[0035] Another delivery approach is by surgical procedure. For example, U.S. Pat. No. 5,767,079 relates to the treatment of ophthalmic disorders including macular holes and macular degeneration, by administration of TGF-β for example by placing an effective amount of the growth factor on the ophthalmic abnormality. In treating the macula and retina, for administration of a drug to the eye a surgical procedure involving a core vitrectomy or a complete pars plana vitrectomy is performed before the growth factor can be directly applied, presumably by administration to the sclera on the anterior segment of the eye at an avascular region or by administration to the sclera behind the retina via a surgical procedure through the vitreous body, retina, and choroids, a dramatic, highly invasive, technique usually suitable only where partial vision loss has already occurred or was imminently threatened.
[0036] Another delivery approach for administration of a drug to the eye is by use of a device and a cannula. For example, U.S. Pat. No. 5,273,530 relates to the intraretinal delivery and withdrawal of samples and a device therefor. Unlike direct intraocular injection techniques, the method disclosed in this patent avoids the use of a pars plana incision and instead uses an insertion path around the exterior of the orbit. The device, having a curved handle and a tip with collar, allows a cannula to be inserted through the posterior sclera and down into the subretinal space without passing through the vitreous body. The collar is stated to regulate the penetration to the desired depth. The device is taught to be adjustable to any part of the eye including the scleral area, the choroidal area, the subretinal area, the retinal area and the vitreous area.
[0037] Another delivery approach for administration of a drug to the eye is by intrascleral injection. For example, U.S. Pat. No. 6,397,849, the contents of which is hereby incorporated by reference in its entirety, discloses a method of intrascleral injection which comprises injecting into the scleral layer of an eye through a location on the exterior surface of the sclera which overlies retinal tissue an effective amount of a therapeutic or diagnostic material. Depending on the injection conditions, the material can form a depot within the scleral layer and diffuse into the underlying tissue layers such as the choroid and/or retina, and/or the material can be propelled through the scleral layer and into the underlying layers. Because the sclera moves with the entire eye including the retina, the site of deposit on the sclera remains constant relative to a point on the underlying retina, even as the eye moves within the eye socket to permit site specific delivery by depositing material into the sclera at a site overlying the macula, thereby allowing material to be delivered to the macula and surrounding tissues. The injection procedure employs a cannula or needle as well as needle-less particle/solution techniques. In a preferred embodiment, a cannula is inserted into the sclera in a rotational direction relative to the eye and not orthogonal to the surface of the sclera.
[0038] Another delivery approach for administration of a drug to the eye is disclosed in U.S. Pat. No. 6,299,895 which discloses a method for delivering a biologically active molecule to the eye comprising implanting a capsule periocularly in the sub-Tenon's space, the capsule comprising a core containing a cellular source of the biologically active molecule and a surrounding biocompatible jacket, the jacket permitting diffusion of the biologically active molecule into the eye, wherein the dosage of the biologically active molecule delivered is between 50 pg and 1000 ng per eye per patient per day. The biologically active molecule can be an anti-angiogenic factor, and a second biologically active molecule or peptide can be co-delivered from the capsule to the eye. The method is disclosed to be useful treating ophthalmic disorders including macular degeneration.
[0039] Other delivery approaches for administration of a drug to the eye which can be useful with compositions of the current invention are well known in the art. For example, U.S. Pat. No. 5,399,163 discloses a method of providing a jet injection by pressurizing a fluid injectant; U.S. Pat. No. 5,383,851 discloses a needleless injection device; U.S. Pat. No. 5,312,335 discloses a needleless injection system; U.S. Pat. No. 5,064,413 discloses an injection device; U.S. Pat. No. 4,941,880 discloses an ampule for non-invasive injecting of a medication; U.S. Pat. No. 4,790,824 discloses a non-invasive hypodermic injection device; U.S. Pat. No. 4,596,556 discloses a pressure-operated hypodermic injection apparatus; U.S. Pat. No. 4,487,603 discloses an implantable micro-infusion pump for dispensing medication at a controlled rate; U.S. Pat. No. 4,486,194 discloses a therapeutic device for administering medicants through the skin; U.S. Pat. No. 4,447,233 discloses a medication infusion pump for delivering medication at a precise infusion rate; U.S. Pat. No. 4,447,224 discloses a variable flow implantable infusion apparatus for continuous drug delivery; U.S. Pat. No. 4,439,196 discloses an osmotic drug delivery system having multi-chamber compartments; and U.S. Pat. No. 4,475,196 discloses an osmotic drug delivery system.
SUMMARY OF THE INVENTION
[0040] In accordance with the present invention a conjugate, drug delivery construct, or fusion protein comprising a therapeutically active agent is provided whereby the active agent may be delivered across a cell wall membrane, the conjugate or fusion protein comprising at least a transport subdomain(s) or moiety(ies) (i.e., transport agent region) in addition to an active agent moiety(ies) (i.e., active agent region). More particularly, as discussed herein, in accordance with the present invention a conjugate or fusion protein is provided wherein the therapeutically active agent is one able to facilitate (for facilitating) axon (or dendrite, or neurite) growth (e.g. regeneration) i.e. a conjugate or fusion protein in the form of a conjugate Rho antagonist.
[0041] The present invention also relates to methods of treatment of macular degeneration associated with subretinal neovascularization and a proliferation of neovascular tissue in the eye of a mammalian host, and to methods of inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue in the eye associated with macular degeneration, and to pharmaceutical compositions useful therein comprising a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport agent and an active agent having ADP-ribosyl transferase activity.
[0042] The present invention also relates to methods of treatment of diabetic neuropathy, especially diabetic retinopathy associated with the damage to blood vessels caused by diabetes that leads to macular edema in the eye and neovascularization, and to methods of inhibiting or substantially reducing the rate of blood vessel damage and proliferation of neovascular tissue in the eye associated with diabetic neuropathy, and to pharmaceutical compositions useful therein comprising a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport agent and an active agent having ADP-ribosyl transferase activity
[0043] The present invention also relates to methods of treatment of retinitis pigmentosa, a group of hereditary retinal diseases associated with degeneration of the retinal neurons, specifically the photoreceptor neurons (also referred to as photoreceptor cells), and to method of inhibiting photoreceptor degeneration in the eye of a mammalian host, and to methods of inhibiting or substantially reducing the rate of photoreceptor cell death associated with retinitis pigmentosa, and to pharmaceutical compositions useful therein comprising a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport agent and an active agent having ADP-ribosyl transferase activity.
[0044] The present invention in particular relates to a means of intracellular delivery of C3 protein (e.g. C3 itself or other active analogues such as C3-like transferases—see below) or other Rho antagonists to repair damage in the nervous system, to prevent ischemic cell death, and to treat various disease where the inactivation of Rho is required. The means of delivery may take the form of chimeric (i.e. conjugate) C3-like Rho antagonists. These conjugate antagonists provide a significant improvement over C3 compounds (alone) because they are 3 to 4 orders of magnitude more potent with respect to the stimulation of axon growth on inhibitory substrates than recombinant C3 alone. Examples of these Rho antagonists have been made as recombinant proteins created to facilitate penetration of the cell membrane (i.e. to enhance cell uptake of the antagonists), improve dose-response when applied to neurons to stimulate growth on growth inhibitory substrates, and to inactivate Rho. Examples of these conjugate Rho antagonists are described below in relation to the designations C3APL, C3APLT, C3APS, C3-TL, C3-TS, C3Basic1, C3Basic2 and C3Basic3.
[0045] The present invention in accordance with an aspect thereof provides a drug delivery construct or conjugate [e.g. able to (for) suppress(ing) the inhibition of neuronal axon growth at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site] comprising at least one transport agent region and an active agent region not naturally associated with the active agent region, wherein the transport agent region is able to facilitate (i.e. facilitates) the uptake of the active agent region into a mammalian (i.e. human or animal) tissue or cell, and wherein the active agent region is an active therapeutic agent region able (i.e. has the capacity or capability) to facilitate axon growth for example on growth inhibitory substrates (e.g. regeneration), either in vivo (in a mammal (e.g., human or animal)) or in vitro (in cell culture), including a derivative or homologue thereof (i.e. pharmaceutically acceptable chemical equivalents thereof—pharmaceutically acceptable derivative or homologue).
[0046] In accordance with the present invention the active agent region may be an ADP-ribosyl transferase C3 region. In accordance with the present invention the ADP-ribosyl transferase C3 may be selected from the group consisting of ADP-ribosyl transferase (e.g., ADP-ribosyl transferase C3) derived from Clostridium botulinum and a recombinant ADP-ribosyl transferase (e.g., recombinant ADP-ribosyl transferase C3) that includes the entire C3 coding region, or only a part (fragment) of the C3 coding region that retains the ADP-ribosyl transferase activity, or analogues (derivatives) of C3 that retains the ADP-ribosyl transferase activity, or enough of the C3 coding region to be able to effectively inactivate Rho. The active agent could also be selected from other known ADP-ribosyl transferases that act on Rho (Wilde et al. 2000 J. Biol. Chem. 275-16478-16483; Wilde et al 2001. J. Biol. Chem. 276:9537-9542).
[0047] In accordance with another aspect the present invention provides a drug conjugate consisting of a transport polypeptide moiety (e.g. rich in basic amino acids e.g. arginine, lysine, histidine, asparagine, glutamine) covalently linked to an active cargo moiety (e.g. by a peptide bond or a labile bond (i.e. a bond readily cleavable or subject to chemical change in the interior target cell environment)) wherein the transport polypeptide moiety is able to or has the capability to facilitate(s) the uptake of the active cargo moiety into a mammalian (e.g. human or animal) tissue or cell (for example, a transport subdomain of HIV (e.g., HIV-1) Tat protein, a homeoprotein transport sequence (referred also as a transport homeoprotein) (e.g. the homeodomain of antennapedia), a Histidine tag (ranging in length from 4 to 30 histidine repeat) or a variation derivative or homologue thereof, (i.e. pharmaceutically acceptable chemical equivalents thereof)) [by a receptor independent process] and wherein the active cargo moiety is an active therapeutic moiety able (i.e. has the capacity or capability) to facilitate (i.e. for facilitating) axon growth (e.g. regeneration, budding) or neuroprotection (prevention of cell death) either in vivo (in a mammal (e.g., human or animal)) or in vitro (in cell culture).
[0048] In accordance with the present invention the transport polypeptide moiety may be selected from the group consisting of SEQ ID NO.: 48, a transport subdomain of HIV (e.g., HIV-1) Tat protein such as for example SEQ ID NO.: 46, SEQ ID NO.:47, a homeodomain of antennapedia, such as for example SEQ ID NO.: 44, SEQ ID NO.: 45, a Histidine tag and a functional derivative and analogues thereof (e.g., SEQ ID NO.: 21, SEQ ID NO.: 26, SEQ ID NO.: 31) [i.e. by the addition of polyamine, or any random sequence enriched in basic amino acids]—[i.e. pharmaceutically acceptable chemical equivalents thereof] and wherein the active cargo moiety is selected from the group consisting of C3 protein able (i.e. has the capacity or capability) to facilitate (i.e. for facilitating) axon growth (e.g. regeneration, budding) or neuroprotection (prevention of cell death) either in vivo (in a mammal (e.g., human or animal)) or in vitro (in cell culture).
[0049] In accordance with the present invention the C3 protein may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogue. In accordance with the present invention the ADP-ribosyl transferase C3 may be selected from the group consisting of ADP-ribosyl transferase (e.g., ADP-ribosyl transferase C3) derived from Clostridium botulinum and a recombinant ADP-ribosyl transferase (e.g., recombinant ADP-ribosyl transferase C3). The ADP-ribosyl transferase may be a protein with a C3-like activity, such as that derived from Staphylococcus aureus (Wilde et al 2001. J. Biol. Chem. 276:9537-9542). The ADP-ribosyl transferase may be any other transferase that acts to inactivate RhoA, RhoB and/or RhoC such as those derived from Clostridium limosum , and Bacillus cereus (Wilde et al 2000. J. Biol. Chem. 275:16478-16483). In accordance with the present invention the transport polypeptide moiety may include an active contiguous amino acid sequence as described herein.
[0050] In accordance with an additional aspect the present invention provides a fusion protein (polypeptide) [e.g. able to (for) suppress(ing) the inhibition of neuronal axon growth at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site] consisting of a carboxy terminal active cargo moiety and an amino terminal transport moiety, wherein the amino terminal transport moiety is selected from the group consisting of a transport subdomain of HIV (e.g., HIV-1) Tat protein, homeoprotein transport sequence (referred also as a transport homeoprotein) (e.g. the homeodomain of antennapedia), a Histidine tag and a functional derivatives and analogues thereof (i.e. pharmaceutically acceptable chemical equivalents thereof) and wherein the active cargo moiety consists of a C3 protein.
[0051] The present invention in particular provides a fusion protein (polypeptide) (e.g. able to (for) suppressing the inhibition of neuronal axon growth at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site) consisting of a carboxy terminal active cargo moiety and an amino terminal transport moiety, wherein the amino terminal transport moiety consists of the homeodomain of antennapedia and the active cargo moiety consists of a C3 protein (i.e. as described herein). The present invention also in particular provides a fusion protein (polypeptide) (e.g. able to (for) suppressing the inhibition of neuronal axon growth at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site) consisting of a carboxy terminal active cargo moiety and an amino terminal transport moiety, wherein the amino terminal transport moiety consists of a transport subdomain of (e.g., HIV-1) Tat protein and the active cargo moiety consists of a C3 protein (i.e. as described herein).
[0052] In accordance with the present invention the C3 protein may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues. In accordance with the present invention the ADP-ribosyl transferase C3 is selected from the group consisting of ADP-ribosyl transferase (e.g., ADP-ribosyl transferase C3) derived from Clostridium botulinum and a recombinant ADP-ribosyl transferase (e.g., recombinant ADP-ribosyl transferase C3).
[0053] In accordance with an additional aspect the present invention provides a fusion protein (polypeptide) [e.g. able to (for) suppress(ing) the inhibition of neuronal axon growth at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site] consisting of an amino terminal active cargo moiety and a carboxy terminal transport moiety, wherein the carboxy terminal transport moiety is selected from the group consisting of a transport subdomain of HIV Tat protein, a homeoprotein transport sequence (referred also as a transport homeoprotein) (e.g. the homeodomain of antennapedia), a Histidine tag and a functional derivatives and analogues thereof (i.e. pharmaceutically acceptable chemical equivalents thereof) and wherein the active cargo moiety consists of a C3 protein.
[0054] The present invention in particular provides a fusion protein (polypeptide) (e.g. able to (for) suppressing the inhibition of neuronal axon growth at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site) consisting of an amino terminal active cargo moiety and a carboxy terminal transport moiety, wherein the carboxy terminal transport moiety consists of the homeodomain of antennapedia and the active cargo moiety consists of a C3 protein (i.e. as described herein).
[0055] The present invention also in particular provides a fusion protein (polypeptide) (e.g. able to (for) suppressing the inhibition of neuronal axon growth at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site) consisting of an amino terminal active cargo moiety and a carboxy terminal transport moiety, wherein the carboxy terminal transport moiety consists of a transport subdomain of HIV Tat protein and the active cargo moiety consists of a C3 protein (i.e. as described herein).
[0056] In accordance with the present invention the C3 protein may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues. In accordance with the present invention the ADP-ribosyl transferase C3 is selected from the group consisting of ADP-ribosyl transferase C3 derived from Clostridium botulinum and a recombinant ADP-ribosyl transferase C3.
[0057] The present invention in a further aspect provides for the use of a member selected from the group consisting of a drug delivery construct as described herein, a drug conjugate as described herein and a fusion protein (polypeptide) as described herein (e.g. including pharmaceutically acceptable chemical equivalents thereof) for suppressing the inhibition of neuronal axon growth.
[0058] The present invention in a further aspect relates to a pharmaceutical composition (e.g. for suppressing the inhibition of neuronal axon growth), the pharmaceutical composition comprising a pharmaceutically acceptable diluent or carrier and an effective amount of an active member selected from the group consisting of a drug delivery construct as described herein, a drug conjugate as described herein, and a fusion protein (polypeptide) as described herein (e.g. including pharmaceutically acceptable chemical equivalents thereof).
[0059] The present invention further provides for the use of a member selected from the group consisting of a drug delivery construct as described herein, a drug conjugate as described herein, and a fusion protein (polypeptide) as described herein (e.g. including pharmaceutically acceptable chemical equivalents thereof) for the manufacture of a pharmaceutical composition (e.g. for suppressing the inhibition of neuronal axon growth).
[0060] The present invention also relates to a method for preparing a drug delivery construct, a conjugate or fusion protein (polypeptide) as defined above comprising
[0061] cultivating a host cell (bacterial or eukaryotic) under conditions which provide for the expression of the drug delivery construct, the conjugate or fusion protein (polypeptide) within the cell; (the drug delivery construct, conjugate or fusion protein (polypeptide), could also be expressed to be produced in an animals, such as, for example, the production of recombinant proteins in the milk of farm animals) and,
[0062] recovering the drug delivery construct, conjugate or fusion protein (polypeptide) by a purification step.
[0063] The purification of the drug delivery construct, conjugate or fusion protein (polypeptide) may be done by affinity methods, ion exchange chromatography, size exclusion chromatography, hydrophobicity or any other purification technique typically used for protein purification. Preferably, the purification step would be performed under non-denaturating conditions. On the other hand, if a denaturating step is required, the protein may be renatured using techniques known in the art.
[0064] The present invention also relates to the expression of the drug delivery construct, conjugate or fusion protein (polypeptide) in a mammalian cell, which when used with a signal sequence, will allow expression and secretion of the fusion protein into the extracellular milieu. Other system of expression (yeast cells, bacterial cells, insect cells, etc.) may be suitable to express (produce) the drug delivery construct, conjugate or fusion protein (polypeptide) of the present invention as discussed herein.
[0065] The present invention in particular provides a fusion protein (polypeptide) selected from the group consisting of C3APL (SEQ ID NO.: 4), C3APLT (SEQ ID NO.: 37), C3APS (SEQ ID NO.:6), C3-TL (SEQ ID NO.:14), C3-TS (SEQ ID NO.: 18), C3Basic1 (SEQ ID NO.:25), C3Basic2 (SEQ ID NO.: 30), C3Basic3 (SEQ ID NO.:35), SEQ ID NO.: 20, and SEQ ID NO.: 43 and pharmaceutically acceptable chemical equivalents thereof.
[0066] In accordance with an additional aspect, the present invention provides a pharmaceutical composition comprising a polypeptide selected from the group consisting of C3APL (SEQ ID NO.:4), C3APLT (SEQ ID NO.:37), C3APS (SEQ ID NO.:6), C3-TL (SEQ ID NO.: 14), C3-TS (SEQ ID NO.:18), C3Basic1 (SEQ ID NO.:25), C3Basic2 (SEQ ID NO.:30), C3Basic3 (SEQ ID NO.:35), SEQ ID NO.: 20 and SEQ ID NO.: 43, and a pharmaceutically acceptable carrier.
[0067] In accordance with the present invention, the pharmaceutical composition may further comprise a biological adhesive, such as, for example, fibrin (fibrin glue).
[0068] In a further aspect the present invention provides a pharmaceutical composition comprising a polypeptide comprising at least one (one or more) transport agent region and an active agent region, said active agent region being selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues, and a pharmaceutically acceptable carrier.
[0069] In accordance with the present invention, the transport agent region may be at the carboxy-terminal end of said polypeptide and the active agent region may be at the amino terminal end of said polypeptide.
[0070] In accordance with the present invention, the pharmaceutical composition may further comprise a biological adhesive, such as, for example, fibrin (fibrin glue).
[0071] In an additional aspect, the present invention provides a polypeptide comprising at least one (one or more) transport agent region and an active agent region, said active agent region being selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues (wherein the transport agent region is able to facilitate the uptake of the active agent region into (inside the cell or in the cell membrane) a cell).
[0072] In an additional aspect, the present invention provides a polypeptide consisting of a carboxy-terminal active agent moiety and an amino-terminal transport moiety region (wherein the transport agent region is able to facilitate the uptake of the active agent region into (inside the cell or in the cell membrane) a cell) and wherein said carboxy-terminal active agent moiety may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues thereof.
[0073] In accordance with the present invention, the carboxy-terminal transport moiety region may be selected from the group consisting of a basic amino acid rich region and a proline rich region.
[0074] In a further aspect, the present invention relates to a polypeptide consisting of an amino-terminal active agent moiety and a carboxy-terminal transport moiety region, wherein said amino-terminal active agent moiety may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues thereof.
[0075] In accordance with the present invention, the carboxy-terminal transport moiety region may be selected from the group consisting of a basic amino acid rich region and a proline rich region.
[0076] In yet a further aspect, the present invention relates to a conjugate comprising at least one transport agent region (including one, two, three or more transport agent region) and an active agent region, said active agent region being selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues, wherein said transport agent region is covalently linked to said active agent region.
[0077] In accordance with the present invention, the transport agent region may be cross-linked (e.g., chemically cross-linked, UV cross-linked) to the active agent region (C3-like proteins of the present invention and analogues thereof).
[0078] In accordance with the present invention, the transport agent region may be fused to ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues according to recombinant DNA technology (e.g., cloning the DNA sequence of the transport agent region in frame with the DNA sequence of the ADP-ribosyl transferase C3 or an ADP-ribosyl transferase C3 analogue comprising or not a spacer DNA sequence (multiple cloning site, linker) or any other DNA sequence that would not interfere with the activity of the C3-like protein once expressed).
[0079] In an additional aspect, the present invention relates to the use of a polypeptide selected from the group consisting of C3APL (SEQ ID NO.: 4), C3APLT (SEQ ID NO.:37), C3APS (SEQ ID NO.:6), C3-TL (SEQ ID NO.: 14), C3-TS (SEQ ID NO.:18), C3Basic1 (SEQ ID NO.:25), C3Basic2 (SEQ ID NO.:30), C3Basic3 (SEQ ID NO.:35), SEQ ID NO.: 20 and SEQ ID NO.: 43, for the manufacture of a pharmaceutical composition.
[0080] In other aspects, the present invention relates to the use of a polypeptide comprising at least one (one or more) transport agent region and an active agent region, for the manufacture of a pharmaceutical composition, or to facilitate (for facilitating) axon growth or for treating (in the treatment of) nerve injury (e.g., nerve injury arising from traumatic nerve injury or nerve injury caused by disease), or for preventing (diminishing, inhibiting (partially or totally)) cell apoptosis (cell death, such as following ischemia in the CNS), or for suppressing (diminishing) the inhibition of neuronal axon growth, or for the treatment of ischemic damage related to stroke, or for suppressing (diminishing) Rho activity, or to regenerate (for regenerating) injured axon (helping injured axon to recover, partially or totally, their function), or to help (for helping) neurons to make new connections (developing axon, dendrite, neurite) with other (surrounding) cells (neuronal cells), in a mammal, (e.g., human, animal), wherein said active agent region being selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues.
[0081] A cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport agent covalently linked to an active agent having ADP-ribosyl transferase activity can be used to treat diseases of the eye selected from the group consisting of macular degeneration (wet AMD and dry AMD), retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy and related diseases of the retina. Cell permeable fusion protein Rho antagonists are expected to prevent both neovascularization and photoreceptor cell death, unlike other treatments that only target the neovascularization present in the disease. This can be particularly advantageous for the treatment of wet macular degeneration.
[0082] In one aspect, a therapeutically effective amount of a pharmaceutical composition comprising a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, for example a fusion protein such as C3APLT, can exhibit anti-angiogenic activity and is useful in the treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy. A therapeutically effective amount can be about 1 microgram per milliliter to about 10 micrograms per milliliter or from about 10 micrograms to about 50 micrograms per milliliter.
[0083] Administration of a pharmaceutical composition of this invention can be selected from the group consisting of intrarticular, intraocular, intranasal, intraneural, intradermal, intraosteal, sublingual, oral, topical, intravesical, intrathecal, intravenous, intraperitoneal, intracranial, intramuscular, subcutaneous, inhalation, atomization and inhalation, application directly into a tissue of or proximal to the eye or CNS, application directly into a disease site especially into a blood vessel that supplies blood to the retina or to a cell or tissue or structure of an eye, application directly on or into the margins remaining after an operative resection such as a resuction of a tumor, enteral, enteral together with a gastroscopic procedure, and ECRP.
[0084] Administration of a pharmaceutical composition of this invention is preferably by injection, such as by injection into an eye, preferably into a blood vessel that supplies blood to the eye or by microinjection into the macula by first penetrating the sclera, by topical application such as to a tissue of the eye such as the cornea or sclera, or by implantation such as by controlled release from a depot or implant comprising a fusion protein of this invention optionally in the presence of a pharmaceutically acceptable matrix or pharmaceutically acceptable carrier, which depot or implant is located proximal to the tissue of the eye, preferably proximal to or embedded into tissue comprising the posterior portion of the eye. A therapeutically effective amount of a fusion protein of this invention can be delivered to the choroid and retina proximal to the macula of the eye to prevent (such as in a prophylactic treatment) or retard the growth of blood vessels that lead to macular degeneration in the eye.
[0085] In one aspect, therapeutic compositions of this invention can be administered to the eye by a number of techniques including by use of medical devices and methods of administration known in the art, such as for example those described in U.S. Pat. Nos. 6,397,849; 6,299,895; 5,770,589; 5,767,079; 5,707,643; 5,632,984; 5,443,505; 5,399,163; 5,383,851; 5,273,530; 5,064,413; 4,941,880; 4,790,824; 4,596,556; 4,487,603; 4,486,194; 4,475,196; 4,447,224; 4,447,233; and 4,439,196 cited hereinabove, which patents are incorporated herein by reference. Many other methods of administration such as a single or multiple implant comprising a poorly water soluble and/or biodegradable matrix composition for controlled release of a protein of this invention, an implantable hydrogel matrix which can be biodegradable and comprising a drug, an injectable delivery system such as a liposome suspension comprising a protein of this invention entrapped in the interior and/or membrane portion of the liposome which liposome is suspended in an aqueous medium, injection methods such as comprising a needleless syringe or cannula or needle and syringe, nanoparticulate implantation methods comprising a protein of this invention and a poorly water soluble and biodegradable carrier, and delivery routes that are applicable to administer a drug to the eye and to blood vessels that feed blood to the eye can be used with the compositions of this invention.
[0086] The fusion proteins and pharmaceutical compositions of fusion proteins of the present invention can be delivered by a variety of techniques to the macula region of the eye, preferably to the posterior segment of the eye proximal to the macula. Examples of such techniques include:
a) use of a sterile, pharmaceutically acceptable biodegradable scleral plug which comprises a fusion protein of this invention and optionally a pharmaceutically acceptable biodegradable matrix such as a polylactic acid or polyglycolic acid or a copolymer of lactic acid and glycolic acid, which plug can be inserted into the eye via an incision in the sclera; b) use of an implant comprising a fusion protein of this invention and optionally a pharmaceutically acceptable biodegradable matrix wherein the sclera is cut to expose the suprachoroid and wherein the implant is placed into a suprachoroidal space form which implant the fusion protein is released for example into the vitreous region of the eye; c) use of intravitreal injection into the vitreous body of a pharmaceutical composition comprising a fusion protein of this invention and a sterile aqueous carrier, wherein the fusion protein comprises a submicron- to about 4 micron-sized pharmaceutically acceptable particulate composition; d) injection or infusion via a flexible cannula that can be inserted through the posterior sclera and down into the subretinal space at the posterior region of the eye; and e) by injection of a pharmaceutical composition comprising a fusion protein of this invention and a pharmaceutically acceptable carrier into an avascular region of the sclera to form a depot comprising a fusion protein of this invention within the scleral layer and from which the fusion protein can diffuse to the macula, choroid layer, and/or retina.
[0092] In one aspect, a pharmaceutical composition of this invention can comprise a pharmaceutically acceptable carrier selected from the group consisting of poly(ethylene-co-vinyl acetate), PVA, partially hydrolyzed poly(ethylene-co-vinyl acetate), poly(ethylene-co-vinyl acetate-co-vinyl alcohol), a cross-linked poly(ethylene-co-vinyl acetate), a cross-linked partially hydrolyzed poly(ethylene-co-vinyl acetate), a cross-linked poly(ethylene-co-vinyl acetate-co-vinyl alcohol), poly-D,L-lactic acid, poly-L-lactic acid, polyglycolic acid, PGA, copolymers of lactic acid and glycolic acid, polycaprolactone, polyvalerolactone, poly(anhydrides), copolymers of polycaprolactone with polyethylene glycol, copolymers of polylactic acid with polyethylene glycol, polyethylene glycol; fibrin, Gelfoam (which is a water-insoluble, off-white, nonelastic, porous, pliable gel foam prepared from purified gelatin such as pork skin gelatin and water for injection), and combinations and blends thereof. Copolymers can comprise from about 1% to about 99% by weight of a first monomer unit such as ethylene oxide and from 99% to about 1% by weight of a second monomer unit such as propylene oxide. Blends of a first polymer such as gelatin and a second polymer such as poly-L-lactic acid or polyglycolic acid can comprise from about 1% to about 99% by weight of the first polymer and from about 99% to about 1% of the second polymer.
[0093] A fusion protein of this invention can be prepared as a solution or as a suspension in an aqueous medium such as a buffered saline or phosphate solution in water for injection, sterilized such as by filtration through a 0.2 micron or smaller pore size filter and injected in to an implanted matrix proximal to the tissue of the eye such as in a sterile gel foam (Gelfoam) matrix which can be absorbed completely. This absorption is dependent on several factors, including the amount used, degree of saturation with blood or other fluids, and the site of use. When placed in soft tissues, Gelfoam can be absorbed completely for example in from four to six weeks, without inducing excessive scar tissue. When applied to bleeding nasal, rectal or vaginal mucosa, it can liquefy within two to five days.
[0094] In another aspect, a pharmaceutical composition of this invention comprises a pharmaceutically acceptable carrier. For example, the carrier can be selected from the group consisting of water, a pharmaceutically acceptable buffer salt, a pharmaceutically acceptable buffer solution, a pharmaceutically acceptable antioxidant such as ascorbic acid, one or more low molecular weight pharmaceutically acceptable polypeptide such as a pharmaceutically acceptable peptide comprising about 2 to about 10 amino acid residues, one or more pharmaceutically acceptable protein such as albumin, one or more pharmaceutically acceptable amino acid such as an essential-to-human amino acid, one or more pharmaceutically acceptable carbohydrate, one or more pharmaceutically acceptable acetylated or otherwise esterified carbohydrate material obtained for example by esterification with a 2 to 20 carbon pharmaceutically acceptable carboxylic acid, a non-reducing sugar, glucose, sucrose, sorbitol, trehalose, mannitol, maltodextrin, dextrins, cyclodextrin, a pharmaceutically acceptable chelating agent, EDTA which is ethylenediamine tertraacetic acid, DTPA, a chelating agent for a divalent metal ion such as zinc ion, a chelating agent for a trivalent metal ion, glutathione, pharmaceutically acceptable nonspecific serum albumin, an antibody to a growth factor, and combinations thereof.
[0095] The pharmaceutical compositions of this invention can be sterile, sterilizable, and sterilized. A preferred method of sterilization comprises filtration of a pharmaceutical composition through a 0.2 micron filter in a sterile environment. The sterile filtered composition can be filled in a vial, preferably into a sterile vial, in a unit dosage volume amount (comprising a therapeutically effective amount of fusion protein of this invention) or in an integral multiple of a unit dosage amount (e.g., as 2 unit dosage amount, 3 unit dosage amounts, 4 unit dosage amounts, et cetera), preferably under an inert atmosphere such as sterile nitrogen or argon, and the vials sealed with a pharmaceutically acceptable stopper, optionally with a crimp cap. In another aspect, pharmaceutical composition is dried by removal of water, for example the aqueous medium can be removed from each vial by a drying process such as by lyophilization or evaporation to leave a dried or dehydrated matrix comprising the fusion protein of this invention, before sealing and capping of the vial. In another aspect, the carrier can comprise a sterile or sterilizable hypertonic solution of a pharmaceutically acceptable matrix-forming material or excipient that is compatible with the fusion protein, for example, such as a pharmaceutically acceptable non-reducing carbohydrate, together with a compound or fusion protein of the invention, which hypertonic solution can be placed in a vial and dried (e.g., by lyophilization) to provide a matrix comprising the fusion protein and the matrix-forming excipient, which can be sealed in the vial with a cap. Prior to use, sterile water can be added to the vial, for example via sterile syringe or cannula, which water can dissolve the matrix to provide a solution or suspension of the fusion protein. Sufficient water can be added to provide the reconstituted solution or suspension as an isotonic solution suitable for injectable or implantable use.
[0096] The pharmaceutical compositions provided herein may be placed within containers along with packaging material which provides instructions regarding the use of such materials. Generally, such instructions will include a description of the concentration of the active agent, as well as within certain embodiments, relative amounts or identities of excipient ingredients or diluents (e.g., water, saline or PBS). In addition, it may be necessary to reconstitute the pharmaceutical composition to a pharmaceutically acceptable solution or suspension by the addition of water and optionally also with shaking or sonication.
[0097] A pharmaceutical composition of the present invention in a therapeutically effective amount (e.g., in the form of a spray or an aerosol) may be delivered via an endoscopic procedure, wherein the composition is sprayed or aerosolized inside a patient to provide a coating comprising a fusion protein of this invention on a tissue inside a patient. In another aspect, coating of a pharmaceutical composition on to a tissue proximal to an eye and preferably accessible to the chorioid of the eye can inhibit angiogenesis in the region of tissue that is coated by the pharmaceutical composition.
[0098] Optionally, the pharmaceutical composition can be packaged in a vial or syringe for injection. The vial or syringe can contain a unit dosage amount of the pharmaceutical composition or of the fusion protein in lyophilized form which can be rehydrated by the addition of water such as water for injection. Optionally, the vial can contain two or more such as three or four or five unit dosage amounts of the fusion protein or a pharmaceutical composition thereof. Optionally, the pharmaceutical composition can by lyophilized. Preferably, the pharmaceutical composition is prepared in the presence of an inert or non-oxidizing or substantially oxygen-free gas or atmosphere such as nitrogen, argon, carbon dioxide, or a fluorocarbon or fluorohydrocarbon gas.
[0099] Preferably, a pharmaceutically acceptable solution of this invention is substantially isotonic with blood.
[0100] In one aspect, the fusion protein can be formed into a sterile aqueous pharmaceutically acceptable solution or nanoparticulate suspension in the presence of a substantially water-insoluble gas such fluorocarbon such as perfluoropropane and optionally in the presence of a pharmaceutically acceptable surface active agent such as a phospholipids or a polyethylene oxide-containing surfactant such as Pluronic F68 or F108, and subjected to vibration such as ultrasonic vibration or rapid shaking, wherein microbubbles comprising the fusion protein and the gas are obtained, preferably having a mean diameter of less than about 2 microns, which microbubbles can be injected by microinjection into the blood vessel which supplies blood to the eye to deliver a therapeutically effective amount of the fusion protein to the corroid and retina proximal to the macula.
[0101] Compositions of the present invention useful for treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy may be formulated in a variety of forms. For example, in one embodiment, a pharmaceutical composition comprising a therapeutically effective amount of a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, can comprise a microsphere, wherein the fusion protein is blended with or embibed into a matrix comprising a pharmaceutically acceptable polymeric carrier, optionally in the presence of water (wherein the blend comprises from about 0.1% to about 50% of a fusion protein of this invention in one embodiment; alternatively, a microsphere comprising a fusion protein of this invention and a polymeric carrier can be suspended in a sterile pharmaceutically acceptable aqueous medium which is preferably isotonic with blood, in another embodiment), a pharmaceutically acceptable buffer salt, a pharmaceutically acceptable surface active agent, a pharmaceutically acceptable carbohydrate, a pharmaceutically acceptable emollient, and the like.
[0102] In another embodiment, a pharmaceutical composition of this invention can comprise a therapeutically effective amount of a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, and can comprise a paste, a cream, an ointment, a suspension, for example in a pharmaceutically acceptable oil such as a pharmaceutically acceptable triglyceride, and the like.
[0103] In another embodiment, a pharmaceutical composition comprising a therapeutically effective amount of a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, can comprise a film, for example wherein the fusion protein is blended or mixed together with a pharmaceutically acceptable carrier such as an aqueous gelatin or an aqueous protein or a polymeric carrier or a combination thereof, optionally by injection in vivo proximal to the eye or proximal to the blood vessels of the eye, optionally in the presence of a pharmaceutically acceptable cross-linking agent species which can crosslink the carrier. In one embodiment, the blend can be injected. In another embodiment, the blend can be coated into a film or laminate, optionally in the present of a film base or a support or matrix, and dried or dehydrated, optionally by the addition of heat or by lyophilization. Films can be prepared in unit dosage forms or in bulk and divided and cut into unit dosage forms.
[0104] In another embodiment, a pharmaceutical composition comprising a therapeutically effective amount of a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, can comprise an aerosol or sprayable or aerosolizable composition such as a suspension or solution of the fusion protein in a microsphere comprising a fusion protein of this invention and a polymeric carrier can be suspended in a sterile pharmaceutically acceptable aqueous medium which is preferably isotonic with blood, in another embodiment), a pharmaceutically acceptable buffer salt, a pharmaceutically acceptable surface active agent, a pharmaceutically acceptable carbohydrate, a pharmaceutically acceptable emollient, and the like.
[0105] In another embodiment, a pharmaceutical composition of this invention can comprise a therapeutically effective amount of a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, and can comprise a paste, a cream, an ointment, a suspension, for example in a pharmaceutically acceptable oil such as a pharmaceutically acceptable triglyceride, and the like.
[0106] In another embodiment, a pharmaceutical composition comprising a therapeutically effective amount of a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, can comprise a film, for example wherein the fusion protein is blended or mixed together with a pharmaceutically acceptable carrier such as an aqueous gelatin or an aqueous protein or a polymeric carrier or a combination thereof, optionally by injection in vivo proximal to the eye or proximal to the blood vessels of the eye, optionally in the presence of a pharmaceutically acceptable cross-linking agent species which can crosslink the carrier. In one embodiment, the blend can be injected. In another embodiment, the blend can be coated into a film or laminate, optionally in the present of a film base or a support or matrix, and dried or dehydrated, optionally by the addition of heat or by lyophilization. Films can be prepared in unit dosage forms or in bulk and divided and cut into unit dosage forms.
[0107] In another embodiment, a pharmaceutical composition comprising a therapeutically effective amount of a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, can comprise an aerosol or sprayable or aerosolizable composition such as a suspension or solution of the fusion protein in a pharmaceutically acceptable fluid such as an aqueous solution of a buffer, optionally with a tonicity modifier; in a pharmaceutically acceptable fluid such as a supercritical or liquefied gas such as carbon dioxide or propane or a low molecular weight fluorocarbon or fluorohydrocarbon or bromofluorocarbon or chlorofluorocarbon and the like, each of which is a gas at 37° C. and ambient pressure, the composition suitable for use, for example, as an aerosol. An aerosol can be used to apply a fusion protein of this invention to the surface of a tissue proximal to the eye or into a tissue of the eye.
[0108] In another aspect, the compositions of the present invention may be formulated to contain a variety of additional compounds, in order to provide the formulated fusion protein formulations with certain physical properties (e.g., elasticity related to incorporation of a pharmaceutically acceptable plasticizing agent, a particular melting point such as about 30° C. such as by use of a polyethylene glycol, or a specified release rate which may be related to degree of crosslinking or rate of hydration in a matrix or to solubilization of a matrix, or to preferential solublization of one component of a matrix which can leave pores in the matrix through which a carrier fluid such a water can assist in transport of the fusion protein out of the matrix and into or onto a desired site such as tissue proximal to or a part of the eye in the body of a mammal.
[0109] A chemical modification of a drug molecule which can produce a lengthening of the half life of the drug molecule in bodily fluids such as blood and in tissue in vivo is PEGylation. PEGylation comprises a covalent attachment of one or more PEG-containing group to a drug molecule such as a protein or a peptide drug molecule. PEG is sometimes known referred to as poly(ethylene glycol) or polyoxyethylene or polyethylene glycol. A PEG-containing group is sometimes referred to as a “PEG” group or as a “MPEG” group where PEG refers to a hydroxy-terminated poly(ethylene glycol) or omega-hydroxy-PEG- or HO-PEG- and MPEG- refers to a methoxy-terminated poly(ethylene glycol) or omega-methoxy-PEG- or CH 3 O-PEG- or MeO-PEG-. Useful PEG and MPEG molecular weights are often from about 1000 Daltons to about 20,000 Daltons or more, preferably from about 2000 to about 20000 Daltons, and more preferably from about 5000 to about 20000 Daltons in average molecular weight. PEGylation can be achieved by chemically reacting an activated PEG or MPEG group (e.g., an MPEG that is terminally substituted with a chemically reactive functional group) with a chemically reactive site of a drug molecule (e.g., an epsilon-amino group of a lysine in a peptide or protein, a terminal amino group of a peptide or protein, a sulfhydryl group, and the like), in a suitable medium such as an aqueous buffer solution. Examples of a chemically reactive functional group on a PEG-containing reagent include an alpha-active ester of a PEG or MPEG such as an alpha-N-hydroxysuccinamidyl PEG or MPEG ester, an alpha-p-nitrophenyl PEG or MPEG ester, a vinyl sulfone group, a chlorotriazinyl group, and the like. The active functional group is usually separated from the PEG group by a spacing group which is, for example, covalently attached by a first covalent bond (e.g, amide bond formed by reaction of an active ester group with an amine; a thioether bond formed by reaction of a sulfhydryl group with a iodomethylcarbonyl group) to the PEG or MPEG group and by a second covalent bond to the chemically reactive functional group. Examples of useful spacing groups include a succinate ester spacing group, a methylenecarbonyl group, an ethylenecarbonyl group, a triazine group, an ethylenesulfonyl group, and the like. Useful pegylation reagents including low-diol pegylation reagents can be obtained commercially, for example, from Nektar Therapeutics, Huntsville, Ala. A useful family of PEG reagents and methods is described in U.S. Pat. No. 5,672,662, the disclosure of which is herein incorporated by reference. PEGylation is often associated with reduction of dose of drug and with lowered toxicity) and in some cases can interfere with generation of an immune response is PEGylation. PEGylation is believed to work by changing the size of the molecule and by changing interactions with other molecules such as antibodies by steric hindrance. PEGylation has been found to be effective for some therapeutic enzymes, peptides and antibodies.
[0110] A useful embodiment of a PEGylated fusion protein of the current invention can comprise a PEG-containing group (e.g., one or two or three or four or five molecules of 20,000 molecular weight PEG-containing group) covalently linked (e.g., by an amide bond or a thioether bond) to a fusion protein of the invention, wherein the cell permeation ability of the transport agent moiety in said PEGylated fusion protein is in the range of about 1% to about 100% (e.g., 10%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 75%, 80%, 80%, 95%, 99%) of the cell permeation ability of said transport agent in said fusion protein that is not PEGylated, and wherein the ADP-ribosyl transferase activity of said PEGylated fusion protein is in the range of about 1% to about 100% (e.g., 10%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 75%, 80%, 80%, 95%, 99%) of the ADP-ribosyl transferase activity of said fusion protein that is not PEGylated when the properties of the PEGylated fusion protein and the corresponding non-PEGylated fusion protein are compared under identical reference experimental conditions.
[0111] Within certain embodiments of the invention, compositions may be combined in order to achieve a desired effect (e.g., two or more compositions such as a first composition of microspheres comprising an amount (e.g., 15% by weight) of a fusion protein of this invention in a gelatin matrix together with 0.1% of a crosslinking agent such as succinaldehye and a second composition of microspheres comprising an amount (e.g., 25% by weight) of a fusion protein of this invention in a gelatin matrix together with about 2% of a crosslinking agent such as succinaldehye may be combined in order to achieve a modified net release rate of a fusion protein of this invention such as both a rapid release plus a slow or prolonged release.
[0112] In one aspect, a rapid release can comprise release of about 50% of the fusion protein in a composition in less than about 8 hours. In another aspect, a slow or prolonged release can comprise release of about 50% of the amount of fusion protein in about 2 weeks.
[0113] Within yet other aspects of the present invention, a pharmaceutical composition of this invention can be coated onto the surface of an implantable device such as a sterile surgical mesh, wire, stent, prosthetic device, and the like, to form a coated device, the coating comprising a fusion protein of this invention and optionally a carrier such as a polymeric carrier, which coated device may be implanted in a tissue or organ in a patient such as tissue proximal to the eye or part of the eye, or in a blood vessel which feeds blood to the eye, as part of a surgical treatment, which pharmaceutical composition is delivered in a therapeutically effective amount which can prevent or inhibit or delay or retard growth of neovascularization proximal to the location of the device such as retard neovascularization proximal to the macula.
[0114] In another aspect, a therapeutically effective amount of fusion protein can prevent or inhibit or delay or retard growth of blood vessels proximal to the macula which is remote from the site of the implanted device.
[0115] The concentration of the fusion protein can be from 0.01% to about 20% by weight of the carrier that forms a coating on the device, and the thickness of the coating can be from about 20 micrometers to about 1 millimeter. The coating can be applied by coating means known in the art of coating devices. For example, a coating comprising a pharmaceutical composition of this invention can be applied to the surface of a device by means of a spray or aerosol applicator in which the pharmaceutical composition as a solution in a liquid or fluid comprising a solvent or as a suspension in a liquid or fluid, which liquid or fluid can evaporate during and after application as a spray or an aerosol, is sprayed or aerosolized onto the surface of a device. Optionally, the coated composition can comprise reactive chemical functional groups such as olefins or anhydride groups or active esters or Michael reaction acceptors such as a carbon-carbon double bond conjugated to a carbonyl group, which double bond can react with an amine of a protein or peptide or gelatin such as a carrier protein, which reactive chemical functional groups can chemically or photochemically form crosslinks in the carrier, which can prevent solubilization or limit or modify or control swelling (as a function of concentration of the number of reactive functional groups or the time of exposure to crosslinking conditions such as ultraviolet or gamma irradiation of the coated device) of the coated carrier by aqueous fluid in the tissue of blood vessel in which the device is implanted. Control of swelling can be useful to control the rate at which a therapeutically effective amount of the fusion protein of this invention migrates from the device into the tissue proximal to the device and further into the body of the patient. A wide variety of crosslinking chemistry known in the art can be useful in this aspect of the invention as long as the biological activity of the fusion protein is not negated or eliminated. If an organic solvent or supercritical fluid or liquefied gas is used in the coating process, then a pharmaceutically acceptable carrier can be selected which does not immediately dissolve in the aqueous medium present in tissue proximal to the site of implantation but permits permeation of a therapeutically effective amount of the fusion protein into the aqueous medium.
[0116] Other methods of coating a device can be used such as dip coating of a composition, painting, curtain coating, and lamination of a pharmaceutical composition of this invention. In one embodiment, the surface of a device can be first coated with a first coating layer or primer layer such as gelatin or polyvinyl alcohol, which is then subsequently optionally crosslinked, and then coated with a pharmaceutical composition of this invention as a second coating layer. The primer layer can be selected to adhere to the surface of the metal or polymeric device and to adhere to the carrier of the second coating layer such as gelatin. The primer layer can also comprise immobilized chemical functional groups (e.g., which can be attached to a polymer in the primer layer) and which can form crosslinking bonds with the second layer. The primer layer can optionally contain relatively mobile molecules comprising for example two or more reactive functional groups such as a dialdehyde such as succinaldehye, which molecules can migrate into the second layer and react with chemical functional groups therein to form crosslinking molecular bridges.
[0117] In another embodiment, a pharmaceutically acceptable third layer can be overcoated on the second layer on the device, the third layer optionally void of a fusion protein of this invention. The third layer (e.g., a gelatin layer) can serve to control or modify the release rate of the fusion protein from the device, for example by being able to dissolve or swell or increase its permeability with respect to water or the fusion protein as a function of time to expose the second layer comprising the pharmaceutical composition of this invention to aqueous media from the tissue.
[0118] Within one embodiment of the invention a surgical mesh device comprising a pharmaceutical composition of the present invention coated on the surface of a wire or polymer mesh may be utilized or implanted in a patient such as during a surgical procedure on the eye of a patient. The coated mesh device can release a therapeutically effective amount of the active component (such as C3APLT or an active mutant or truncated form thereof) of the pharmaceutical composition sufficient to prevent neovascularization in Bruch's membrane proximal to the macula and proximal to the site of implantation of the coated device. The fusion protein can migrate from the device at a rate sufficient to provide a therapeutically effective concentration range in the tissue proximal to the device.
[0119] A currently preferred concentration range is about 0.0001 micrograms of fusion protein per cubic centimeter (cc) of tissue to about 100 micrograms per cubic centimeter of tissue can be useful. A currently more preferred therapeutically effective concentration range is about 0.001 micrograms per cc to about 50 micrograms per cc of tissue.
[0120] In one embodiment of the invention, the fusion protein can have molecular weight of from about 240,000 daltons to about 300,000 daltons.
[0121] Another aspect of the invention comprises a pharmaceutical composition of this invention in a kit of parts such as a kit comprising a container and a pharmaceutical composition of this invention; a kit comprising a sealed vial and a pharmaceutical composition of this invention; a kit comprising a sterile syringe and a pharmaceutical composition of this invention; a kit comprising a sterile syringe containing a pharmaceutical composition of this invention; a kit comprising a spray or aerosol applicator and a pharmaceutical composition of this invention; a kit comprising a brush applicator and a pharmaceutical composition of this invention; a kit comprising a cannula and a pharmaceutical composition of this invention; a kit comprising a powder applicator and a pharmaceutical composition of this invention (which powder applicator can be used to administer a pharmaceutical dosage form of this invention as a powder by sprinkle application of a dried (e.g., lyophilized) powder in a topical application to a tissue; a kit comprising a coated implantable device and a pharmaceutical composition of this invention, wherein administration is by implantation.
[0122] In accordance with the present invention, the transport agent region may be at the amino-terminal end of the polypeptide (i.e., protein) and the ADP-ribosyl transferase C3 or ADP-ribosyl transferase C3 analogue may be at the carboxy-terminal end of the polypeptide (i.e., protein).
[0123] In accordance with the present invention, the transport agent region may be at the carboxy-terminal end of the polypeptide (i.e., protein) and the ADP-ribosyl transferase C3 or ADP-ribosyl transferase C3 analogue may be at the amino-terminal end of the polypeptide (i.e., protein).
[0124] In a further aspect, the present invention provides a method of (for) suppressing the inhibition of neuronal axon growth (e.g., in a mammal, (e.g., human, animal)) comprising administering (e.g., delivering) a member selected from the group consisting of a drug delivery construct, a drug conjugate, a fusion protein and a polypeptide (e.g. including pharmaceutically acceptable chemical equivalents thereof), said polypeptide comprising at least one (one or more) transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues (directly) at (to) a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site (of a patient), in an amount effective to counteract said inhibition. Such application could be useful for treatment of a wide variety of peripheral neuropathies, such as diabetic neuropathy.
[0125] The present invention, for example, provides recombinant Rho antagonists comprising C3 enzymes with basic stretches of amino acids (e.g., a basic amino acid rich region) or a proline rich region added to the C3 coding sequence to facilitate the uptake thereof into tissue or cells for the repair and/or promotion of repair or promotion of growth in the CNS, even in the lack of traumatic axon damage. Examples of basic amino acid rich regions and proline rich regions are given below.
[0126] In yet a further aspect, the present invention provides a method of (for) facilitating axon growth (e.g., in a mammal, (e.g., human, animal)) comprising delivering a polypeptide or conjugate comprising at least one transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues directly at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site, in an amount effective to facilitate said growth.
[0127] In an additional aspect, the present invention provides a method of (for) treating nerve injury (e.g., in a mammal, (e.g., human, animal)) comprising delivering a polypeptide or conjugate comprising at least one transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues directly at (to) a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site.
[0128] In yet an additional aspect, the present invention provides a method of (for) preventing cell apoptosis (e.g., in a mammal, (e.g., human, animal)) comprising delivering a polypeptide or conjugate comprising at least one transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues directly at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site.
[0129] In another aspect, the present invention provides a method of (for) treating ischemic damage related to stroke (e.g., in a mammal, (e.g., human, animal)) comprising delivering a polypeptide or conjugate comprising at least one transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues directly at a central nervous system (CNS) lesion site (to said mammal).
[0130] In yet another aspect, the present invention provides a method of (for) suppressing Rho activity comprising delivering a polypeptide or conjugate comprising at least one transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues directly at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site, in an amount effective to suppress said activity.
[0131] In accordance with an additional aspect, the present invention provides a method of (for) regenerating injured axon (e.g., in a mammal, (e.g., human, animal)) comprising delivering a polypeptide or conjugate comprising at least one transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues directly at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site (e.g., in a mammal), in an amount effective to regenerate said injured axon.
[0132] In accordance with a further aspect, the present invention provides a method of (for) helping neurons to make new cell connection (developing axon, dendrite, neurite with other (surrounding) cells (neuronal cells) comprising delivering a polypeptide or conjugate comprising at least one transport agent region and an active agent region selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues directly at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site.
[0133] In an additional aspect, the present invention provides a method for (of) preparing a polypeptide comprising at least one (one or more) transport agent region and an active agent region, wherein said transport agent region may be selected from the group consisting of SEQ ID NO.: 21, SEQ ID NO.: 26, SEQ ID NO.: 31, SEQ ID NO.: 44, SEQ ID NO.: 45, SEQ ID NO.: 46, SEQ ID NO.: 47, SEQ ID NO.: 48 and analogues thereof, and wherein said active agent region may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues, said method comprising:
a) cultivating a host cell under conditions which provide for the expression of the polypeptide within the cell; and b) recovering the polypeptide by a purification step.
[0136] In accordance with the present invention, the purification of polypeptide may be done by affinity methods, ion exchange chromatography, size exclusion chromatography, hydrophobicity or any other purification technique typically used for protein purification. Preferably, the purification step would be performed under non-denaturating conditions. On the other hand, if a denaturating step is required, the protein may be renatured using techniques known in the art.
[0137] In another aspect, the present invention provides a polypeptide consisting of a basic amino acid rich region and an active agent region, wherein, amino acids from said basic rich region comprises amino acids selected from the group consisting of Histidine, Asparagine, Glutamine, Lysine and Arginine and wherein the active agent region is ADP-ribosyl transferase C3.
[0138] In yet another aspect, the present invention relates to the use of a polypeptide comprising at least one transport agent region and an active agent region, said active agent region being selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues for the manufacture of a medicament (or a pharmaceutical composition) for suppressing the inhibition of neuronal axon growth.
[0139] In accordance with the present invention, the polypeptide may be selected from the group consisting of C3APL (SEQ ID NO.: 4), C3APL (SEQ ID NO.:37), C3APS (SEQ ID NO.:6), C3-TL (SEQ ID NO.:14), C3-TS (SEQ ID NO.:18), C3Basic1 (SEQ ID NO.:25), C3Basic2 (SEQ ID NO.:30), C3Basic3 (SEQ ID NO.:35), SEQ ID NO.: 20 and SEQ ID NO.: 43.
[0140] In a further aspect, the present invention relates to the use of a polypeptide comprising at least one transport agent region and an active agent region, said active agent region being selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues for the manufacture of a medicament (or pharmaceutical composition) for facilitating axon growth.
[0141] In accordance with the present invention, the polypeptide may be selected from the group consisting of C3APL (SEQ ID NO.: 4), C3APLT (SEQ ID NO.:37), C3APS (SEQ ID NO.:6), C3-TL (SEQ ID NO.:14), C3-TS (SEQ ID NO.:18), C3Basic1 (SEQ ID NO.:25), C3Basic2 (SEQ ID NO.:30), C3Basic3 (SEQ ID NO.:35), SEQ ID NO.: 20 and SEQ ID NO.: 43.
[0142] In yet a further aspect the present invention relates to the use of a polypeptide comprising at least one (one or more) transport agent region and an active agent region, said active agent region being selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues for the manufacture of a medicament (or pharmaceutical composition) for treating nerve injury (e.g., in a mammal, (e.g., human, animal)).
[0143] In accordance with the present invention, the polypeptide may be selected from the group consisting of C3APL (SEQ ID NO.: 4), C3APLT (SEQ ID NO.:37), C3APS (SEQ ID NO.:6), C3-TL (SEQ ID NO.:14), C3-TS (SEQ ID NO.:18), C3Basic1 (SEQ ID NO.:25), C3Basic2 (SEQ ID NO.:30), C3Basic3 (SEQ ID NO.:35), SEQ ID NO.: 20 and SEQ ID NO.: 43.
[0144] In accordance with the present invention, the transport agent region discussed herein may be selected from the group consisting of a basic amino acid rich region (region comprising basic amino acid (e.g., arginine, lysine, histidine, glutamine, and/or asparagine)) and a proline rich region (e.g. region comprising prolines).
[0145] In accordance with the present invention, the basic amino acid rich region discussed herein may be selected from the group consisting of SEQ ID NO.: 48, a subdomain of HIV Tat protein (e.g., SEQ ID NO.: 46, SEQ ID NO.: 47, or any other subdomain of Tat, that could act as a transport sequence), a homeodomain of antennapedia (e.g., SEQ ID NO.: 44, SEQ ID NO.: 45, or any other domain of antennapedia, that could act as a transport sequence), a homeoprotein transport sequence, a Histidine tag, and analogues thereof (e.g., SEQ ID NO.: 21, SEQ ID NO.: 26, SEQ ID NO.:31).
[0146] In accordance with the present invention, the basic amino acid region discussed herein may be selected from the group consisting of SEQ ID NO.: 21 (Basic 1), SEQ ID NO.: 26 (Basic2), SEQ ID NO.: 31 (Basic3), SEQ ID NO.: 44 (APL), SEQ ID NO.: 45 (APS) SEQ ID NO.: 46 (TL), SEQ ID NO.: 47 (TS), and analogues thereof.
[0147] In accordance with the present invention, the proline rich region discussed herein may be selected from the group consisting of SEQ ID NO.: 48 (APLT) and analogues thereof.
[0148] In another aspect, the present invention provides an isolated polynucleotide comprising at least the polynucleotide sequence (for example the polynucleotide sequence disclosed herein in addition with (or in some cases without) a suitable (DNA) backbone (e.g., plasmid, viral vector)) selected from the group consisting of SEQ ID NO.: 3, SEQ ID NO.: 5, SEQ ID NO.: 13, SEQ ID NO.: 17, SEQ ID NO.: 19, SEQ ID NO.: 24, SEQ ID NO.: 29, SEQ ID NO.: 34, SEQ ID NO.: 36, and SEQ ID NO.: 42.
[0149] In yet another aspect, the present invention provides a cell transformed (transfected, transduced, infected, electroporated, micro-injected, etc.) with an isolated polynucleotide comprising at least the polynucleotide sequence (for example the polynucleotide sequence disclosed herein in addition with (or in some cases without) a suitable backbone (e.g., plasmid, viral vector)) selected from the group consisting of SEQ ID NO.: 3, SEQ ID NO.: 5, SEQ ID NO.: 13, SEQ ID NO.: 17, SEQ ID NO.: 19, SEQ ID NO.: 24, SEQ ID NO.: 29, SEQ ID NO.: 34, SEQ ID NO.: 36, and SEQ ID NO.: 42.
[0150] In a further aspect, the present invention provides a delivery agent consisting of a cargo moiety in combination with a transport moiety, wherein the transport moiety is selected from the group consisting of SEQ ID NO: 48 and analogues thereof. SEQ ID NO: 48 and analogues thereof act as a transport moiety which facilitate penetration of the cell membrane. Any cargo moiety (e.g., protein, chemicals) linked (e.g. attached) to SEQ ID NO: 48 or to some analogues thereof are encompassed by the present invention. For example, SEQ ID NO: 48 and analogues thereof may be fused to an anticancer agent, a therapeutic agent, an apoptotic agent, an anti-apoptotic agent, a reporter protein, an antibody, an antibody fragment, a dye, a probe, a marker etc. In one aspect, the polypeptidic cell-membrane transport moiety can comprise a peptide containing from about 5 to about 50 amino acids.
[0151] In accordance with the present invention, the cargo moiety may retain biological activity following transport moiety-dependent intracellular delivery. Biological activity may include for example, biological properties (e.g. enzymatic activity) as well as its immunological properties. The cargo moiety may have a direct biological effect on the cell, such as for example killing the cell following its internalization or may have an indirect biological effect, for example, the cargo moiety may be a pro-drug that is inactive by itself but becomes active following modification (e.g., cleavage, phosphorylation, etc.) or when a second molecules is introduced inside the cell. The cargo moiety may also be a biologically inactive (i.e., inert) compound such as a labeling molecule (e.g., chemicals, proteins), an imaging molecule etc.
[0152] In accordance with the present invention, the agent may be a fusion protein having an amino-terminal that is the cargo moiety and having a carboxy-terminal that is the transport moiety.
[0153] In accordance with the present invention the cargo moiety may be selected from the group consisting of analytical molecules (e.g., molecules used in tissue culture experiments, markers, probes, dyes, reporter proteins) therapeutic molecules (e.g., toxin, drug, pro-drug), prophylactic molecules and diagnostic molecules (i.e., molecules used in in vivo or in vitro detection of a specific condition, metabolite, other molecule). Examples of analytical molecules, therapeutic molecules, prophylactic molecules and diagnostic molecules includes proteins (e.g., enzymes (e.g., nucleases, proteases, kinases, etc.), cytokines, chemokines, antigen, antibodies, antibody fragments, reporter proteins such as horseradish peroxidase, beta-galactosidase, fluorescent proteins (e.g., green fluorescent protein)), nucleic acids, polysaccharides, dyes, isotopes (e.g., radioisotope), markers, probes, and other types of chemicals. Transport polypeptides of the present invention may be advantageously attached to cargo molecules by chemical cross-linking or by genetic fusion.
[0154] In accordance with the present invention the cargo moiety may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues thereof.
[0155] In an additional aspect, the present invention relates to the polypeptide set forth in SEQ ID NO: 48 and analogues thereof.
[0156] In yet an additional aspect, the present invention provides a polypeptide as set forth in SEQ ID NO: 48 and analogues thereof, wherein said polypeptide and analogues may be able to act as a transport agent for the intracellular delivery of a cargo agent selected from the group consisting of analytical molecules, therapeutic molecules, prophylactic molecules, and diagnostic molecules.
[0157] In accordance with the present invention, the cargo agent may be selected from the group consisting of ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues thereof.
[0158] The transport of a cargo moiety across the cellular membrane (intracellular delivery) may be facilitated (increased) when linked (e.g., genetically fused, chemically cross-linked, etc.) to SEQ ID NO: 48 and analogues thereof. Therefore it is an object of the present invention to provide a method for the intracellular delivery of a cargo moiety, the method comprising exposing the cell to a delivery agent comprising a cargo moiety and a transport moiety, said transport moiety being selected from the group consisting of SEQ ID NO: 48 and analogues thereof and wherein said transport moiety enables the delivery agent to be delivered inside the cell (i.e., across cellular membranes). An example of a cargo moiety that may be delivered across the cell membrane is ADP-ribosyl transferase C3 and analogues thereof. Other examples of a cargo moiety are mentioned herein. The method also comprise bringing the delivery agent comprising a cargo moiety and a transport moiety (SEQ ID NO: 48 and analogues thereof) in the surrounding of a target cell in a manner (e.g., concentration) sufficient to permit the uptake of the delivery agent by the cell. For example, in the case of in vitro (e.g., cell culture) delivery, the delivery agent (in a pharmaceutically acceptable carrier, diluent, excipient, etc.) may be added directly to the extracellular milieu (e.g., cell culture media) of adherent cells (i.e., cell lines or primary cells) or cells in suspension. Alternatively, cells may be harvested and concentrated before being put in contact with the delivery agent. Intracellular delivery may be monitored by techniques known in the art, such as for example, immunofluorescence, immunohistochemistry or by the intrinsic properties of the cargo moiety (e.g., its enzymatic activity).
[0159] In vivo delivery (in a mammal) may be performed for example, by exposing (i.e., contacting) a tissue, a nerve injury site, an open wound, etc. with the delivery agent (in a pharmaceutically acceptable carrier, diluent, excipient, fibrin gel etc.) of the present invention in an amount sufficient to promote the biological effect of the cargo moiety (e.g., recovery, healing of the wounded tissue, etc.). In addition, in vivo delivery may be performed by other methods known in the art such as for example, injection via the intramuscular (IM), subcutaneous (SC), intra-dermal (ID), intra-venous (IV) or intra-peritoneal (IP) routes or administration at the mucosal membranes including the oral and nasal cavity membranes using any suitable means. Alternatively, cells may be isolated from a mammal and treated (exposed) ex-vivo (e.g., in gene therapy techniques) with the delivery agent of the present invention before being re-infused in the same individual or in a compatible individual.
[0160] The term “Rho antagonists” as used herein includes, but is not restricted to, (known) C3, including C3 chimeric proteins, and like Rho antagonists.
[0161] The term “C3 protein” refers to ADP-ribosyl transferase C3 isolated from Clostridium botulinum or a recombinant ADP-ribosyl transferase.
[0162] The term “C3-like protein”, “ADP-ribosyl transferase C3-like protein”, “ADP-ribosyl transferase C3 analogue”, “C3-like transferase” or “C3 chimeric proteins” as used herein refers to any protein (polypeptide) having a biological activity similar (e.g., the same, substantially similar), to ADP-ribosyl transferase C3. Examples of such C3-like protein include, for example, but are not restricted to C3APL, C3APLT, C3APS, C3-TL, C3-TS, C3Basic1, C3Basic2 and C3Basic3 and the protein defined in SEQ ID NO.: 20.
[0163] The term “nerve injury site” refers to a site of traumatic nerve injury or nerve injury caused by disease. The nerve injury site may be a single nerve (eg sciatic nerve) or a nerve tract comprised of many nerves (eg. damaged region of the spinal cord). The nerve injury site may be in the central nervous system or peripheral nervous system or in any region needing repair. The nerve injury site may form as a result of damage caused by stroke. The nerve injury site may be in the brain as a result of surgery, brain tumour removal or therapy following a cancerous lesion. The nerve injury site may result from stroke, Parkinson's disease, Alzheimer's disease, amyotrophic lateral sclerosis (ALS), diabetes or any other type of neurodegenerative disease.
[0164] The term “cargo” refers to a molecule other than the transport moiety and that is either (1) not inherently capable of entering a cell (e.g., cell compartment) or (2) not inherently capable of entering a cell (e.g., cell compartment) at a useful rate. The term “cargo” as used herein refers either to a molecule per se, i.e., before conjugation, or to the cargo moiety of a transport polypeptide-cargo conjugate. Examples of “cargo” include, but are not limited to, small molecules and macromolecules such as polypeptides, nucleic acids (polynucleotides), polysaccharides and chemicals.
[0165] As used herein, the term “delivery agent” relates to an agent comprising a cargo moiety and a transport moiety. Examples of cargo moiety are discussed above and includes for example ADP-ribosyl transferase C3 and ADP-ribosyl transferase C3 analogues. Examples of transport moiety comprise for example SEQ ID NO: 48 and analogues thereof.
[0166] “Polynucleotide” generally refers to any polyribonucleotide or polydeoxyribonucleotide, which may be unmodified RNA or DNA, or modified RNA or DNA. “Polynucleotides” include, without limitation single- and double-stranded DNA, DNA that is a mixture of single- and double-stranded regions, single- and double-stranded RNA, and RNA that is a mixture of single- and double-stranded regions, hybrid molecules comprising DNA and RNA that may be single-stranded or, more typically, double-stranded or a mixture of single- and double-stranded regions. In addition, “polynucleotide” refers to triple-stranded regions comprising RNA or DNA or both RNA and DNA. The term polynucleotide also includes DNAs or RNAs containing one or more modified bases and DNAs or RNAs with backbones modified for stability or for other reasons. “Modified” bases include, for example, tritylated bases and unusual bases such as inosine. A variety of modifications has been made to DNA and RNA; thus “polynucleotide” embraces chemically, enzymatically or metabolically modified forms of polynucleotides as typically found in nature, as well as the chemical forms of DNA and RNA characteristic of viruses and cells. “Polynucleotide” includes but is not limited to linear and end-closed molecules. “Polynucleotide” also embraces relatively short polynucleotides, often referred to as oligonucleotides.
[0167] “Polypeptides” refers to any peptide or protein comprising two or more amino acids joined to each other by peptide bonds or modified peptide bonds (i.e., peptide isosteres). “Polypeptide” refers to both short chains, commonly referred as peptides, oligopeptides or oligomers, and to longer chains generally referred to as proteins. As described above, polypeptides may contain amino acids other than the 20 gene-encoded amino acids.
[0168] As used herein the term “analogues” relates to mutants, variants, chimeras, fusions, deletions, additions and any other type of modifications made relative to a given polypeptide. The term “analogue” is synonym of homologue, derivative and chemical equivalent or biological equivalent.
[0169] As used herein, the term “homologous” sequence relates to nucleotide or amino acid sequence derived from the DNA sequence or polypeptide sequence of C3APL, C3APLT, C3APS, C3-TL, C3-TS, C3Basic1, C3Basic2 and C3Basic3.
[0170] As used herein, the term “heterologous” sequence relates to DNA sequence or amino acid sequence of a heterologous polypeptide and includes sequence other than that of C3APL, C3APLT, C3APS, C3-TL, C3-TS, C3Basic1, C3Basic2 and C3Basic3.
[0171] As used herein the term “basic amino acid rich region” relates to a region of a protein with a high content of the basic amino acids such as Arginine, Histidine, Asparagine, Glutamine, Lysine (Lys). A “basic amino acid rich region” may have, for example 15% or more (up to 100%) of basic amino acids. In some instance, a “basic amino acid rich region” may have less than 15% of basic amino acids and still function as a transport agent region. More preferably, a basic amino acid region will have 30% or more (up to 100%) of basic amino acids.
[0172] As used herein the term “proline rich region” refers to a region of a protein with 5% or more (up to 100%) of proline in its sequence. In some instance a “proline rich region” may have between 5% and 15% of prolines. Additionally, a “proline rich region” refers to a region, of a protein containing more prolines than what is generally observed in naturally occurring proteins (e.g., proteins encoded by the human genome). “Proline rich region” of the present invention function as a transport agent region.
[0173] The term “proline-rich region” can further refer to any linear sequence of 10 amino acids linked together by peptide amide bonds within a molecule comprising a peptide or protein, wherein at least 3 out of the 10 amino acids in the linear sequence are proline residues, wherein each proline is covalently linked in a peptide amide bond at its nitrogen and in another peptide amide bond at its carboxylic (carbonyl) site. A proline-rich region in any 10 amino acid sequence within a peptide can comprise 2 or more proline residues and 8 or fewer non-proline amino acids. For example, in one aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 2 proline residues and 8 non-proline amino acid residues distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 3 proline residues and 7 non-proline amino acid residues distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 4 proline residues and 6 non-proline amino acid residues distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 5 proline residues and 5 non-proline amino acid residues distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 6 proline residues and 4 non-proline amino acid residues distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 7 proline residues and 3 non-proline amino acid residues distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 8 proline residues and 2 non-proline amino acid residues distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 9 proline residues and 1 non-proline amino acid residue distributed in any combination among the 10 amino acids. In another aspect, a proline-rich region in a peptide comprising a 10 amino acid sequence within a peptide comprising 10 or more amino acids can comprise 10 proline residues.
[0174] In another aspect, a “proline-rich region” refers to an amino acid sequence region of a protein containing more prolines than that which is generally observed in naturally occurring proteins (e.g., proteins encoded by the human genome).
[0175] A “proline-rich region” of a peptide in a composition of the present invention can function to enhance the rate of transport of a fusion protein of this invention through a cell membrane.
[0176] A non-proline-rich region of a peptide or protein can comprise a sequence of 10 amino acids covalently linked by peptide bonds, which region contains zero or one proline residues.
[0177] A cell membrane transport-enhancing peptide of a composition of this invention can comprise one or more than one proline-rich regions, each of which can be the same or different sequence of amino acids, and each of which is covalently linked together by a peptide bond or by the peptide bonds comprising one or more non-proline-rich amino-acid sequence which may each be the same or different when the non-proline-rich amino-acid sequence comprises more than 10 amino acids.
[0178] In one aspect of this invention, a preferred composition comprises a cell-permeable fusion protein conjugate comprising a proline-rich polypeptidic cell-membrane transport moiety comprising a proline-rich amino acid sequence added to the C-terminal region of a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, in a fusion protein conjugate. An especially preferred composition is a fusion protein designated C3APLT. In another aspect of this invention, a preferred composition comprises a cell-permeable fusion protein conjugate comprising a proline-rich polypeptidic cell-membrane transport moiety comprising a proline-rich amino acid sequence added to the N-terminal region of a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, in a fusion protein conjugate. Fusion protein compositions comprising a proline-rich amino acid sequence added to the N-terminal region of a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof, are sometimes referred to herein as analogs or variants of C3APLT.
[0179] Fusion protein functional analogs of a Clostridium botulinum C3 exotransferase unit can comprise polypeptides such as biologically active fragments and altered-amino-acid-sequence analogs of a fusion protein such as C3APLT, wherein the biological activity of such fragments and altered-amino-acid-sequence analogs of C3APLT derives from a mechanism of action essentially similar to that of C3APLT. Such fragments can comprise or encompass amino acid sequences having truncations of one or more amino acids relative to that in C3APLT. Such fragments comprise or encompass amino acid sequences having truncations (or eliminations) of one or more amino acids relative to the sequence of amino acids in C3APLT, wherein a truncation may originate from the amino or N-terminus, from the carboxy or C-terminus, or from the interior of the protein sequence. Analogs and variants of a fusion protein such as C3APLT of the invention can comprise an insertion or a substitution of one or more amino acids.
[0180] Compositions of this invention comprising fragments, analogs and variants useful in this invention have the biological property of C3APLT and C3 that is capable of inactivation a Rho GTPase by ADP-ribosylation. Preferably a fusion protein of this invention is capable of inactivation of more than one Rho GTPase. Preferably the activity of a fusion protein of this invention with respect to ADP-ribosylation of a Rho GTPase is in the range of 0.5 to 10 times the activity of Clostridium botulinum C3 in inactivation of a Rho GTPase, more preferably 0.5 to 100 times the activity of Clostridium botulinum C3 in inactivation of a Rho GTPase, and most preferably 0.8 to 1000 times the activity of Clostridium botulinum C3 in inactivation of a Rho GTPase.
[0181] With respect to inactivation of a Rho GTPase by ADP-ribosylation, the activity provided by the presence of the Glu 173 residue in Clostridium botulinum C3 exoenzyme is present in fusion proteins of this invention. Preferably, the amino acid sequence of a fusion protein of this invention comprises the Glu 173 amino acid residue in Clostridium botulinum C3 exoenzyme and the fusion protein of this invention exhibits ADP-ribosylation activity in the range of 0.5 to 10 times the ADP-ribosylation activity of Clostridium botulinum C3, more preferably 0.5 to 100 times the ADP-ribosylation activity of Clostridium botulinum C3, and most preferably 0.8 to 1000 times the ADP-ribosylation activity of Clostridium botulinum C3. The particular portion of the structure of Clostridium botulinum C3 that must be conserved to retain ADP-ribosylation activity can be found in Saito et al., FEBS Letters, 371:105-109, 1995, the entire contents of which is hereby incorporated by reference.
[0182] As used herein the term “to help neuron make new connections with other cells” or “helping neurons to make new cell connection” means that upon treatment of cells (e.g., neuron(s)) or tissue with a drug delivery construct, a conjugate, a fusion-protein, a polypeptide or a pharmaceutical compositions of the present invention, neurons may grow (develop) for example new dendrite, new axon or new neurite (i.e., cell bud), or already existing dendrite(s), axon or neurite (i.e., cell bud) are induce to grow to a greater extent.
[0183] As used herein, the term “vector” refers to an autonomously replicating DNA or RNA molecule into which foreign DNA or RNA fragments are inserted and then propagated in a host cell for either expression or amplification of the foreign DNA or RNA molecule. The term “vector” comprises and is not limited to a plasmid (e.g., linearized or not) that can be used to transfer DNA sequences from one organism to another.
[0184] The term “pharmaceutically acceptable carrier” or “adjuvant” and “physiologically acceptable vehicle” and the like are to be understood as referring to an acceptable carrier or adjuvant that may be administered to a patient, together with a compound of this invention, and which does not destroy the pharmacological activity thereof. Further, as used herein “pharmaceutically acceptable carrier” or “pharmaceutical carrier” are known in the art and include, but are not limited to, 0.01-0.1 M and preferably 0.05 M phosphate buffer or 0.8% saline. Additionally, such pharmaceutically acceptable carriers may be aqueous or non-aqueous solutions, suspensions, and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's or fixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers such as those based on Ringer's dextrose, and the like. Preservatives and other additives may also be present, such as, for example, antimicrobials, antioxidants, collating agents, inert gases and the like.
[0185] As used herein, “pharmaceutical composition” means therapeutically effective amounts (dose) of the agent together with pharmaceutically acceptable diluents, preservatives, solubilizers, emulsifiers, adjuvant and/or carriers. A “therapeutically effective amount” as used herein refers to that amount which provides a therapeutic effect for a given condition and administration regimen. Such compositions are liquids or lyophilized or otherwise dried formulations and include diluents of various buffer content (e.g., Tris-HCl, acetate, phosphate), pH and ionic strength, additives such as albumin or gelatin to prevent absorption to surfaces, detergents (e.g., Tween 20, Tween 80, Pluronic F68, bile acid salts). Solubilizing agents (e.g., glycerol, polyethylene glycerol), anti-oxidants (e.g., ascorbic acid, sodium metabisulfite), preservatives (e.g., thimerosal, benzyl alcohol, parabens), bulking substances or tonicity modifiers (e.g., lactose, mannitol), covalent attachment of polymers such as polyethylene glycol to the protein, complexation with metal ions, or incorporation of the material into or onto particulate preparations of polymeric compounds such as polylactic acid, polyglycolic acid, hydrogels, etc, or onto liposomes, microemulsions, micelles, unilamellar or multilamellar vesicles, erythrocyte ghosts, or spheroplasts. Such compositions will influence the physical state, solubility, stability, rate of in vivo release, and rate of in vivo clearance. Controlled or sustained release compositions include formulation in lipophilic depots (e.g., fatty acids, waxes, oils). Also comprehended by the invention are particulate compositions coated with polymers (e.g., poloxamers or poloxamines). Other embodiments of the compositions of the invention incorporate particulate forms protective coatings, protease inhibitors or permeation enhancers for various routes of administration, including parenteral, pulmonary, nasal and oral routes. In one embodiment the pharmaceutical composition is administered parenterally, paracancerally, transmucosally, transdermally, intramuscularly, intravenously, intradermally, subcutaneously, intraperitonealy, intraventricularly, intracranially intratumorally or more preferably, directly at a central nervous system (CNS) lesion site or a peripheral nervous system (PNS) lesion site.
[0186] In addition, the term “pharmaceutically effective amount” or “therapeutically effective amount” refers to an amount (dose) effective in treating a patient, having, for example, a nerve injury. It is also to be understood herein that a “pharmaceutically effective amount” may be interpreted as an amount giving a desired therapeutic effect, either taken into one dose or in any dosage or route or taken alone or in combination with other therapeutic agents. In the case of the present invention, a “pharmaceutically effective amount” may be understood as an amount of ADP-ribosyl transferase C3 or ADP-ribosyl transferase C3 analogues (e.g., fusion proteins) of the present invention which may for example, suppress (e.g., totally or partially) the inhibition of neuronal axon growth, facilitate axon growth, prevent cell apoptosis, suppress Rho activity, help regenerate injured axon, or which may help neurons to make new connections with other cells.
[0187] As may be appreciated, a number of modifications may be made to the polypeptides of the present invention, such as for example the active agent region (e.g., ADP-ribosyl transferase C3 or ADP-ribosyl transferase C3 analogue) or the transport agent region (e.g., a subdomain of HIV Tat protein, or a homeodomain of antennapedia) and fragments thereof without deleteriously affecting the biological activity of the polypeptides or fragments. Polypeptides of the present invention comprises for example, those containing amino acid sequences modified either by natural processes, such as posttranslational processing, or by chemical modification techniques which are known in the art. Modifications may occur anywhere in a polypeptide including the polypeptide backbone, the amino acid side-chains and the amino or carboxy termini. It will be appreciated that the same type of modification may be present in the same or varying degrees at several sites in a given polypeptide. Also, a given polypeptide may contain many types of modifications. Polypeptides may be branched as a result of ubiquitination, and they may be cyclic, with or without branching. Cyclic, branched and branched cyclic polypeptides may result from posttranslational natural processes or may be made by synthetic methods. Modifications comprise for example, without limitation, acetylation, acylation, addition of acetomidomethyl (Acm) group, ADP-ribosylation, amidation, covalent attachment to fiavin, covalent attachment to a heme moiety, covalent attachment of a nucleotide or nucleotide derivative, covalent attachment of a lipid or lipid derivative, covalent attachment of phosphatidylinositol, cross-linking, cyclization, disulfide bond formation, demethylation, formation of covalent cross-links, formation of cystine, formation of pyroglutamate, formylation, gamma-carboxylation, glycosylation, GPI anchor formation, hydroxylation, iodination, methylation, myristoylation, oxidation, proteolytic processing, phosphorylation, prenylation, racemization, selenoylation, sulfation, transfer-RNA mediated addition of amino acids to proteins such as arginylation and ubiquitination (for reference see, Protein-structure and molecular properties, 2 nd Ed., T. E. Creighton, W.H. Freeman and Company, New-York, 1993).
[0188] Other type of polypeptide modification may comprises for example, amino acid insertion (i.e., addition), deletion and substitution (i.e., replacement), either conservative or non-conservative (e.g., D-amino acids, desamino acids) in the polypeptide sequence where such changes do not substantially alter the overall biological activity of the polypeptide. Polypeptides of the present invention comprise for example, biologically active mutants, variants, fragments, chimeras, and analogues; fragments encompass amino acid sequences having truncations of one or more amino acids, wherein the truncation may originate from the amino terminus (N-terminus), carboxy terminus (C-terminus), or from the interior of the protein. Analogues of the invention involve an insertion or a substitution of one or more amino acids. Variants, mutants, fragments, chimeras and analogues may have the biological properties of polypeptides of the present invention which comprise for example (without being restricted to the present examples) to facilitate neuronal axon growth, to suppress the inhibition of neuronal axon growth, to facilitate neurite growth, to inhibit apoptosis, to treat nerve injury, to regenerate injured axon and/or to act as a Rho antagonist.
[0189] As it may be exemplified (Example 13: reverse Tat sequence), in some instance, the order of the amino acids in a particular polypeptide is not critical. As for the transport agent region described herein, the transport function of this region may be preserved even if the amino acids are not in their original (as it is found in nature) order (sequence).
[0190] Example of substitutions may be those, which are conservative (i.e., wherein a residue is replaced by another of the same general type). As is understood, naturally occurring amino acids may be sub-classified as acidic, basic, neutral and polar, or neutral and non-polar. Furthermore, three of the encoded amino acids are aromatic. It may be of use that encoded polypeptides differing from the determined polypeptide of the present invention contain substituted codons for amino acids, which are from the same group as that of the amino acid being replaced. Thus, in some cases, the basic amino acids Lys, Arg and His may be interchangeable; the acidic amino acids Asp and Glu may be interchangeable; the neutral polar amino acids Ser, Thr, Cys, Gln, and Asn may be interchangeable; the non-polar aliphatic amino acids Gly, Ala, Val, Ile, and Leu are interchangeable but because of size Gly and Ala are more closely related and Val, Ile and Leu are more closely related to each other, and the aromatic amino acids Phe, Trp and Tyr may be interchangeable.
[0191] It should be further noted that if the polypeptides are made synthetically, substitutions by amino acids, which are not naturally encoded by DNA may also be made. For example, alternative residues include the omega amino acids of the formula NH 2 (CH 2 ) n COOH wherein n is 2-6. These are neutral nonpolar amino acids, as are sarcosine, t-butyl alanine, t-butyl glycine, N-methyl isoleucine, and norleucine. Phenylglycine may substitute for Trp, Tyr or Phe; citrulline and methionine sulfoxide are neutral nonpolar, cysteic acid is acidic, and ornithine is basic. Proline may be substituted with hydroxyproline and retain the conformation conferring properties.
[0192] It is known in the art that mutants or variants may be generated by substitutional mutagenesis and retain the biological activity of the polypeptides of the present invention. These variants have at least one amino acid residue in the protein molecule removed and a different residue inserted in its place (one or more nucleotide in the DNA sequence is changed for a different one using known molecular biology techniques, giving a different amino acid upon translation of the corresponding messenger RNA to a polypeptide). For example, one site of interest for substitutional mutagenesis may include but are not restricted to sites identified as the active site(s), or immunological site(s). Other sites of interest may be those, for example, in which particular residues obtained from various species are identical. These positions may be important for biological activity. Examples of substitutions identified as “conservative substitutions” are shown in Table 1. If such substitutions result in a change not desired, then other type of substitutions, denominated “exemplary substitutions” in Table 1, or as further described herein in reference to amino acid classes, are introduced and the products screened.
[0193] In some cases it may be of interest to modify the biological activity of a polypeptide by amino acid substitution, insertion, or deletion. For example, modification of a polypeptide may result in an increase in the polypeptide's biological activity, may modulate its toxicity, may result in changes in bioavailability or in stability, or may modulate its immunological activity or immunological identity. Substantial modifications in function or immunological identity are accomplished by selecting substitutions that differ significantly in their effect on maintaining (a) the structure of the polypeptide backbone in the area of the substitution, for example, as a sheet or helical conformation. (b) the charge or hydrophobicity of the molecule at the target site, or (c) the bulk of the side chain. Naturally occurring residues are divided into groups based on common side chain properties:
i. hydrophobic: norleucine, methionine (Met), Alanine (Ala), Valine (Val), Leucine (Leu), Isoleucine (Ile) ii. neutral hydrophilic: Cysteine (Cys), Serine (Ser), Threonine (Thr) iii. acidic: Aspartic acid (Asp), Glutamic acid (Glu) iv. basic: Asparagine (Asn), Glutamine (Gln), Histidine (His), Lysine (Lys), Arginine (Arg) v. residues that influence chain orientation: Glycine (Gly), Proline (Pro); and vi. aromatic: Tryptophan (Trp), Tyrosine (Tyr), Phenylalanine (Phe)
[0200] Non-conservative substitutions will entail exchanging a member of one of these classes for another.
[0000]
TABLE 1
Preferred amino acid substitution
Original
Exemplary
Conservative
residue
substitution
substitution
Ala (A)
Val, Leu, Ile
Val
Arg (R)
Lys, Gln, Asn
Lys
Asn (N)
Gln, His, Lys, Arg
Gln
Asp (D)
Glu
Glu
Cys (C)
Ser
Ser
Gln (Q)
Asn
Asn
Glu (E)
Asp
Asp
Gly (G)
Pro
Pro
His (H)
Asn, Gln, Lys, Arg
Arg
Ile (I)
Leu, Val, Met, Ala,
Leu
Phe, norleucine
Leu (L)
Norleucine, Ile, Val,
Ile
Met, Ala, Phe
Lys (K)
Arg, Gln, Asn
Arg
Met (M)
Leu, Phe, Ile
Leu
Phe (F)
Leu, Val, Ile, Ala
Leu
Pro (P)
Gly
Gly
Ser (S)
Thr
Thr
Thr (T)
Ser
Ser
Trp (W)
Tyr
Tyr
Tyr (Y) T
rp, Phe, Thr, Ser
Phe
Val (V)
Ile, Leu, Met, Phe,
Leu
Ala, norleucine
[0201] Amino acids sequence insertions (e.g., additions) include amino and/or carboxyl-terminal fusions ranging in length from one residue to polypeptides containing a hundred or more residues, as well as intrasequence insertions of single or multiple amino acid residues. Other insertional variants include the fusion of the N- or C-terminus of the protein to a homologous or heterologous polypeptide forming a chimera. Chimeric polypeptides (i.e., chimeras, polypeptide analogue) comprise sequence of the polypeptides of the present invention fused to homologous or heterologous sequence. Said homologous or heterologous sequence encompass those which, when formed into a chimera with the polypeptides of the present invention retain one or more biological or immunological properties.
[0202] Other type of chimera generated by homologous fusion includes new polypeptides formed by the repetition of two or more polypeptides of the present invention. The number of repeat may be, for example, between 2 and 50 units (i.e., repeats). In some instance, it may be useful to have a new polypeptide with a number of repeat greater than 50. For example, it may be useful to fuse (using cross-linking techniques or recombinant DNA technology techniques) polypeptides such as C3APL, C3APLT, C3APS, C3-TL, C3-TS, C3Basic1, C3Basic2 and C3Basic3 either to themselves (e.g., C3APLT fused to C3APLT) or to another polypeptide of the present invention (e.g., C3APLT fused to C3APL).
[0203] In addition, a transport agent such as for example, a subdomain of HIV Tat protein, and a homeodomain of antennapedia may be repeated more than one time in a polypeptide comprising the ADP-ribosyl transferase C3 or ADP-ribosyl transferase C3 analogues. The transport agent region may be either at the amino-terminal region of an ADP-ribosyl transferase C3 or ADP-ribosyl transferase C3 analogues or at its carboxy-terminal region or at both regions. The repetition of a transport agent region may affect (e.g., increase) the uptake of the ADP-ribosyl transferase C3 or ADP-ribosyl transferase C3 analogues by a desired cell.
[0204] Heterologous fusion includes new polypeptides made by the fusion of polypeptides of the present invention with heterologous polypeptides. Such polypeptides may include but are not limited to bacterial polypeptides (e.g., betalactamase, glutathione-S-transferase, or an enzyme encoded by the E. coli trp locus), yeast protein, viral proteins, phage proteins, bovine serum albumin, chemotactic polypeptides, immunoglobulin constant region (or other immunoglobulin regions), albumin, or ferritin.
[0205] Other type of polypeptide modification includes amino acids sequence deletions (e.g., truncations). Those generally range from about 1 to 30 residues, more preferably about 1 to 10 residues and typically about 1 to 5 residues.
Mutants, Variants and Analogues Proteins
[0206] Mutant polypeptides will possess one or more mutations, which are deletions (e.g., truncations), insertions (e.g., additions), or substitutions of amino acid residues. Mutants can be either naturally occurring (that is to say, purified or isolated from a natural source) or synthetic (for example, by performing site-directed mutagenesis on the encoding DNA or made by other synthetic methods such as chemical synthesis). It is thus apparent that the polypeptides of the invention can be either naturally occurring or recombinant (that is to say prepared from the recombinant DNA techniques).
[0207] A protein at least 50% identical, as determined by methods known to those skilled in the art (for example, the methods described by Smith, T. F. and Waterman M. S. (1981) Ad. Appl. Math., 2:482-489, or Needleman, S. B. and Wunsch, C. D. (1970) J. Mol. Biol., 48: 443-453), to those polypeptides of the present invention, for example C3APL, C3APLT, C3APS, C3-TL, C3-TS, C3Basic1, C3Basic2 and C3Basic3 are included in the invention, as are proteins at least 70% or 80% and more preferably at least 90% identical to the protein of the present invention. This will generally be over a region of at least 5, preferably at least 20 contiguous amino acids.
[0208] “Variant” as the term used herein, is a polynucleotide or polypeptide that differs from reference polynucleotide or polypeptide respectively, but retains essential properties. A typical variant of a polynucleotide differs in nucleotide sequence from another, reference polynucleotide. Changes in the nucleotide sequence of the variant may or may not alter the amino acid sequence of a polypeptide encoded by the reference polynucleotide. Nucleotide changes may result in amino acid substitutions, additions, deletions, fusion and truncations in the polypeptide encoded by the reference sequence, as discussed herein. A typical variant of a polypeptide differs in amino acid sequence from another, reference polypeptide. Generally, differences are limited so that the sequence of the reference polypeptide and the variant are closely similar overall and, in many regions, identical. A variant and reference polypeptide may differ in amino acid by one or more substitutions, additions, deletions, or any combination therefore. A substituted or inserted amino acid residue may or may not be one encoded by the genetic code. A variant polynucleotide or polypeptide may be a naturally occurring such as an allelic variant, or it may be a variant that is not known to occur naturally. Non-naturally occurring variants of polynucleotides and polypeptides may be made by mutagenesis techniques or by direct synthesis.
[0209] Amino acid sequence variants may be prepared by introducing appropriate nucleotide changes into DNA, or by in vitro synthesis of the desired polypeptide. Such variant include, for example, deletions, insertions, or substitutions of residues within the amino acid sequence. A combination of deletion, insertion and substitution can be made to arrive at the final construct, provided that the final protein product possesses the desired biological activity, or characteristics. The amino acid changes also may alter posttranslational processes such as changing the number or position of the glycosylation sites, altering the membrane anchoring characteristics, altering the intra-cellular location by inserting, deleting or otherwise affecting the transmembrane sequence of the native protein, or modifying its susceptibility to proteolytic cleavage.
[0210] Unless otherwise indicated, the recombinant DNA techniques utilized in the present invention are standard procedures, known to those skilled in the art. Example of such techniques are explained in the literature in sources such as J. Perbal, A Practical Guide to Molecular Cloning, John Wiley and Sons (1984), J. Sambrook et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory Press (1989), T. A. Brown (editor), Essential Molecular Biology: A Practical Approach, Volumes 1 and 2, IRL Press (1991), D. M. Glover and B. D. Hames (editors), DNA Cloning: A Practical Approach, Volumes 1-4, IRL Press (1995 and 1996), and F. M. Ausubel et al. (editors), Current Protocols in Molecular Biology, Greene Pub. Associates and Wiley-Interscience (1988, including all updates until present) and are incorporated herein by reference.
[0211] It is to be understood herein, that if a “range” or “group of substances” is mentioned with respect to a particular characteristic (e.g. amino acid groups, temperature, pressure, time and the like) of the present invention, the present invention relates to and explicitly incorporates herein each and every specific member and combination of sub-ranges or sub-groups therein whatsoever. Thus, any specified range or group is to be understood as a shorthand way of referring to each and every member of a range or group individually as well as each and every possible sub-ranges or sub-groups encompassed therein; and similarly with respect to any sub-ranges or sub-groups therein. Thus, for example,
a) with respect to a sequence comprising up to 50 base units it is to be understood as specifically incorporating herein each and every individual unit, as well as sub-range of units; b) with respect to reaction time, a time of 1 minute or more is to be understood as specifically incorporating herein each and every individual time, as well as sub-range, above 1 minute, such as for example 1 minute, 3 to 15 minutes, 1 minute to 20 hours, 1 to 3 hours, 16 hours, 3 hours to 20 hours etc.; c) with respect to polypeptides, a polypeptide analogue comprising a particular sequence and having an addition of at least one amino acid to its amino-terminus or to its carboxy terminus is to be understood as specifically incorporating each and every individual possibility, such as for example one, two, three, ten, eighteen, forty, etc.; d) with respect to polypeptides, a polypeptide analogue having at least 90% of its amino acid sequence identical to a particular amino acid sequence is to be understood as specifically incorporating each and every individual possibility (excluding 100%), such as for example, a polypeptide analogue having 90%, 90.5%, 91%, 93.7%, 97%, 99%, etc., of its amino acid sequence identical to a particular amino acid sequence; e) with respect to polypeptides, a polypeptide analogue having at least 70% of its amino acid sequence identical to a particular amino acid sequence is to be understood as specifically incorporating each and every individual possibility (excluding 100%), such as for example, a polypeptide analogue having 70%, 72.3%, 73%, 88.6%, 98% etc., of its amino acid sequence identical to a particular amino acid sequence; f) with respect to polypeptides, a polypeptide analogue having at least 50% of its amino acid sequence identical to a particular amino acid sequence is to be understood as specifically incorporating each and every individual possibility (excluding 100%), such as for example, a polypeptide analogue having 50%, 54%, 66.7%, 70.2%, 84%, 93% etc., of its amino acid sequence identical to that particular amino acid sequence; g) with respect to polypeptide, a polypeptide comprising at least one transport agent region is to be understood as specifically incorporating each and every individual possibility, such as for example a polypeptide having one, two, five, ten, etc., transport agent region; and h) similarly with respect to other parameters such as low pressures, concentrations, elements, etc.
[0220] It is also to be understood herein that “g” or “gm” is a reference to the gram weight unit; and that “C”, or “° C.” is a reference to the Celsius temperature unit.
[0000]
TABLE 2
Abbreviations
Abbreviation
Full name
C3
ADP-ribosyl transferase C3
NGF
Nerve growth factor
BDNF
Brain-derived neurotrophic factor
C. or ° C.
Degree Celcius
ml
milliliter
μl or ul
microliter
μM or uM
micromolar
mM
millimolar
M
molar
N
normal
CNS
Central nervous system
PNS
Peripheral nervous system
HIV
Human immunodeficiency virus
HIV-1
Human immunodeficiency virus type-1
kDa
kilodalton
GST
Glutathione S-transferase
MTS
Membrane transport sequence
SDS-PAGE
Sodium dodecyl sulfte polyacrylamide gel electrophoresis
PBS
Phosphate buffered saline
U
unit
BBB
Basso, Beattie Breshnahan behavior recovery scale
IPTG
Isopropyl.beta.-D-thiogalactopyranoside
rpm
Rotation per minutes
DTT
dithiothreitol
PMSF
Phenylmethylsulfonyl fluoride
NaCl
Sodium chloride
MgCl 2
Magnesium chloride
HBSS
Hank's balanced salt solution
NaOH
Sodium hydroxide
CSPG
chondroitin sulfate proteoglycan
PKN
Protein kinase N
RSV
Rous sarcoma virus
MMTV
Mouse mammary tumor virus
LTR
Long terminal repeat
HL
Hind limb
FL
Fore limb
neo
neomycin
hygro
hygromycin
IN-1
monoclonal antibody called IN-1
ADP
Adenosine di-phosphate
ATP
Adenosine tri-phosphate
32 P
Isotope 32 of phosphorus
DHFR
Dihydrofolate reductase
PCR
Polymerase chain reaction
[0221] The invention in particular provides C3-like proteins, which may have additional amino acids added to the carboxy terminal end of the C3 proteins. Examples of such proteins includes:
[0222] C3APL: (C3 antennapedia-long) created by annealing sequences from the antennapedia transcription factor to the 3′ end of the sequence encoding C3 cDNA. The long antennapedia sequence of 60 amino acids containing the homeodomain of antennapedia, was used;
[0223] C3APLT: (C3 antennapedia-truncated) created by annealing sequences from the antennapedia transcription factor to the 3′ end of the sequence encoding C3 cDNA. This clone with a frameshift mutation gives a proline-rich transport peptide with good transport activity. This sequence is truncated i.e. shorter than C3APL.
[0224] C3APS: A short 11 amino acid sequence of antennapedia that has transmembrane transport properties was fused to the carboxy terminal of C3 to create C3APS;
[0225] C3-TL: C3 Tat-long created by fusing amino acids 27 to 72 of Tat to the carboxy terminal of C3 protein;
[0226] C3-TS: C3 Tat-short created by fusing the amino acids YGRKRRQRRR (SEQ ID NO:49) to the C3 protein;
[0227] C3Basic1 a random basic charge sequence added to the C-terminal of C3;
[0228] C3Basic2: a random basic charge sequence added to the C-terminal of C3;
[0229] C3Basic3: C3 Tat-short created by fusing the reverse sequence of Tat amino acids RRQRRKKR (SEQ ID NO:50) to the C3 protein.
[0230] C3-07: The sequence of C3APLT modified to remove the GST sequence used for purification, and with silent amino acid changes induced when cloned into the pEt expression vector, but which silent amino acid changes maintaining ADP-ribosylation activity of the protein.
[0231] C3-07Q189A: The sequence of C3-07 with an amino acid substitution of Glu 189 to Gln 189 in the catalytic domain that removes ADP-ribosylation activity to create an inactive construct.
[0232] It has been found that conjugates or fusion proteins (C3-like proteins) Rho antagonists of the present invention are effective to stimulate repair in the CNS after spinal cord injury. The increased cell permeability of new Rho antagonist (new chimeric C3) would now allow treatment of victims of stroke and neurodegenerative disease because Rho signaling pathway is important in repair after stroke (Hitomi, et al. (2000) 67: 1929-39. Trapp et al 2001. Mol. Cell. Neurosci. 17: 883-84). Treatment with Rho antagonists in the adhesive delivery system could be used to enhance the rate of axon growth in the PNS. Also, evidence in the literature now links Rho signaling with formation of Alzheimer's disease tangles through its ability to activate PKN which then phosphorylates tau and neurofilaments (Morissette, et al. (2000) 278: H1769-74., Kawamata, et al. (1998) 18: 7402-10., Amano, et al. (1996) 271: 648-50., Watanabe, et al. (1996) 271: 645-8.). Therefore, Rho antagonists are expected to be useful in the treatment of Alzheimer's disease. The new chimeric C3 drugs should be able to diffuse readily and therefore can promote repair for diseases that are neurodegenerative. Examples include, but are not limited to stroke, traumatic brain injury, Parkinson's disease, Alzheimer's disease and ALS. Moreover, it is now well established that Rho signaling antagonists are effective in the treatment of other diseases. These include, but are not limited to eye diseases such as glaucoma (Honjo, et al. (2001) 42: 137-44., Rao, et al. (2001) 42: 1029-1037) eye diseases such as macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, cancer cell migration and metastasis (Sahai, et al. (1999) 9: 136-45., Takamura, et al. (2001) 33: 577-81., Imamura, et al. (2000) 91: 811-6). The effects of the Rho signaling pathway on smooth muscle relaxation are well established. This has led to the identification of Rho signaling antagonists as effective in treatment of hypertension (Chitaley, et al. (2001) 3: 139-144., Somlyo (1997) 389: 908-911, Uehata, et al. (1997) 389: 990-994), asthma (Nakahara, et al. (2000) 389: 103-6., Ishizaki, et al. (2000) 57: 976-83), and vascular disease (Miyata, et al. (2000) 20: 2351-8., Robertson, et al. (2000) 131: 5-9.) as well as penile erectile dysfunction (Chitaley, et al. (2001) 7: 119-22.). Rho is also important as a cardioprotective protein (Lee et al. 2001. FASEB J. 15:1886-1894).
[0233] Rho GTPases include members of the Rho, Rac and Cdc42 family of proteins. Our invention concerns Rho family members of the Rho class. Rho proteins consist of different variants encoded by different genes. For example, PC-12 cells express RhoA, RhoB and RhoC (Lehmann et al 1999 supra); PC-12 cells: Pheochromocytom cell line (Greene A and Tischler, A S PNAS 73:2424 (1976). To inactivate Rho proteins inside cells, Rho antagonists of the C3 family type are effective because they inactivate all forms of Rho (e.g. RhoA, Rho B etc). In contrast, gene therapy techniques, such as introduction of a dominant negative RhoA family member into a diseased cell, will only inactivate that specific RhoA family member.
[0234] Recombinant C3 proteins, or C3 proteins that retain the ribosylation activity are also effective in our delivery system and are covered by this invention. In addition, Rho kinase is a well-known target for active Rho, and inactivating Rho kinase has the same effect as inactivating Rho, at least in terms of neurite or axon growth (Kimura and Schubert (1992) Journal of Cell Biology. 116:777-783, Keino-Masu, et al. (1996) Cell. 87:175-185, Matsui, et al. (1996) EMBO J. 15:2208-2216, Matsui, et al. (1998) J. Cell Biol. 140:647-657, Ishizaki (1997) FEBS Lett. 404: 118-124), the biological activity that concerns this invention.
[0235] The C3 polypeptides of the present invention include biologically active fragments and analogues of C3; fragments encompass amino acid sequences having truncations of one or more amino acids, wherein the truncation may originate from the amino terminus, carboxy terminus, or from the interior of the protein. Fragments containing Glu(173) of C3 are included in this invention (Saito et al. 1995. FEBS Lett. 371-105). Analogues of the invention involve an insertion or a substitution of one or more amino acids. Fragments and analogues will have the biological property of C3 that is capable of inactivating Rho GTPase on Asn(41) on Rho. Also encompassed by the invention are chimeric polypeptides comprising C3 amino acid sequences fused to heterologous amino acid sequences. Said heterologous sequences encompass those which, when formed into a chimera with C3 retain one or more biological or immunological properties of C3. A host cell transformed or transfected with nucleic acids encoding C3 protein or C3 chimeric protein are also encompassed by the invention. Any host cell which produces a polypeptide having at least one of the biological properties of C3 may be used. Specific examples include bacterial, yeast, plant, insect or mammalian cells. In addition, C3 protein may be produced in transgenic animals. Transformed or transfected host cells and transgenic animals are obtained using materials and methods that are routinely available to one skilled in the art. Host cells may contain nucleic acid sequences having the full-length gene for C3 protein including a leader sequence and a C-terminal membrane anchor sequence (see below) or, alternatively, may contain nucleic acid sequences lacking one or both of the leader sequence and the C-terminal membrane anchor sequence. In addition, nucleic acid fragments, variants and analogues which encode a polypeptide capable of retaining the biological activity of C3 may also be resident in host expression systems.
[0236] C3 is produced as a 26 kDa protein. The full length C3 protein inactivates Rho by ADP-ribosylating asparagine 41 of Rho A (Han et al. (2001) J. Mol. Biol. 305: 95). Truncated, elongated or altered C3 proteins or C3-derived peptides that retain the ability to ribosylate Rho are included in this invention and can be used to make fusion proteins. The crystal structure of C3 has been determined giving insight to elements of the C3 protein that could be changed without affecting ribosylating activity (Han et al. (2001) J. Mol. Biol. 305: 95).
[0237] The Rho antagonist that is a recombinant proteins can be made according to methods present in the art. The proteins of the present invention may be prepared from bacterial cell extracts, or through the use of recombinant techniques. In general, C3 proteins according to the invention can be produced by transformation (transfection, transduction, or infection) of a host cell with all or part of a C3-encoding DNA fragment in a suitable expression vehicle. Suitable expression vehicles include: plasmids, viral particles, and phages. For insect cells, baculovirus expression vectors are suitable. The entire expression vehicle, or a part thereof, can be integrated into the host cell genome. In some circumstances, it is desirable to employ an inducible expression vector.
[0238] Those skilled in the field of molecular biology will understand that any of a wide variety of expression systems can be used to provide the recombinant protein. The precise host cell used is not critical to the invention. The C3 and C3-like proteins may be produced in a prokaryotic host (e.g., E. coli or B. subtilis ) or in a eukaryotic host (e.g., Saccharomyces or Pichia ; mammalian cells, e.g., COS, NIH 3T3, CHO, BHK, 293, or HeLa cells; or insect cells).
[0239] To determine the relative and effective Rho antagonist activity of the compositions of this invention, a tissue culture bioassay system can be used. A fusion protein such as C3APLT at a concentration range of from about 0.01 to about 10 μg/ml (microgram per milligram) is useful and is not toxic to cells.
[0240] Proteins and polypeptides may also be produced by plant cells. For plant cells viral expression vectors (e.g., cauliflower mosaic virus and tobacco mosaic virus) and plasmid expression vectors (e.g., Ti plasmid) are suitable. Such cells are available from a wide range of sources (e.g., the American Type Culture Collection, Rockland, Md.). The methods of transformation or transfection and the choice of expression vehicle will depend on the host system selected.
[0241] The host cells harboring the expression vehicle can be cultured in conventional nutrient media adapted as need for activation of a chosen gene, repression of a chosen gene, selection of transformants, or amplification of a chosen gene. One expression system is the mouse 3T3 fibroblast host cell transfected with a pMAMneo expression vector (Clontech, Palo Alto, Calif.). pMAMneo provides an RSV-LTR enhancer linked to a dexamethasone-inducible MMTV-LTR promotor, an SV40 origin of replication which allows replication in mammalian systems, a selectable neomycin gene, and SV40 splicing and polyadenylation sites. DNA encoding a C3 or C3-like protein would be inserted into the pMAMneo vector in an orientation designed to allow expression. The recombinant C3 or C3-like protein would be isolated as described below. Other preferable host cells that can be used in conjunction with the pMAMneo expression vehicle include COS cells and CHO cells (ATCC Accession Nos. CRL 1650 and CCL 61, respectively).
[0242] C3 polypeptides can be produced as fusion proteins. For example, expression vectors may be used to create lacz fusion proteins. The pGEX vectors can be used to express foreign polypeptides as fusion proteins with glutathione S-transferase (GST). In general, such fusion proteins are soluble and can be easily purified from lysed cells by adsorption to glutathione-agarose beads followed by elution in the presence of free glutathione. The pGEX vectors are designed to include thrombin or factor Xa protease cleavage sites so that the cloned target gene product can be released from the GST moiety. Another strategy to make fusion proteins is to use the His tag system.
[0243] In an insect cell expression system, Autographa californica nuclear polyhedrosis virus AcNPV), which grows in Spodoptera frugiperda cells, is used as a vector to express foreign genes. A C3 coding sequence can be cloned individually into non-essential regions (for example the polyhedrin gene) of the virus and placed under control of an AcNPV promoter, e.g., the polyhedrin promoter. Successful insertion of a gene encoding a C3 or C3-like protein (polypeptide) will result in inactivation of the polyhedrin gene and production of non-occluded recombinant virus (i.e., virus lacking the proteinaceous coat encoded by the polyhedrin gene). These recombinant viruses are then used to infect Spodoptera frugiperda cells in which the inserted gene is expressed (see, Lehmann et al for an example of making recombinant MAG protein).
[0244] In mammalian host cells, a number of viral-based expression systems can be utilized. In cases where an adenovirus is used as an expression vector, the C3 nucleic acid sequence can be ligated to an adenovirus transcription/translation control complex, e.g., the late promoter and tripartite leader sequence. This chimeric gene can then be inserted into the adenovirus genome by in vitro or in vivo recombination. Insertion into a non-essential region of the viral genome (e.g., region E1 or E3) will result in a recombinant virus that is viable and capable of expressing a C3 gene product in infected hosts.
[0245] Specific initiation signals may also be required for efficient translation of inserted nucleic acid sequences. These signals include the ATG initiation codon and adjacent sequences. In cases where an entire native C3 gene or cDNA, including its own initiation codon and adjacent sequences, is inserted into the appropriate expression vector, no additional translational control signals may be needed. In other cases, exogenous translational control signals, including, perhaps, the ATG initiation codon, must be provided. Furthermore, the initiation codon must be in phase with the reading frame of the desired coding sequence to ensure translation of the entire insert. These exogenous translational control signals and initiation codons can be of a variety of origins, both natural and synthetic. The efficiency of expression may be enhanced by the inclusion of appropriate transcription enhancer elements, transcription terminators.
[0246] In addition, a host cell may be chosen which modulates the expression of the inserted sequences, or modifies and processes the gene product in a specific, desired fashion. Such modifications (e.g., glycosylation) and processing (e.g., cleavage) of protein products may be important for the function of the protein. Different host cells have characteristic and specific mechanisms for the post-translational processing and modification of proteins and gene products. Appropriate cell lines or host systems can be chosen to ensure the correct modification and processing of the foreign protein expressed. To this end, eukaryotic host cells that possess the cellular machinery for proper processing of the primary transcript, glycosylation, and phosphorylation of the gene product can be used. Such mammalian host cells include, but are not limited to, CHO, VERO, BHK, HeLa, COS, MDCK, 293, 3T3, W138, and in particular, choroid plexus cell lines.
[0247] Alternatively, a C3 protein can be produced by a stably-transfected mammalian cell line. A number of vectors suitable for stable transfection of mammalian cells are available to the public; methods for constructing such cell lines are also publicly available. In one example, cDNA encoding the C3 protein may be cloned into an expression vector that includes the dihydrofolate reductase (DHFR) gene. Integration of the plasmid and, therefore, the C3 or C3-like protein-encoding gene into the host cell chromosome is selected for by including 0.01-300 μM (micromole) methotrexate in the cell culture medium (as described in Ausubel et al., supra). This dominant selection can be accomplished in most cell types. Recombinant protein expression may be increased by DHFR-mediated amplification of the transfected gene. Methods for selecting cell lines bearing gene amplifications are known in the art; such methods generally involve extended culture in medium containing gradually increasing levels of methotrexate. DHFR-containing expression vectors commonly used for this purpose include pCVSEII-DHFR and pAdD26SV(A). Any of the host cells described above or, preferably, a DHFR-deficient CHO cell line (e.g., CHO DHFR cells, ATCC Accession No. CRL 9096) are among the host cells preferred for DHFR selection of a stably-transfected cell line or DHFR-mediated gene amplification.
[0248] A number of other selection systems may be used, including but not limited to the herpes simplex virus thymidine kinase, hypoxanthine-guanine phosphoribosyltransferase, and adenine phosphoribosyltransferase genes can be employed in tk, hgprt, or aprt cells, respectively. In addition, gpt, which confer resistance to mycophenolic acid; neo, which confers resistance to the aminoglycoside G-418; and hygro, which confers resistance to hygromycin may be used.
[0249] Alternatively, any fusion protein can be readily purified by utilizing an antibody specific for the fusion protein being expressed. For example, a system described in Janknecht et al. (1981) Proc. Natl. Acad. Sci. USA 88, 8972, allows for the ready purification of non-denatured fusion proteins expressed in human cell lines. In this system, the gene of interest is subcloned into a vaccinia recombination plasmid such that the gene's open reading frame is translationally fused to an amino-terminal tag consisting of six histidine residues. Extracts from cells infected with recombinant vaccinia virus are loaded onto Ni2+nitriloacetic acid-agarose columns, and histidine-tagged proteins are selectively eluted with imidazole-containing buffers.
[0250] Alternatively, C3, C3-like protein or a portion (fragment) thereof, can be fused to an immunoglobulin Fc domain. Such a fusion protein can be readily purified using a protein A column.
[0251] To test Rho antagonists for activity, a tissue culture bioassay system was used. This bioassay is used to define activity of Rho antagonists that will be effective in promoting axon regeneration in spinal cord injury, stroke or neurodegenerative disease.
[0252] Neurons do not grow neurites on inhibitory myelin substrates. When neurons are placed on inhibitory substrates in tissue culture, they remain rounded. When an effective Rho antagonist is added, the neurons are able to grow neurites on myelin substrates. The time that it takes for neurons to growth neurites upon the addition of a Rho antagonist is the same as if neurons had been plated on growth permissive substrate such as laminin or polylysine, typically 1 to 2 days in cell culture. The results can be scored visually. If needed, a quantitative assessment of neurite growth can be performed. This involved measuring the neurite length in a) control cultures where neurons are plated on myelin substrates and left untreated b) in positive control cultures, such as neurons plated on polylysine c) or treating cultures with different concentrations of the test antagonist.
[0253] To test C3 in tissue culture, it has been found that the best concentration is 25-50 ug/ml. (Lehmann et al, 1999. J. Neurosci. 19: 7537-7547; Jin & Strittmatter, 1997. J. Neurosci. 17: 6256-6263). Thus, high concentrations of this Rho antagonist are needed as compared to the growth factors used to stimulate neurite outgrowth. Growth factors, such as nerve growth factor (NGF) are used at concentrations of 1-100 ng/ml in tissue culture. However, growth factors are not able to overcome growth inhibition by myelin. Our tissue culture experiments are all performed in the presence of the growth factor BDNF for retinal ganglion cells, or NGF for PC-12 cells. When growth factors have been tested in vivo, typically the highest concentrations possible are used, in the ug/ml range. Also they are often added to the CNS with the use of pumps for prolonged delivery (e.g. Ramer et al, supra). For in vivo experiments the highest concentrations possible was used when working with C3 stored as a frozen 1 mg/ml solution.
[0254] The Rho antagonist C3 is stable at 37° C. for at least 24 hours. The stability of C3 was tested in tissue culture with the following experiment. The C3 was diluted in tissue culture medium, left in the incubator at 37° C. for 24 hours, then added to the bioassay system described above, using retinal ganglion cells as the test cell type. These cells were able to extend neurites on inhibitory substrates when treated with C3 stored for 24 hours at 37° C. Therefore, the minimum stability is 24 hours. This is in keeping with the stability projection based on amino acid composition (see sequence data, below).
[0255] A compound can be confirmed as a Rho antagonist in one of the following ways:
a. Cells are cultured on a growth inhibitory substrate as above, and exposed to the candidate Rho antagonist; b. Cells of step a) are homogenized and a pull-down assay is performed. This assay is based on the capability of GST-Rhotektin to bind to GTP-bound Rho. Recombinant GST-Rhotektin or GST rhotektin binding domain (GST-RBD) is added to the cell homogenate made from cells cultured as in a). It has been found that inhibitory substrates activate Rho, and that this activated Rho is pulled down by GST-RBD. Rho antagonists will block activation of Rho, and therefore, an effective Rho antagonist will block the detection of Rho when cell are cultured as described by a) above; or c. An alternate method for this pull-down assay would be to use the GTPase activating protein, Rho-GAP as bait in the assay to pull down activated Rho, as described (Diekmann and Hall, 1995. In Methods in Enzymology Vol. 256 part B 207-215).
[0259] Another method to confirm that a compound is a Rho antagonist is as follows: When added to living cells antagonists that inactivate Rho by ADP-ribosylation of the effector domain can be identified by detecting a molecular weight shift in Rho (Lehmann et al, 1999 supra). The molecular weight shift can be detected after treatment of cells with Rho antagonist by homogenizing the cells, separating the proteins in the cellular homogenate by SDS polyacrylamide gel electrophoresis. The proteins are transferred to nitrocellulose paper, then Rho is detected with Rho-specific antibodies by a Western blotting technique.
[0260] Another method to confirm that compound is a Rho-kinase antagonist is as follows:
a. Recombinant Rho kinase tagged with myc epitope tag, or a GST tag or any suitable tag is expressed in Hela cells or another suitable cell type by transfection; b. The kinase is purified from cell homogenates by immunoprecipitation using antibodies directed against the specific tag (e.g., myc tag or the GST tag); and c. The recovered immunoprecipitates from b) are incubated with [ 32 P] ATP and histone type 2 as a substrate in the presence or absence of the Rho kinase inhibitor. In the absence of Rho kinase inhibitor activity, the Rho kinase phosphorylated histone. In the presence of Rho kinase inhibitor the phosphorylation activity of Rho kinase (i.e. phosphorylation of histone) is blocked, and as such identified the compound as a Rho kinase antagonist.
[0264] Turning now to the transport side of the conjugates of the present invention, known methods are available to add transport sequences that allow proteins to penetrate into the cell; examples include membrane translocating sequence (Rojas (1998) 16: 370-375), Tat-mediated protein delivery (Vives (1997) 272: 16010-16017), polyargine sequences (Wender et al. 2000, PNAS 24: 13003-13008) and antennapedia (Derossi (1996) 271: 18188-18193). Examples of known transport agents, moities, subdomains and the like are also shown for example in Canadian patent document no. 2,301,157 (conjugates containing homeodomain of antennapedia) as well as in U.S. Pat. Nos. 5,652,122, 5,670,617, 5,674,980, 5,747,641, and 5,804,604 (conjugates containing amino acids of Tat HIV protein (hereinafter Tat HIV protein is sometimes simply referred to as Tat); the entire contents of each of these patent documents is incorporated herein by reference.
[0265] A 16 amino acid region of the third alpha-helix of antennapedia homeodomain has been shown to enable proteins (made as fusion proteins) to cross cellular membranes (PCT international publication number WO 99/11809 and Canadian application No.: 2,301,157 (Crisanti et al,) incorporated herein as references). Here we have generated fusion-proteins comprising C3 and having an antennapedia homeodomain sequence located at the carboxy-terminal end of the fusion-protein. The biological activity (e.g., promoting axon growth) of these fusion proteins was demonstrated on primary mammalian cells such as neurons. Similarly, HIV Tat protein was shown to be able to cross cellular membranes (Frankel A. D. et al., Cell, 55: 1189). We have shown here using a sequence spanning amino acid 27 to 72 of HIV Tat, that Tat-mediated delivery of biologically active C3 protein is possible in neuronal cells and more specifically, in primary neuronal cells.
[0266] In addition to HIV Tat and antennapedia-mediated transport of C3 proteins and analogs, new transport sequences (i.e., transport polypeptide moiety, transport agent region, etc.) are presented herein.
[0267] Several receptor-mediated transport strategies have been used to try and improve function of ADP ribosylases: these methods include fusing C2 and C3 sequences (Wilde, et al. (2001) 276: 9537-9542.) and use of receptor-mediated transport with the diphtheria toxin receptor (Aullo, et al. (1993) 12: 921-31; Boquet, P. et al. (1995) Meth. Enzymol. 256: 297-306).). These methods have not been demonstrated to dramatically increase the potency of C3. Moreover, these proteins require receptor-mediated transport. This means that the cells must express the receptor, and must express sufficient quantities of the receptor to significantly improve transport. Moreover, when C3 enters the cell by endocytosis, it will be locked within a membrane compartment, and therefore most of it will not be available to inactivate Rho. In the case of diphtheria toxin, not all cells express the appropriate receptor, limiting its potential use. The clinical importance for any of these has not been tested or shown. A C2/C3 fusion protein has also been made to try and improve the effectiveness of C3. In this case, the addition of a C211 binding protein to the tissue culture medium is needed, along with the C2-C3 fusion toxin to allow uptake of C3 by receptor-mediated endocytosis (Barthe et al. (1998) Infection and Immunity 66:1364). The disadvantage of this system is that much of the C3 in the cell will be restrained within a membrane compartment. More importantly, two different proteins must be added separately for transport to occur (Wahl et al. 2000. J. Cell Biol. 149:263), which make this system difficult to apply to in vivo for treatment of disease. Moreover, none of the methods to inactivate Rho with C3 or C3 analogues (C3-like protein) have been demonstrated to be sufficient to overcome growth inhibition in tissue culture, or to promote recovery after CNS damage in vivo.
[0268] One strategy which may be used in accordance with the present invention is to exploit the antennapedia homeodomain that is able to transport proteins across the plasma membrane by a receptor-independent mechanism (Derossi (1996) 271: 18188-18193); an alternate strategy is to exploit Tat-mediated delivery (Vives (1997) 272: 16010-16017, Fawell (1994) 91: 664-668, Frankel (1988) 55: 1189-1193).
[0269] The Antennapedia strategy has been used for protein translocation into neurons (Derossi (1996) 271: 18188-18193). Antennapedia has, for example, been used to transport biotin-labeled peptides in order to demonstrate the efficacy of the technique; see U.S. Pat. No. 6,080,724 (the entire contents of this patent are incorporated herein by reference). Antennapedia enhances growth and branching of neurons in vitro (Bloch-Gallego (1993) 120: 485-492). Homeoproteins are transcription factors that regulate development of body organization, and antennapedia is a Drosophila homeoprotein. Tat on the other hand is a regulatory protein from human immunodeficiency virus (HIV). It is a highly basic protein that is found in the nucleus and can transport reporter genes into cell. Moreover, Tat-linked proteins can penetrate cells after intraperitoneal injection, and it can even cross the blood brain barrier to enter cells within the brain (Schwarze, et al. (1999) 285: 1569-72).
[0270] Other transport sequences that have been tested in other contexts, (i.e., to show that they work through the use of reporter sequences), are known. One transport peptide, a 12 mer, AAVLLPVLLAAP (SEQ ID NO:51), is rich in proline. It was made as a GST-MTS fusion protein and is derived from the h region of the Kaposi FGF signal sequence (Royas et al. 1998 Nature Biotech. 16: 370-375. Another example is the sperm fertiline alpha peptide, HPIQIAAFLARIPPISSIGTCILK (SEQ ID NO:52) (This is reviewed in Pecheur, J. Sainte-Marie, A. Bienvenuie, D. Hoekstra. 1999. J. Membrane Biol. 167: 1-17). It must be noted however that the alpha helix-breaking propensity of proline (Pro) residues is not a general rule, since the putative fusion peptide of sperm fertilin alpha displays a high alpha helical content in the presence of liposomes. However, the Pro-Pro sequence is required for efficient fusion properties of fertilin. The C3APLT fusion protein that we tested fits the requirement of having a two prolines for making an effective transport peptide. Therefore, proline-rich sequences and random sequences that have helix-breaking propensity that act as effective transporters would also be effective if fused to C3.
[0271] In the context of axon growth on inhibitory substrates, axon regeneration after injury, or axon regeneration in the brain or spinal cord, no method using these transport sequences has been devised. In particular, it should be noted that the ability of antennapedia to enhance growth was tested with neurons placed on laminin-coated coverslips. Laminin supports axon growth and overrides growth inhibition (David, et al. (1995) 42: 594-602) thus, it is not a suitable substrate to test the potential for regeneration. There is an enormous wealth of literature over the last 20 years on substances that promote axon growth under such favorable tissue culture conditions, but none of these has lead to clinical advances in the treatment of spinal cord injury. The effect of antennapedia was shown to act as similar to a growth factors. Growth factors do not overcome growth inhibition by CNS growth inhibitory substrates (Lehmann, et al. (1999) 19: 7537-7547, Cai, et al. (1999) 22: 89-101). Growth factors applied in vivo do not support regeneration, only sprouting (Schnell, et al. (1994) 367: 170-173).
[0272] The transport sequence may be added to the N-terminal (amino-terminal) sequence of the C3 protein. Alternatively, the transport sequence may be added on the C-terminal (carboxy-terminal) end of the C3 protein; because the C-terminal is already quite basic, this should enhance further the transport properties. This is likely one of the reasons that C3APLT shows activity in addition to its basic charge and the proline-rich sequences.
[0273] The new chimeric C3 may be used to treat spinal cord injury to promote functional repair. We have demonstrated that both C3APLT and C3APS can overcome growth inhibition on complex inhibitory substrates that include myelin and mixed chondroitin sulfate proteoglycans. Further, we demonstrate that C3APLT can promote functional recovery after application to injured spinal cord in adult mice. The new chimeric protein may be used to promote axon regeneration and reduce scarring after CNS injury. Scarring is a barrier to nerve regeneration.
[0274] The advantage of the new chimeric C3 is the ability to treat the injured axons after a significant delay between the injury and the treatment. Also, the new recombinant protein may be useful in the treatment of chronic injury. The chimeric C3 can also be used to treat neurodegenerative diseases such as Alzheimer's disease and Parkinson's disease where penetration of the Rho antagonist to the affected neuronal population is required for effective treatment. The chimeric C3 (fusion proteins) will also be of benefit for the treatment of stroke and traumatic brain injury. Moreover, much evidence suggests efficacy in the treatment of cancer cell migration. Rho antagonists are also useful in the treatment of disease involving smooth muscle, such as vascular disease, hypertension, asthma, and penile dysfunction.
[0275] For treatment of spinal cord injury, the conjugate Rho antagonists of the present invention may be used in conjunction with cell transplantation. Many different cell transplants have been extensively tested for their potential to promote regeneration and repair, including, but not restricted to, Schwann cells, fibroblasts modified to express growth factors, fetal spinal cord transplants, macrophages, embryonic or adult stem cells, and olfactory ensheathing glia. C3 fusion proteins may be used in conjunction with neurotrophins, apoptosis inhibitors, or other agents that prevent cell death. They may be used in conjunction with cell adhesion molecules such as L1, laminin, and artificial growth matrices that promote axon growth. The chimeric C3 constructs of the present invention may also be used in conjunction with the use of antibodies that block growth inhibitory protein substrates to promote axon growth. Examples of such antibody methods are the use of IN-1 or related antibodies (Schnell and Schwab (1990) 343: 269-272) or through the use of therapeutic vaccine approaches (Huang (1999) 24: 639-647).
[0276] The compositions of this invention can be administered to the eye, for example by intravenous delivery to the eye, by implantation of a depot comprising a composition of the invention, by injection into the eye or into tissues proximal to the eye.
[0277] The bulb of the eye is imbedded in the fat of the orbit from which it is separated by a thin membrane, the fascia bulbi, which envelops the bulb from the optic nerve to the ciliary region. The smooth inner surface of the facia is separated from the outer surface of the sclera by the periscleral lymph space which is continuous with the subdural and subarachnoid cavities. The fascia is perforated by the ciliary vessels and nerves, and fuses with the sheath of the optic nerve and with the sclera around the entrance of the optic nerve. The optic nerve enters its eyeball about 3 millimeters to the nasal side and a little below the level of the central point of the posterior curvature of the eye. Optic nerve fiber growth is centripetal, and during their formation, most optic nerve fibers grow backward into the optic stalk from nerve cells of the retina, but some optic nerve fibers extend and are derived from nerve cells in the brain. The optic nerve fiber layer is composed principally of axons of the retinal ganglion cells that project to the brain through the optic nerve and the supporting glial cells.
[0278] The outer layer of the eye comprises the sclera and cornea. The sclera is an opaque, firm membrane, as much as 1 millimeter thick, and constitutes the posterior five-sixths of the eye. The sclera is formed of white fibrous tissue intermixed with fine elastic fibers; flattened connective-tissue corpuscles, some of which are pigmented, are contained in cell spaces between the fibers. Compositions of this invention can be administered for example by injection into and/or through the sclera or by formation of a depot proximal to and/or in the sclera, preferably in the posterior of the eye.
[0279] The inner surface of the sclera is separated from the outer surface of the choroid by an extensive lymph space or spatium perichorioideale which is traversed by fine cellular tissue, the lamina suprachorioidea. The sclera is pierced by the optic nerve, and is continuous through the fibrous sheath of this nerve with the dura mater. Where the optic nerve passes through the sclera, the sclera forms a thin cribriform lamina, the lamina cribrosa sclerx. Minute orifices in this lamina serve for the transmission of nervous filaments, and the retinal ganglion cell axons distal to the lamina cribrosa are myelinated by oligodedrocytes. The fibrous septa dividing them from one another are continuous with the membranous processes which separate the bundles of nerve fibers. One of these openings, larger than the rest, occupies the center of the lamina; it transmits the central artery and vein of the retina. Around the entrance of the optic nerve are numerous small apertures for the transmission of the ciliary vessels and nerves. About midway between this entrance and the sclerocorneal junction are four or five large apertures for the transmission of veins, the venæ vorticosæ. Compositions of this invention can be administered, for example by injection or perfusion or from a depot such as an implanted matrix comprising a composition of the invention, into a blood vessel which delivers blood to the retina, preferably to the region proximal to the macula.
[0280] The vascular tunic of the eye comprises the choroid, the ciliary body, and the iris. The choroid invests the posterior five-sixths of the bulb of the eye proximal to the retina, and extends forward to the ora serrata of the retina. The ciliary body connects the choroid to the circumference of the iris.
[0281] The choroid comprises a thin spongy layer between the sclera and the retina; the choroid is filled with blood vessels. The choroid is a thin, highly vascular, dark brown membrane investing the posterior five-sixths of the globe of the eye; it is pierced behind by the optic nerve, and in this situation is firmly adherent to the sclera. It is thicker behind than in front. Its outer surface is loosely connected by the lamina suprachorioidea with the sclera; its inner surface is attached to the pigmented layer of the retina. Compositions of this invention can be administered, for example by injection or perfusion or from a depot such as an implanted matrix comprising a composition of the invention, into a blood vessel which delivers blood to the choroid, preferably to the region proximal to the macula.
[0282] The choroid consists mainly of a dense capillary plexus, and of small arteries and veins carrying blood to and returning it from this plexus. On its external surface is a thin membrane, the lamina suprachorioidea, composed of delicate non-vascular lamellæ. Each lamella consists of a network of fine elastic fibers among which are branched pigment cells. The spaces between the lamellæ are lined by endothelium, and open freely into the perichoroidal lymph space, which communicates with the periscleral space by the perforations in the sclera through which the vessels and nerves are transmitted. Internal to this lamina is the choroid proper which consists of two layers: an outer layer, composed of small arteries and veins, with pigment cells interspersed between them; and an inner layer, consisting of a capillary plexus. The outer layer, or lamina vasculosa, consists, in part, of the larger branches of the short ciliary arteries which run forward between the veins before they bend inward to end in capillaries. The venæ vorticosæ is formed principally of veins which converge to four or five equidistant trunks, which pierce the sclera about midway between the sclero-corneal junction and the entrance of the optic nerve. Interspersed between the vessels are dark star-shaped pigment cells, the processes of which, communicating with those of neighboring cells, form a delicate network or stroma, which toward the inner surface of the choroid loses its pigmentary character. The inner layer of the choroid, or lamina choriocapillaris, consists of an exceedingly fine capillary plexus formed by the short ciliary vessels. This network is closer and finer in the posterior than in the anterior part of the choroid. About 1.25 centimeters behind the cornea its meshes become larger, and are continuous with those of the ciliary processes. These two laminæare connected by a stratum intermedium consisting of fine elastic fibers. On the inner surface of the lamina choriocapillaris is a very thin, structureless or faintly fibrous membrane, the lamina basalis, which is closely connected with the stroma of the choroid, and separates it from the pigmentary layer of the retina.
[0283] The retina is a nervous tissue in the eye, and contains millions of rod and cone cells which convert light energy into chemical electrical or neural signals which are sent to the brain via the optic nerve. The outer surface of the retina is in contact with the choroid. The inner surface of the retina is in contact with the hyaloid membrane of the vitreous body. The retina is continuous with the optic nerve, and gradually diminishes in thickness from the posterior of the eye forward, extending nearly as far as the ciliary body, where it appears to end in a jagged margin, the ora serrata. At the ora serrata, the nervous tissues of the retina end, but a thin prolongation of the membrane extends forward over the back of the ciliary processes and iris, forming the pars ciliaris retinæ and pars iridica retina. The retina is soft, semitransparent, and purple in tint due to the presence of rhodopsin.
[0284] The macula lutea resides at the center of the posterior part of the retina at a point corresponding to the axis of the eye where the sense of vision is most acute, i.e., where finer or higher resolution visual detail and visual focus occurs to provide the greatest degree of visual acuity. The macula comprises an oval yellowish area in which the color is deepest toward the center, and is about 6 by 7 millimeters (mm) in size. The fovea centralis comprises a central depression in the macula, wherein the retina is exceedingly thin. The fovea is about 1.5 mm in diameter and located just behind the macula, where the highest concentration of cone photoreceptors are concentrated. Light rays are focused in the eye by the lens onto the fovea for straight ahead vision and fine detail.
[0285] The ganglionic layer (retinal ganglion layer (RGC layer)) of the macula lutea consists of several strata of cells. There are no rod cells, but only cone cells which are longer and narrower than in other parts of the retina. In the outer nuclear layer there are only cone-cells, the processes of which are very long and arranged in curved lines. The layers of the fovea centralis comprise cone cells plus the outer nuclear layer, the cone-fibers of which are almost horizontal in direction, plus a thin inner plexiform layer.
[0286] About 3 millimeters to the nasal side of the macula lute is the entrance of the optic nerve, i.e., the optic disk, the circumference of which is slightly raised to form an eminence or colliculus nervi optici; the arteria centralis retinæ pierces the center of the disk. This part of the surface of the retina, termed the blind spot is insensitive to light. The optic nerve and the central retinal blood vessels enter the back of the eye at the disc comprising the blind spot.
[0287] The arteria centralis retina and its accompanying vein pierce the optic nerve, and enter the bulb of the eye through the porus opticus. The artery immediately bifurcates into an upper and a lower branch, and each of these again divides into a medial or nasal and a lateral or temporal branch, which at first run between the hyaloid membrane and the nervous layer before entering the latter to pass forward, dividing dichotomously. From these branches a minute capillary plexus is given off, which does not extend beyond the inner nuclear layer. The macula receives two small branches, which are the superior and inferior macular arteries, from the temporal branches and small arterial twigs directly from the central artery. These do not reach as far as the fovea centralis, which has no blood vessels. The branches of the arteria centralis retina do not anastomose with each other, i.e., they are terminal arteries.
[0288] The nervous structures of the retina are supported by a series of non-nervous or sustentacular fibers and the retina consist of seven layers: the stratum opticum or fiber layer which is composed of axons of the retinal ganglion cells (RGC); the ganglionic layer or RGC layer composed of cell bodies of RGCs and some displaced amacrine cells; the inner plexiform layer composed of dendrites of the RGCs and amacrine cells; the inner nuclear layer, or layer with cell bodies of the interneurons of the retina; the outer plexiform layer, a layer with dentrites; the outer nuclear layer composed of cell bodies of the photoreceptor cells; and the layer of rods and cones.
[0289] The stratum opticum is formed by the RGC axons that extend to the optic nerve. As the nerve fibers pass through the lamina cribrosa sclera toward the eye they lose their myelinated sheaths and are continued onward through the choroid and retina as simple unmylinated axons. When they reach the internal surface of the retina they radiate from their point of entrance over this surface grouped in bundles, and in many places are arranged in plexuses. Most of the fibers are centripetal, and are the direct continuations of the axis-cylinder processes of the cells of the RGC layer, but a few of them are centrifugal and ramify in the inner plexiform and inner nuclear layers, where they end in enlarged extremities.
[0290] The RGC layer consists of a single layer of large ganglion cells, except in the macula lutea, where there are several strata of ganglion cells. The ganglion cells rest on and each sends off a prolonged axon into the stratum opticum. Numerous dendrites extend into the inner plexiform layer, where they branch and form flattened arborizations at different levels. The ganglion cells vary in size, and the dendrites of the smaller ones arborize in the inner plexiform layer as soon as they enter it; while the dendrites of the larger cells ramify close to the inner nuclear layer.
[0291] The inner plexiform layer is made up of a dense reticulum of minute fibrils formed by the interlacement of the dendrites of the ganglion cells with those of the cells of the inner nuclear layer; within this reticulum a few branched spongioblasts are sometimes imbedded.
[0292] The inner nuclear layer or layer of inner granules (cells) comprises three varieties of closely packed cells: bipolar cells, horizontal cells, and amacrine cells. The bipolar cells are the most numerous, and are round or oval in shape. Each is prolonged into an inner and an outer process. They are divisible into rod bipolars and cone bipolars. The inner processes of the rod bipolars run through the inner plexiform layer and arborize around the bodies of the cells of the ganglionic layer; their outer processes end in the outer plexiform layer in tufts of fibrils around the ends of the inner processes of the rod cells. The inner processes of the cone bipolars ramify in the inner plexiform layer in contact with the dendrites of the ganglionic cells. The horizontal cells have flattened cell bodies and lie in the outer part of the inner nuclear layer. Their dendrites divide into numerous branches in the outer plexiform layer, while their axons run horizontally for some distance and finally ramify in the same layer. The amacrine cells are found in the inner part of the inner nuclear layer. Their dendrites undergo extensive ramification in the inner plexiform layer.
[0293] The outer plexiform layer is thinner than the inner plexiform layer, and consists of a dense network of minute fibrils derived from the processes of the horizontal cells of the preceding layer. The outer processes of the rod and cone bipolar cells, which ramify in it, form arborizations around the enlarged ends of the rod fibers and with the branched foot plates of the cone fibers.
[0294] The outer nuclear layer, like the inner nuclear layer, contains cell bodies which are of two kinds: rod and cone cells, which are respectively connected with the rods and cones of the next layer. The rods are much more numerous than the cones, and are placed at different levels throughout the layer. Prolonged from either extremity of each rod cell is a fine process, one of which is continuous with a single rod of the layer of rods and cones, while the other ends in the outer plexiform layer in an enlarged extremity, and is imbedded in the tuft into which the outer processes of the rod bipolar cells break up. The cones are close to the membrana limitans externa through which they are continuous with the cones of the layer of rods and cones. From one extremity of the cone a thick process passes into the outer plexiform layer where it expands into a pyramidal enlargement or foot plate, from which are given off numerous fine fibrils, that come in contact with the outer processes of the cone bipolar cells.
[0295] The layer of rods and cones comprises rods and cones (photoreceptor cells), the former being much more numerous than the latter except in the macula lutea. The rods are cylindrical, of nearly uniform thickness, and are arranged perpendicularly to the surface. Each rod consists of two segments, an outer and inner, of about equal lengths. The outer segment is marked by transverse striæ, and tends to break up into a number of thin disks superimposed on one another. The deeper part of the inner segment is granular; its more superficial part presents a longitudinal striation, being composed of fine, highly refracting fibrils. Rhodopsin is found only in the outer segments. The cones are conical shaped, with their broad ends resting upon the membrana limitans externa, and the narrow extremity being turned to the choroid. Like the rods, each is made up of two segments, outer and inner; the outer segment is a short conical process, which, like the outer segment of the rod, exhibits transverse striæ. The inner segment resembles the inner segment of the rods in structure, presenting a superficial striated and deep granular part, but differs from it by being bulged out laterally and flask-shaped. The chemical and optical characters of the two portions are identical with those of the rods.
[0296] The term retinal cell can refer herein to any of the cell types that comprise the retina, such as retinal ganglion cells, amacrine cells, horizontal cells, bipolar cells, and photoreceptor cells including rods and cones, Muller glial cells, and retinal pigmented epithelium.
[0297] Advanced wet macular degeneration is a disease of the eye which comprises neovascularization of the choroid tissue underlying the photoreceptor cells in the macula. Macular degeneration, particularly in its advanced stages, is characterized by the pathological growth of new blood vessels in the choroid underlying the macula. Angiogenic blood vessels in the subretinal choroid can leak vision obscuring fluids, leading to blindness.
[0298] In one aspect, diseases of the eye which exhibit neovascularization proximal to the retina such as wet macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy can be treated to reduce the rate of neovascularization by administration of a composition of this invention comprising a fusion protein of this invention having angiogenesis inhibiting activity.
[0299] In another aspect, diseases of the eye which exhibit neovascularization proximal to the retina such as wet macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy can be treated to prevent or reduce the rate of photoreceptor cell death by administration of a composition of this invention comprising a fusion protein of this invention.
[0300] The compositions of the present invention when administered to the eye or to blood vessels that feed into the eye of a patient can be useful to treat diseases such as wet macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy by reducing the rate of formation of neovascularization and thereby slow the progress of the disease. The rate of neovascularization which occurs in such a disease in a patient is preferably reduced by administration of a fusion protein of this invention to at most 90%, more preferably to at most 50%, even more preferably to at most 25%, even more preferably to at most 10%, even more preferably to at most 5%, even more preferably to at most 1%, and most preferably to at most 0.1% of (times) the rate of neovascularization which occurs in such a disease in the absence of administration of a fusion protein of this invention (i.e., in an untreated patient).
[0301] The compositions of the present invention when administered to the eye or to blood vessels that feed into the eye of a patient can be useful to treat diseases such as wet macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy by reducing the rate of photoreceptor cell death and thereby slow the progress of the disease. The rate of photoreceptor cell death which occurs in such a disease in a patient is preferably reduced by administration of a fusion protein of this invention to at most 90%, more preferably to at most 50%, even more preferably to at most 25%, even more preferably to at most 10%, even more preferably to at most 5%, even more preferably to at most 1%, and most preferably to at most 0.1% of (times) the rate of photoreceptor cell death which occurs in such a disease in the absence of administration of a fusion protein of this invention (i.e., in an untreated patient).
[0302] Neovascularization proximal to the retina as a result of a disease, especially neovascularization proximal to the macula, can lead to photoreceptor cell death in the retina of a patient. Photoreceptor cell death in the retina can be produced as a consequence of a disease of the retina as a result of neovascularization as well as other mechanisms of cell death.
[0303] Advanced dry macular degeneration comprises the deposition of drusen and death of photoreceptor cells. The mechanism of drusen deposition is unknown, but exocytosis from cells is one likely mechanism of release into the extracellular space. Another embodiment of the present invention comprises the inhibition of drusen deposition and prevention of photoreceptor cell death by a cell-permeable fusion protein conjugate comprising a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating cellular uptake of the active agent, for example a fusion protein such as C3APLT. In one aspect, the functional analog of a Clostridium botulinum C3 exotransferase unit comprises a protein exhibiting an ADP-ribosyl transferase activity in the range of 50% to 500% of the ADP-ribosyl transferase activity of Clostridium botulinum C3 exotransferase. Inactivation of Rho in a cell by a fusion protein of this invention after penetration of the cell membrane can block or inhibit exocytosis and thereby block or inhibit the release from the cell of cellular debris or cellular-derived material that can form drusen. A fusion protein of this invention can also prevent injury-induced cell death of a cell in the CNS.
[0304] Angiogenesis in neovascularization is the complex process of blood vessel formation. The process involves both biochemical and cellular events, including (1) activation of endothelial cells (ECs) by an angiogenic stimulus; (2) degradation of the extracellular matrix, invasion of the activated endothelial cells into the surrounding tissues, and migration toward the source of the angiogenic stimulus; and (3) proliferation and differentiation of endothelial cells to form new blood vessels (Folkman et al., 1991, J. Biol. Chem. 267:10931-10934).
[0305] The control of angiogenesis is a highly regulated process involving angiogenic stimulators and inhibitors. In healthy humans and animals, angiogenesis occurs under specific, restricted situations. For example, angiogenesis is normally observed in fetal and embryonal development, development and growth of normal tissues and organs, wound healing, and the formation of the corpus luteum, endometrium and placenta. Another embodiment of the present invention comprises the inhibition of angiogenesis by a cell-permeable fusion protein conjugate comprising a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating cellular uptake of the active agent, for example a fusion protein such as C3APLT. In one aspect, the functional analog of a Clostridium botulinum C3 exotransferase unit comprises a protein exhibiting an ADP-ribosyl transferase activity in the range of 50% to 500% or more of the ADP-ribosyl transferase activity of Clostridium botulinum C3 exotransferase.
[0306] Another embodiment of the present invention comprises the inhibition of angiogenesis by an effective amount of a pharmaceutical composition comprising a cell-permeable fusion protein conjugate comprising a polypeptidic cell-membrane transport moiety and a Clostridium botulinum C3 exotransferase unit, or a functional analog thereof retaining an ADP-ribosyl transferase activity, for example a fusion protein such as C3APLT.
[0307] In one embodiment, this invention discloses a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, the method comprising administration to a patient in need of such treatment a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide consisting of SEQ ID NO:43 and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection.
[0308] In another embodiment, this invention discloses a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, the method comprising administration to a patient in need of such treatment a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of a subdomain of HIV Tat protein, a homeodomain of antennapedia, and a Histidine tag, said polypeptide having ADP-ribosyl transferase activity, and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection.
[0309] In another embodiment, this invention discloses a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, the method comprising administration to a patient in need of such treatment a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of SEQ ID NO: 21, SEQ ID NO: 26, SEQ ID NO: 31, SEQ ID NO: 44, SEQ ID NO: 45, SEQ ID NO: 46, SEQ ID NO: 47, and SEQ ID NO: 48, said polypeptide having ADP-ribosyl transferase activity, and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection.
[0310] In another embodiment, this invention discloses a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, the method comprising administration to a patient in need of such treatment a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or an amino acid sequence having at least 90% sequence identity with the amino acid sequence of SEQ ID NO: 43 and retaining ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of a subdomain of HIV Tat protein, a homeodomain of antennapedia, and a Histidine tag, said polypeptide having ADP-ribosyl transferase activity, and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection. In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide.
[0311] In another embodiment, this invention discloses a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, the method comprising administration to a patient in need of such treatment a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or an amino acid sequence having at least 90% sequence identity with the amino acid sequence of SEQ ID NO: 43 and retaining ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of SEQ ID NO: 21, SEQ ID NO: 26, SEQ ID NO: 31, SEQ ID NO: 44, SEQ ID NO: 45, SEQ ID NO: 46, SEQ ID NO: 47, and SEQ ID NO: 48, and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection. In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide.
[0312] In another embodiment, this invention discloses a method of inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue, preventing drusen deposition and protecting retinal photoreceptors from cell death (i.e., reducing the rate of drusen deposition and reducing the rate of retinal photoreceptor cell death) in the eye of a mammalian host comprising administration to said host a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide consisting of SEQ ID NO:43 and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection.
[0313] In another embodiment, this invention discloses a method of inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue preventing drusen deposition and protecting retinal photoreceptors from cell death (i.e., reducing the rate of drusen deposition and reducing the rate of retinal photoreceptor cell death) in the eye of a mammalian host comprising administration to said host a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of a subdomain of HIV Tat protein, a homeodomain of antennapedia, and a Histidine tag, said polypeptide having ADP-ribosyl transferase activity, and; b) a pharmaceutically acceptable carrier.
[0314] In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection.
[0315] In another embodiment, this invention discloses a method of inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue, preventing drusen deposition and protecting retinal photoreceptors from cell death (i.e., reducing the rate of drusen deposition and reducing the rate of retinal photoreceptor cell death) in the eye of a mammalian host comprising administration to said host a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of SEQ ID NO: 21, SEQ ID NO: 26, SEQ ID NO: 31, SEQ ID NO: 44, SEQ ID NO: 45, SEQ ID NO: 46, SEQ ID NO: 47, and SEQ ID NO: 48, said polypeptide having ADP-ribosyl transferase activity, and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection.
[0316] In another embodiment, this invention discloses a method of inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue, preventing drusen deposition and protecting retinal photoreceptors from cell death (i.e., reducing the rate of drusen deposition and reducing the rate of retinal photoreceptor cell death) in the eye of a mammalian host comprising administration to said host a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or an amino acid sequence having at least 90% sequence identity with the amino acid sequence of SEQ ID NO: 43 and retaining ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of a subdomain of HIV Tat protein, a homeodomain of antennapedia, and a Histidine tag, said polypeptide having ADP-ribosyl transferase activity, and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection. In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide.
[0317] In another embodiment, this invention discloses a method of inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue, preventing drusen deposition and protecting retinal photoreceptors from cell death (i.e., reducing the rate of drusen deposition and reducing the rate of retinal photoreceptor cell death) in the eye of a mammalian host comprising administration to said host a therapeutically effective amount of a pharmaceutical composition comprising: a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or an amino acid sequence having at least 90% sequence identity with the amino acid sequence of SEQ ID NO: 43 and retaining ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of SEQ ID NO: 21, SEQ ID NO: 26, SEQ ID NO: 31, SEQ ID NO: 44, SEQ ID NO: 45, SEQ ID NO: 46, SEQ ID NO: 47, and SEQ ID NO: 48, and; b) a pharmaceutically acceptable carrier. In one aspect of this embodiment, the carrier comprises a biological adhesive. In one aspect of this embodiment, the carrier comprises fibrin. In one aspect of this embodiment, the administration comprises injection. In one aspect of this embodiment, the amino acid sequence of the transport agent is at the carboxy-terminal end of said polypeptide and the amino acid sequence of the active agent is at the amino terminal end of said polypeptide.
[0318] In one aspect, a therapeutically effective amount of a polypeptide of this invention is an amount which will retard the progress of neovascularization proximal to the macula to a rate of at least 90%, preferably to a rate of at least 50%, more preferably to a rate of at least 10%, more preferably to a rate of at least 1%, and most preferably to a rate of at least 0.1% of the rate of neovascularization observed proximal to the macula in an untreated patient or in a patient treated with a control vehicle such as a carrier of a pharmaceutical composition of this invention which does not contain a polypeptide of this invention.
[0319] In another aspect, a therapeutically effective amount of a polypeptide of this invention is an amount which can retard or inhibit the rate of deposition of drusen in an eye of an average patient in a statistically relevant population of patients to produce a mean delay in the onset of vision loss that can result from said deposition, the mean delay of onset of vision loss being measured relative to the mean time of onset of vision loss that occurs in an average patient in the statistically relevant population of patients in the absence of said amount of polypeptide, the mean delay in the onset of vision loss comprising a period of at least 1 month, and more preferably a period of at least 6 months, and most preferably a period of greater than 6 months.
[0320] In another aspect, a therapeutically effective amount of a polypeptide of this invention is an amount which can retard or inhibit the progress (or rate) of photoreceptor cell death in an eye of an average patient in a statistically relevant population of patients to produce a mean delay in the onset of vision loss that can result from said cell death, the mean delay of onset of vision loss being measured relative to the mean time of onset of vision loss that occurs in an average patient in the statistically relevant population of patients in the absence of said amount of polypeptide, the mean delay in the onset of vision loss comprising a period of at least 1 month, and more preferably a period of at least 6 months, and most preferably a period of greater than 6 months.
[0321] In another aspect, a therapeutically effective amount of a polypeptide of this invention is an amount which can retard or inhibit the rate of deposition of drusen and retard or inhibit the progress (or rate) of cell death in an eye of an average patient in a statistically relevant population of patients to produce a mean delay in the onset of vision loss that can result from said deposition and said cell death, the mean delay of onset being measured relative to the mean time of onset of vision loss that occurs in an average patient in the statistically relevant population of patients in the absence of said amount of polypeptide, the mean delay in the onset of vision loss comprising a period of at least 1 month, and more preferably a period of at least 6 months, and most preferably a period of greater than 6 months.
[0322] A therapeutically effective amount or dose of a compound or composition of this invention can refer to that amount which will produce a desirable result upon administration. A therapeutically effective amount or dose can depend on a number of factors including the route of administration.
BRIEF DESCRIPTION OF THE FIGURES
[0323] FIG. 1 illustrates the dose response of normal C3 with and without trituration;
[0324] FIG. 2 illustrates ADP ribosylation by C3APLT and C3APS, but not C3 after passively adding the compounds to PC-12 cells;
[0325] FIG. 3A illustrates that C3APLT penetrates cells;
[0326] FIG. 3B illustrates a lower level of cell penetration by C3 as compared to FIG. 3A ;
[0327] FIG. 4 illustrates the effectiveness of C3APLT and C3APS at low doses;
[0328] FIG. 5 illustrates the effectiveness of C3APLT and C3APS at low doses;
[0329] FIG. 6 illustrates the effectiveness of C3APLT to stimulate axon regeneration of primary neurons;
[0330] FIG. 7 illustrates the effectiveness of C3APLT to promote functional recovery after spinal cord injury;
[0331] FIG. 8 illustrates effectiveness of Tat transport sequences to enhance growth as C3-Tat (C3-TL and C3-TS) chimeras;
[0332] FIGS. 9A and 9B illustrate axon regeneration after spinal cord injury and treatment with C3APLT;
[0333] FIG. 10 illustrates effectiveness of C3APLT to prevent cell death after spinal cord injury, thereby showing that it is neuroprotective,
[0334] FIG. 11 illustrates a comparison of C3APLT and C3Basic3 to promote neurite outgrowth, and;
[0335] FIG. 12 illustrates that C3APLT promotes neurite outgrowth from retinal neurons plated on inhibitory myelin or CSPG substrates. Retinal neurons plated on myelin (dark bars) or CSPG (dotted bars) substrates and treated with C3-05. FIG. 12 A illustrates the percentage of cells with neurites neurites longer than 1 cell body diameter (neurite outgrowth); FIG. 12 B illustrates the length of the longest neurite per cell (neurite length);
[0336] FIG. 13A illustrates tube formation by HUVEC endothelial cells cultured in a Matrigel™ matrix (BD Biosciences). This assay is a cell culture assay for antiogenesis. Tube formation (area 30) can be seen in the control HUVEC endothelial cell culture which does not contain a fusion protein of this invention. This tube formation can be a model for neovascularization;
[0337] FIG. 13B illustrates a substantial reduction in tube formation of HUVEC endothelial cells cultured in a Matrigel™ matrix. Cultures treated with a composition of this invention comprising a fusion protein, C3APLT as SEQ ID 43, had fewer tubes (area 31) formed in the presence of the fusion protein, thereby demonstrating an inhibition of angiogenesis by administration of the fusion protein to the cells. This substantial reduction in tube formation can be a model for a substantial reduction in neovascularization;
[0338] FIG. 14 illustrates activity of a fusion protein of the invention, C3-07, and lack of activity of an inactive mutant of the C3-07 fusion protein, C3-07Q189A, as assayed by bioassay with NG-108 cells. NG-108 cells cultured with fusion protein C3-07 exhibit accelerated neurite outgrowth (bar 42 in FIG. 14 , which shows approximately 40% neurite outgrowth). Neurite outgrowth of NG-108 cells treated with C3-07A189A (bar 41, which shows approximately 12% neurite outgrowth) is similar to that of the control (bar 40, which shows approximately 14% neurite outgrowth) of untreated cells demonstrating that protein C3-07Q189A is not active as a fusion protein to induce accelerated neurite outgrowth; and
[0339] FIG. 15 illustrates that an injection of fusion protein C3-07 can prevent death of retinal ganglion cells (RGCs) induced by crush of the optic nerve following a single injection. After axotomy (bar 51) or axotomy with injection of vehicle (bar 52), where the vehicle is phosphate buffered saline, cells die after axotomy of the optic nerve. When C3-07Q189A, an inactive mutant of fusion protein C3-07, is injected into the eye it is not able to prevent death of the RGCs (bar 53). A single injection of C3-07 prevents cell death (bar 54) and the number of surviving cells is similar to that in control (bar 50), non-axotomized retinas. The results demonstrate that C3-07 can prevent death of retinal neurons, and the neuroprotective activity of C3-07 requires that the enzymatic activity of the C3 fusion protein is retained.
DETAILED DESCRIPTION
[0340] Referring to FIG. 1 , PC-12 cells were plated on inhibitory myelin substrates (0). Unmodified C3 added to the tissue culture medium at concentration from 0.00025-50 ug/ml did not significantly improve neurite outgrowth over the untreated control (grey bars). C3 was only effective in stimulating neurite outgrowth for cells plated on myelin substrates after scrape-loading (black bars). This Figure demonstrates the limited or no penetration in cells when passively added to the tissue culture medium. Please see Example 4 below for techniques.
[0341] Referring to FIG. 2 , this Figure provides a demonstration that C3APLT and C3APS, ADP ribosylate Rho. Western blot showing RhoA in untreated cells (lane 1), and cells treated with C3APLT (lane 2) or C3APS (lane 3). When Rho is ADP ribosylated by C3 it undergoes a molecular weight shift (Lehmann et al supra), as observed for lanes 2 and 3. Please see Example 4 below for techniques.
[0342] Referring to FIG. 3 , this Figure shows intracellular activity after treatment with C3APLT. Detection that the new fusion C3 penetrates into the cells. Immunocytochemistry with anti-C3 antibody of PC-12 cells plated on myelin and treated with C3 (A) or C3APLT (13). Cells in A ( FIG. 3A ) are not immunoreactive because C3 has not penetrated into the cells. Cells in B ( FIG. 3B ) are immunoreactive and they are able to extend neurites on myelin substrates. Please see Example 4 below for techniques.
[0343] Turning to FIG. 4 , this Figure shows that C3-antennapedia fusion proteins promote growth on inhibitory substrates. The percent of neurons that grow neurites was counted for each treatment. The dose response experiment shows that C3APLT and C3APS promote more neurite growth per cell than control PC-12 cells plated on myelin (0). PC-12 cells were plated on myelin and either scrape loaded with unmodified C3 (C3 50) left untreated (0) or treated with various concentrations of C3APLT. Compared to C3 used at 25 ug/ml, C3APS is effective at stimulating more cells to grow neurites at 0.0025 ug/ml, a dose 10,000× less. Please see Example 4 below for techniques.
[0344] FIG. 5 shows a dose-response experiment showing that C3APLT and C3APS elicit long neurites to grow when cells are plated on inhibitory substrates. The length of neurites was measured for each treatment. PC-12 cells were plated on myelin and either scrape loaded with unmodified C3 (C3 50) left untreated (0) or treated with various concentrations of C3APLT. Compared to C3 used at 25 ug/ml, C3APS is effective at stimulating more cells to longer neurite growth at 0.0025 ug/ml, a dose 10,000.times. less. Please see Example 4 below for techniques.
[0345] As may be seen FIG. 6 shows primary neurons growing on inhibitory substrates after treatment with C3APLT. Rat retinal ganglion cells were plated on myelin substrates and treated with different concentrations of C3APLT. Concentrations of 0.025 and above promoted significantly longer neurites. This dose is 1000.times. lower than that of C3 needed to promote growth on myelin.
[0346] Referring to FIG. 7 , this Figure shows behavioral recovery after treatment of adult mice with C3APLT in a dose-response experiment. Mice received a dorsal hemisection of the spinal cord and were left untreated (transection), were treated with fibrin alone (fibrin) or were treated with fibrin plus C3APLT at the indicated concentrations given in ug/mouse. Each point represents one animal. The BBB score (see Example 6 for details) was assessed 24 hours after treatment. Animals treated with C3APLT exhibited a significant improvement in behavioral recovery compared to untreated animals. The effective dose of 0.5 μg is 100.times. less than unmodified C3 used (see previous experiment shown in Canadian patent application 2,325,842). Please see Example 6.
[0347] Referring to FIG. 8 , this Figure shows promotion of axon growth by C3-Tat chimeric proteins. The dose-response experiment shows that C3-TS and C3-TL promote more neurite growth per cell than control PC-12 cells plated on myelin. PC-12 cells were plated on myelin and either scrape loaded with unmodified C3 (scrape load) left untreated (myelin) or treated with various concentrations of C3-TS (grey bars) or C3-TL (black bars). Compared to C3 used at 25 ug/ml, C3-TL is effective at stimulating more cells to grow neurites at 0.0025 ug/ml, a dose 10,000.times. less than C3.
[0348] Referring to FIGS. 9A and 9B , these Figures show axon regeneration in injured spinal cord, i.e. anatomical regeneration after treatment with C3APLT. Section of the spinal cord after anterograde labeling with horseradish peroxidase conjugated to wheat germ agglutinin (WGA-HRP). A) Sprouting of cut axons into the dorsal white matter. Arrows show regenerating axons distal to the lesion. B) Same section 3 mm from the lesion site. Arrows show regenerating axons.
[0349] Referring to FIG. 10 , this Figure shows that C3-APLT protected neurons from cell death following spinal cord injury. Apoptotic (dying) cells were counted following TUNEL labeling (see Example 16) 2 mm rostral to the lesion (Rostral) at the lesion site (lesion) and 2 mm caudal to the lesion site (caudal). Bars show average counts of Tunel positive cells from 4 animals treated with fibrin only after spinal cord injury as control (white bars), or with C3APLT in fibrin at 1 μg (black bars). Treatment with C3APLT show significantly reduced numbers of Tunel-labeled cells (dying cells). Non-injured spinal cord samples were also processed and these spinal cords did not show Tunel labeling, as expected.
[0350] Referring to FIG. 11 , this Figure shows that C3APLT and C3Basic3 promote rapid neurite outgrowth compared to untreated cells when cells are plated on plastic as part of a rapid bioassay (see Example 4).
[0351] Referring to FIGS. 12A and 12B , to further support the ability of C3-like chimeric proteins to promote neurite outgrowth on inhibitory substrates, we examined the response of primary cultures plated on inhibitory substrates to C3APLT treatment. Purified retinal ganglion cells (RGCs) were plated on myelin, or CSPG substrates and treated with varying concentrations of C3APLT. During the RGC dissection great care was taken in order to try to limit the amount of mechanical manipulation of the cells, however, the isolation protocol requires that some triturating take place in order to dissociate and separate the cells. When RGCs are plated on inhibitory substrates, they maintained a similar round appearance to PC-12 cells plated on myelin. Treatment of RGCs with C3APLT promoted neurite outgrowth and increased neurite length on both myelin and CSPG substrates. In contrast to the wide range of concentrations shown to be effective in other PC-12 experiments a narrower range of C3APLT treatment, 0.025 ug/ml to 50 ug/ml promoted neurite outgrowth and increased neurite length on myelin. In the case of RGCs plated on CSPG substrates, effective concentration ranges of 0.0025 ug/ml to 50 ug/ml were observed.
[0352] Referring to FIG. 13 , a fusion protein of this invention, C3APLT, can inhibit neovascularization represented by tube formation in an in vitro model comprising HUVEC endothelial cells in culture. In the absence of the fusion protein, extensive tube formation by HUVEC endothelial cells is observed ( FIG. 13A , area 30) when the cells are cultured in a Matrigel™ matrix (BD Biosciences). This assay is a cell culture assay for antiogenesis. Tube formation in vitro can be a model for angiogenesis and neovascularization in vivo. However, in the presence of a fusion protein of this invention (e.g., C3APLT as SEQ ID 43 was administered to the cell culture in this example), a substantial reduction in the number and density of tubes formed by HUVEC endothelial cells when the cells are cultured in a Matrigel™ matrix is observed ( FIG. 13B , area 31), demonstrating an inhibition of angiogenesis by the fusion protein. Reduction in tube formation can indicate inhibition of angiogenesis. Neovascularization in retinal diseases such as macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, can be reduced or eliminated by inhibition of angiogenesis comprising administration of a fusion protein of this invention to the eye of a patient. Administration of a fusion protein of this invention can be useful to treat such diseases.
[0353] Thus, in one aspect, this invention comprises a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy, the method comprising administration to a patient in need of such treatment a therapeutically effective amount of a pharmaceutical composition comprising:
a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of a subdomain of HIV Tat protein, a homeodomain of antennapedia, and a Histidine tag, said polypeptide having ADP-ribosyl transferase activity, and; b) a pharmaceutically acceptable carrier.
[0356] In another aspect, this invention comprises a method of inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue in the eye of a mammalian host comprising administration to said host a therapeutically effective amount of a pharmaceutical composition comprising:
a) a) a polypeptide comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, said amino acid sequence of said active agent consisting of ADP-ribosyl transferase C3 or a fragment thereof retaining an ADP-ribosyl transferase activity, said amino acid sequence of said transport agent facilitating uptake of the active agent by a receptor-independent mechanism and being selected from the group consisting of a subdomain of HIV Tat protein, a homeodomain of antennapedia, and a Histidine tag, said polypeptide having ADP-ribosyl transferase activity, and; b) b) a pharmaceutically acceptable carrier.
[0359] Referring to FIG. 14 , the intentional inactivity of a mutant of the C3-07 fusion protein, i.e., inactive C3-07Q189A, as assayed by a bioassay with NG-108 cells is illustrated. NG-108 cells cultured with an active fusion protein of this invention, C3-07, exhibit accelerated neurite outgrowth, which neurite outgrowth is the result of the presence of C3-07. However, neurite outgrowth of cells treated with intentionally inactive mutant C3-07A189A is similar to that of the control cells which are not treated with additional protein. The similarity to the control group demonstrates that the intentionally inactive mutant protein C3-07Q189A is inactive with respect to stimulation of neurite outgrowth.
[0360] Referring to FIG. 15 , an injection of a fusion protein of this invention, C3-07, can prevent (substantially reduce the observed rate of) death of retinal ganglion cells (RGCs) induced by crush of the optic nerve following a single injection. After axotomy or axotomy with injection of vehicle (phosphate buffered saline) cells die after axotomy of the optic nerve. When C3-07Q189A, an intentionally inactive mutant of C3-07, is injected into the eye it is not able to prevent death of the RGCs. A single injection of C3-07 prevents cell death and the number of surviving cells is similar to that in control, non-axotomized retinas. The results demonstrate that C3-07 as a fusion protein of this invention can prevent death of retinal neurons; the neuroprotective activity of C3-07 requires that the enzymatic activity of the C3 fusion protein is retained.
[0361] C3-07 exhibits ADP-ribosylation activity, whereas C3-07Q189A is intentionally inactive with respect to ADP-ribosylation activity.
[0362] Administration of a pharmaceutical composition comprising a fusion protein of this invention to a patient in need of treatment for a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy can substantially reduce or prevent angiogenesis associated with subretinal neovascularization, choroid neovascularization underlying the macula, and a proliferation of neovascular tissue in the subretinal choroid proximal to the macula in an eye in a mammalian host and comprises a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy. In one aspect, the compositions of this invention are useful for inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue related to a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy. The method can be useful as a prophylactic treatment to prevent further onset or progression of macular degeneration in an eye that exhibits symptoms of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy. In another aspect, the method can be useful as a prophylactic treatment to prevent the deposition of drusen and the death of cells in the macula. In another aspect, the method can prevent the death of photoreceptor cells (which photoreceptor cells are also herein referred to as photoreceptors) in the eye of a patient by acting on intracellular mechanisms of the regulation of cell death. The method can also be useful to prevent onset or progression of macular degeneration in an eye that does not exhibit vision-obscuring symptoms of macular degeneration, especially in an eye of a patient whose other eye does exhibit vision-obscuring symptoms of macular degeneration.
[0363] In another aspect of this invention, a method of treatment of a disease of the eye selected from the group consisting of macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy comprises administration such as by injection or implantation into tissue proximal to the eye of a therapeutically effective amount of a polypeptide of this invention, or of a sterile pharmaceutical composition of this invention suitable for injectable administration and comprising a polypeptide of this invention and a carrier suitable for injectable use (e.g., sterile, sterilizable, and isotonic with blood), which polypeptide or pharmaceutical composition can prevent or delay the onset of angiogenesis associated with the group consisting of subretinal neovascularization, choroid neovascularization underlying the macula, and a proliferation of neovascular tissue in the subretinal choroid proximal to the macula in an eye of an average patient in a statistically relevant population of patients to produce a mean delay in the onset of vision loss that can result from said angiogenesis, the mean delay of onset being measured relative to the mean time of onset of vision loss that occurs in an average patient in the statistically relevant population of patients in the absence of said amount of polypeptide, the mean delay in the onset of vision loss comprising a period of at least 1 month, and more preferably a period of at least 6 months, and most preferably a period of greater than 6 months.
[0364] Inhibition of angiogenesis by a pharmaceutical composition comprising a fusion protein of this invention such as C3APLT can be evaluated in an in vitro system that can also be useful for the study of angiogenesis in the growth of a tumor, i.e., a system comprising cultivation of endothelial cells in the presence of an extract of basement membrane (Matrigel™) as a model for angiogenesis and for neovascularization and proliferation of neovascular tissue in the eye of a mammal. In the experimental observation conditions, capillary-like structures or tubules associated with angiogenesis or blood vessel capillary formation can be viewed under a microscope. The inhibitory effect of a fusion protein of this invention such as C3APLT on the progress of angiogenesis or on the formation of a tubular capillary network or on the disruption of the process or progress of tumor-associated angiogenesis can be observed by following the disappearance of tubular structures in a Matrigel assay.
[0365] Matrigel™ Matrix (BD Biosciences) is a solubulized basement membrane preparation extracted from EHS mouse sarcoma, a tumor rich in ECM proteins. Its major components are laminin, collagen IV, heparan sulfate proteoglycans, and entactin. At room temperature, BD Matrigel™ Matrix polymerizes to produce biologically active matrix material which can mimic mammalian cellular basement membrane, wherein cells can behave in vitro in a manner similar to in vivo conditions. Matrigel™ Matrix can provide a physiologically relevant environment for studies of cell morphology, biochemical function, migration or invasion, and gene expression.
[0366] In a Matrigel assay, Matrigel (about 12.5 mg/mL) is thawed at about 4° C. The matrix (about 50 microliters (uL)) is added to each well of a 96 well plate and allowed to solidify for about 10 min at about 37° C. The wells containing solid Matrigel are incubated for about 30 minutes with human umbilical vein endothelial cells (HUVEC cells) at a concentration of about 15,000 cells per well. When the cells are adhered, medium is removed and replaced by fresh medium supplemented with a fusion protein of this invention such as C3APLT and incubated at 37° C. for about 6 to about 8 hours. Control wells are incubated with medium alone. To analyze the growth, tube formation can be visualized by microscopy at, for example, about 50× magnification. The relative mean length, Yx, of an angiogenesis-derived capillary network observed in an evaluation of a pharmaceutical composition comprising a fusion protein, x, of this invention can be quantified using Northern Eclipse software according to the instructions.
[0367] Data from a typical Matrigel assay experiment, for example relating to the effect of a pharmaceutical composition comprising a fusion protein designated as C3APLT on length of an angiogenesis-derived capillary network are summarized in Table 3. These data show that the network formation was inhibited by approximately 13% to about 20% under the dose and formulation conditions used versus the inhibition produced by a control vehicle wherein zero inhibition provides 100% growth. This effect on angiogenesis can be enhanced by using higher doses of fusion protein and by preincubation of the HUVEC cells with fusion protein C3APLT prior to addition of the cells to Matrigel. The anti-angiogenesis effect of a composition comprising a polypeptide of this invention comprising an amino acid sequence of a transport agent covalently linked to an amino acid sequence of an active agent, wherein the amino acid sequence of the active agent retains an ADP-ribosyl transferase activity can be useful for inhibiting or substantially reducing the rate of subretinal neovascularization and proliferation of neovascular tissue in the eye of a mammalian host when the composition is administered to the mammal according to the methods of this invention.
[0000]
TABLE 3
Anti-angiogenesis effect of a pharmaceutical composition comprising
a fusion protein, C3APLT, on the mean length of a capillary network
in a Matrigel matrix assay
Relative mean length of
a capillary network
produced in the presence
of a pharmaceutical
Mean length
composition comprising
of a
Relative mean length of a
a fusion protein,
capillary network
capillary network produced
C3APLT, at a
associated with
in the presence of a vehicle
concentration of 10
angiogenesis
control
micrograms per milliter
Y1
100
86.4
Y2
100
78.2
Y3
100
86.7
[0368] It is an advantage that the current invention provides compositions comprising a fusion protein of this invention, which fusion protein after administration to a mammal, preferably proximal to the eye or into a blood vessel that provides blood to the eye, has the ability to penetrate endothelial cells in the eye that in the absence of the fusion protein can form new blood vessels. Thus, when administered to the eye of a mammal, the compositions of this invention can inhibit or substantially reduce the rate of subretinal neovascularization and proliferation of neovascular tissue in the eye of the mammal.
Description of how to Measure Effect on Cell Death In Vivo
[0369] One system to examine the neuroprotective effect of fusion proteins in the eye is a model of optic nerve axotomy. In the visual system, retinal ganglion cells die after optic nerve injury, and the severity and rate of cell death depends on the proximity of axonal injury to the eye. In rats, transection of the optic nerve close to the eye causes a delayed RGC death, with cells beginning to die approximately 4 days after axotomy. It has been well demonstrated that intervention with factors that prevent cell death give partial and transient rescue of cells. Intraocular injection of growth factors that include BDNF, NT4, GDNF, CNTF and FGF can rescue RGCs from axotomy-induced cell death. Other ways to rescue cells are to interfere with enzymes that contribute to apoptotic cell death. Lens injury that induces macrophage activation and injection of zymosan from yeast cell walls promote survival of RGCs. To study the inactivation of Rho on RGC survival C3-07 was injected into the vitreous after axotomy: To separate effects of C3-07 on Rho activation from possible inflammatory responses induced by the intravitreal injection of a protein, we used an intentionally inactive mutant of C3-07 protein, i.e., C3-07Q189A, that lacks ADP-ribosylation activity but maintains normal glycohydrolysis activity. To our knowledge, this is the first in vivo study using a mutant C3 exoenzyme or C3-fusion proteins to study cell survival in the retina. We found that a single injection of C3-APLT or C3-07 promoted survival of RGCs equivalent to rates reported for BDNF, and that the effect of C3-07 is dependant on its ability to inactivate Rho.
[0370] Other animal models can be used to assess damage to and rescue of photoreceptor cells (e.g., reduction in the rate of death of photoreceptor cells). Useful are genetic models of retinal degeneration and other diseases of the eye in mice. The rescue of photoreceptors can be demonstrated in RCS rats that have an inherited retinal degeneration, or in transgenic lines of mice that express mutated forms of rhodopsin that cause retinitis pigmentosa in human. Such mice are commercially available from Jackson labs. Retinal detachment also leads to death of photoreceptor cells, and this provides another animal model to demonstrate neuroprotection (e.g., reduction in the rate of death of photoreceptor cells). To assess the effect of compounds on neovascularization that occurs in wet macular degeneration and related diseases, animal models are also used. Useful to model neovascularization of the retina are rodent models of oxygen-induced retinopathy of the neuroborn rodents, sometimes referred to as retinopathy of prematurity (ROP).
Method for Making the C3APL, C3APLT, and C3APS
[0371] C3APL is the name given to the protein made by ligating a cDNA encoding C3 (Dillon and Feig (1995) 256: 174-184) with cDNA encoding the antennapedia homeodomain (Bloch-Gallego (1993) 120: 485-492). The stop codon at the 3′ end of the DNA was replaced with an EcoR I site by polymerase chain reaction (PCR) using the primers (oligonucleotides) 5′GAA TTC TTT AGG ATT GAT AGC TGT GCC 3′ (SEQ ID NO: 1) and 5′GGT GGC GAC CAT CCT CCA AAA 3′ (SEQ ID NO: 2). The PCR product was sub-cloned into a pSTBlue-1 vector (Novagen, city), then cloned into a pGEX-4T vector using BamH I and Not I restriction site. This vector was called pGEX-4T/C3. The antennapedia sequence used to add to the 3′ end of C3 in pGEX-4T/C3 was created by PCR from the pET-3a vector (Bloch-Gallego (1993) 120: 485-492, Derossi (1994) 269: 10444-10450), subcloned into a pSTBlue-1 blunt vector, then cloned into the pGEX-4T/C3, using the restriction sites EcoR I and Sal I, creating pGEX-4T/C3APL. Another clone (C3APLT) with a frameshift mutation was selected, and the protein made and tested. When the cultures tested positive despite the mutation, the clone was resequenced by another company to confirm the mutation, and this clone was called C3APLT. To confirm the sequence of C3APLT, the coding sequence from both strands was sequenced. The sequence for this clone is given in Examples 16 and 17 (nucleotide sequence of C3APLT; SEQ ID NO: 42, amino acid sequence of C3APLT; SEQ ID NO: 43).
[0372] A shorter version of the Antennapedia (pGEX-4T/C3APS) was also made. This chimeric sequence was made by ligating oligonucleotides encoding the short antennapedia peptide (Maizel (1999) 126: 3183-3190) into the pGEX-4T/C3 vector cut with EcoR I and Sal I. The recombinant C3APLT and C3APS cDNAs were separately transformed into bacteria, and after the recombinant proteins were produced, a bacterial homogenate was obtained by sonication, and the homogenate cleared by centrifugation. Glutathione-agarose beads (Sigma) were added to the cleared lysate and placed on a rotating plate for 2-3 hours, then washed extensively. To remove the glutathione S transferase sequence from the recombinant protein, 20 U (unit) of Thrombin was added, the beads were left on a rotator overnight at 4° C. After cleavage with thrombin, the beads were loaded into an empty 20 ml column, and the proteins eluted with PBS (phosphate buffered saline). Aliquots containing recombinant protein were pooled and 100 μl p-aminobenzamidine agarose beads (Sigma) were added and left mixing for 45 minutes at 4° C. to remove thrombin, then recombinant protein was isolated from the beads by centrifugation. Purity of the sample was determined by sodium dodecyl sulfate polyacrylamide gel electrophoresis (SDS-PAGE), and bioactivity bioassay with PC-12 cells was performed (See Lehmann et al supra).
[0373] Other possible methods for making bioactive chimeric proteins include anion exchange chromatography. For this, the GST tag is not required and can be removed. The cDNA can then be cloned into a high expression bacterial vector, such as pET, as given in Example 16.
[0374] The Rho antagonist is a recombinant protein and can be made according to methods present in the art. The proteins of the present invention may be prepared from bacterial cell extracts, or through the use of recombinant techniques by transformation, transfection, or infection of a host cell with all or part of a C3-encoding DNA fragment with an antennapedia-derived transport sequence in a suitable expression vehicle. Those skilled in the field of molecular biology will understand that any of a wide variety of expression systems can be used to provide the recombinant protein. The precise host cell used is not critical to the invention.
[0375] Any fusion protein can be readily purified by utilizing either affinity purification techniques or more traditional column chromatography. Affinity techniques include, but are not restricted to GST (gluathionie-S-transferase), or the use of an antibody specific for the fusion protein being expressed, or the use of a histidine tag. Alternatively, recombinant protein can be fused to an immunoglobulin Fc domain. Such a fusion protein can be readily purified using a protein A column. It is envisioned that small molecule mimetics of the above-described antagonists are also encompassed by the invention.
Testing the Bioactivity of C3APLT, C3APS, C3-TL and C3-TS
[0376] To test the efficacy of C3APLT, C3APS, C3-TL and C3-TS a number of experiments were performed with PC-12 cells, a neural cell line, grown on growth inhibitory substrates (see Lehmann et al supra). PC-12 cells were plated on myelin substrates as described (Lehmann et al, supra). C3, C3APLT, C3APS, C3-TL or C3-TS were added at different concentrations without trituration (please refer to FIGS. 4 , 5 and 8 for concentrations used). C3 added passively to the culture medium in this way was not able to promote neurite growth in the growth inhibitory substrates because cells must be triturated for C3 to enter the cells and be active ( FIG. 1 ). Both C3APLT and C3APS were able to ADP ribosylate Rho to cause a shift in the molecular weight of RhoA ( FIG. 2 ). Both C3APLT and C3APS were able to promote neurite growth and enter neurons after being added passively to the culture medium ( FIG. 3 , FIGS. 4 and 5 ). Dose-response experiment where concentrations of 0.25 ng/ml, 2.5 ng/ml, 25 ng/ml, 250 ng/ml and 2.5 μg/ml (2.5 microgram/milliliter) and 25 μg/ml (25 microgram/milliliter) were tested and showed that C3APLT and C3APS helped more neurons differentiate neurites at doses 10,000 fold less than C3 ( FIG. 4 ). Dose response experiments where concentrations of 0.25 ng/ml, 2.5 ng/ml, 25 ng/ml, 250 ng/ml and 2.5 μg/ml (2.5 microgram/milliliter) and 25 μg/ml (25 microgram/milliliter) were tested and showed that C3APLT was able to promote long neurite growth when added at a minimum concentration of 0.0025 ug/ml (0.0025 microgram/milliliter) ( FIG. 5 ). These concentrations of 2.5 ng/ml and 25 ng/ml for C3APLT and C3APS, represent 10,000 and 1,000 times less than the dose needed with C3, respectively. Moreover, at the highest concentration tested, 50 ug/ml (50 microgram/milliliter), these two new Rho antagonists did not exhibit toxic effects on PC-12 cells, and were able to stimulate neurite outgrowth on growth inhibitory substrates.
[0377] C3-TL and C3-TS also were tested at concentrations of 0.25 ng/ml, 2.5 ng/ml, 25 ng/ml, 250 ng/ml and 2.5 μg/ml (2.5 microgram/milliliter) and 25 μg/ml (25 microgram/milliliter) and were found to be able to promote neurite growth on myelin substrates at doses significantly less than C3 ( FIG. 8 ). C3Basic3 was tested at 50 ug/ml in a fast growth assay ( FIG. 11 ).
[0378] To verify the ability of C3APLT and C3APS to promote growth from primary neurons, primary retinal cultures were prepared, and the neurons were plated on myelin substrates as described with respect to Example 5. In the absence of treatment with C3APLT or C3APS, the cells remained round and were not able to grow neurites. When treated with C3APLT or C3APS, retinal neurons were able to extend long neurites on inhibitory myelin substrates ( FIG. 6 ).
[0379] Next, was tested the ability of C3APLT and C3APS to promote growth on a different type of growth inhibitory substrate relevant to the type of growth inhibitory proteins found at glial scars. Chamber slides were coated with a mixture of chondroitin sulfate proteoglycans (Chemicon), and then plated with retinal neurons (results presented in FIG. 12 ). The neurons were not able to extend neurites on the proteoglycan substrates, but when treated with C3APLT or C3APS, they extended long neurites. These studies demonstrate that C3APLT and C3APS can be used to promote neurite growth on myelin and on proteoglycans, the major classes of inhibitory substrates that prevent repair after injury in the CNS.
[0000] Testing Ability of C3APLT to Promote Regeneration and Functional Recovery after Spinal Cord Injury
[0380] To test if C3APLT could promote repair after spinal cord injury, fully adult mice were used (as described with respect to Example 6). A dorsal hemisection was made at T8 (thoracic spinal level 8), and mice were treated with different amounts ( FIG. 7 ) of C3APLT in a fibrin glue as described (McKerracher, US patent pending (delivery patent)). In previous known experiments with C3, it was found that 40-50 μg was needed to promote anatomical regeneration in optic nerve (Lehmann et all supra). We tested different doses (see FIG. 7 ) of C3APLT ranging from 1 μg (1 microgram/milliliter) to 50 μg (50 microgram/milliliter) and assessed animals for behavioral recovery according the BBB scale (Basso (1995) 12: 1-21).
[0381] The day following surgery and application of C3APLT, behavioral testing began. The animals were placed in an open field environment that consisted of a rubber mat approximately 4′ by 3′ in size. The animals were left to move randomly, the movement of the animals were videotaped. For each test two observers scored the animals for ability to move ankle, knee and hip joints in the early phase of recovery. Previously C3 treatment of mice was seen to lead to functional recovery observable 24 hours after treatment. In mice treated with C3APLT, functional recovery could be observed as early as 24 hours after spinal cord injury ( FIG. 7 ). Untreated mice exhibit a function recovery score according to the BBB scale averaging 0, whereas mice treated with C3 are able to walk and have a BBB score averaging 8 ( FIG. 7 ). At higher concentrations of 50 ug, about 50% of the mice treated with C3APLT died within 24 hours. However, of the mice that survived, they exhibited good long-term functional recovery. These results demonstrate that C3APLT effectively promotes functional recovery early after spinal cord injury, and that it is effective at much lower doses than C3. However, at high concentrations, C3APLT appears to exhibit toxicity, and therefore careful doing will be required for clinical use.
[0382] Qualitative observations of the videotapes showed that only animals that received C3APLT reached the late phase of recovery after 30 days of treatment. Untreated control animals did not typically pass beyond the early phase of recovery. These results indicate that the application of C3APLT improved long-term functional recovery after spinal cord injury compared to no treatment, injury alone, or fibrin adhesive alone.
[0383] To test if the early recovery was due to neuroprotection, spinal cord sections were examined for apoptosis by Tunel labeling following manufacturer's instruction (Roche Diagnostic). C3APLT was able to reduce the number of dying cells observed at the lesion site. Therefore, C3APLT should be an effective neuroprotective agent for treatment of ischemia, such as follows stroke.
EXAMPLE 1
DNA and Protein Sequence Details of C3APL
Nucleotide Sequence of C3APL
[0384] It has been reported that the long version of antennapedia transport sequence can enhance neurite growth (Bloch-Gallego, E., LeRoux, I.-, Joliot, A. H., Volovitch, M., Henderson, C. E., Prochiantz, A. 1993. J. Cell Biol. 120:485). Therefore, this sequence is expected to enhance neurite growth. For the sequence given below, the start site, is in the GST sequence of the plasmid (not shown). The vector with the GST sequence is commercially available and thus the entire GST sequence including the start was not sequenced. It was desired to determine only the sequence located 3′ to the thrombin cleavage site which releases C3 conjugate from the GST sequence. The GST sequence is cleaved with thrombin.
[0385] The APL transport sequence (SEQ ID NO.: 44) is as follows:
[0000]
Val Met Glu Ser Arg Lys Arg Ala Arg Gln Thr Tyr
1 5 10
Thr Arg Tyr Gln Thr Leu Glu Leu Glu Lys Glu Phe
15 20
His Phe Asn Arg Tyr Leu Thr Arg Arg Arg Arg Ile
25 30 35
Glu Ile Ala His Ala Leu Cys Leu Thr Glu Arg Gln
40 45
Ile Lys Ile Trp Phe Gln Asn Arg Arg Met Lys Trp
50 55 60
Lys Lys Glu Asn
[0386] Nucleotide Sequence of C3APL (SEQ ID NO: 3)
[0000]
ggatcctcta gagtcgacct gcaggcatgc aatgcttatt ccattaatca aaaggcttat
60
tcaaatactt accaggagtt tactaatatt gatcaagcaa aagcttgggg taatgctcag
120
tataaaaagt atggactaag caaatcagaa aaagaagcta tagtatcata tactaaaagc
180
gctagtgaaa taaatggaaa gctaagacaa aataagggag ttatcaatgg atttccttca
240
aatttaataa aacaagttga acttttagat aaatctttta ataaaatgaa gacccctgaa
300
aatattatgt tatttagagg cgacgaccct gcttatttag gaacagaatt tcaaaacact
360
cttcttaatt caaatggtac aattaataaa acggcttttg aaaaggctaa agctaagttt
420
ttaaataaag atagacttga atatggatat attagtactt cattaatgaa tgtctctcaa
480
tttgcaggaa gaccaattat tacacaattt aaagtagcaa aaggctcaaa ggcaggatat
540
attgacccta ttagtgcttt tcagggacaa cttgaaatgt tgcttcctag acatagtact
600
tatcatatag acgatatgag attgtcttct gatggtaaac aaataataat tacagcaaca
660
atgatgggca cagctatcaa tcctaaagaa ttcgtgatgg aatcccgcaa acgcgcaagg
720
cagacataca cccggtacca gactctagag ctagagaagg agtttcactt caatcgctac
780
ttgacccgtc ggcgaaggat cgagatcgcc cacgccctgt gcctcacgga gcgccagata
840
aagatttggt tccagaatcg gcgcatgaag tggaagaagg agaactga
888
[0387] Amino Acid Sequence of C3APL (SEQ ID NO: 4)
[0000]
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Ile Asn
1 5 10 15
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Ile Asp Gln
20 25 30
Ala Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys
35 40 45
Ser Glu Lys Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala Ser Glu Ile
50 55 60
Asn Gly Lys Leu Arg Gln Asn Lys Gly Val Ile Asn Gly Phe Pro Ser
65 70 75 80
Asn Leu Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Lys Met
85 90 95
Lys Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp Pro Ala Tyr
100 105 110
Leu Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr Ile
115 120 125
Asn Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp
130 135 140
Arg Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val Ser Gln
145 150 155 160
Phe Ala Gly Arg Pro Ile Ile Thr Gln Phe Lys Val Ala Lys Gly Ser
165 170 175
Lys Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Gln Gly Gln Leu Glu
180 185 190
Met Leu Leu Pro Arg His Ser Thr Tyr His Ile Asp Asp Met Arg Leu
195 200 205
Ser Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met Gly Thr
210 215 220
Ala Ile Asn Pro Lys Glu Phe Val Met Glu Ser Arg Lys Arg Ala Arg
225 230 235 240
Gln Thr Tyr Thr Arg Tyr Gln Thr Leu Glu Leu Glu Lys Glu Phe His
245 250 255
Phe Asn Arg Tyr Leu Thr Arg Arg Arg Arg Ile Glu Ile Ala His Ala
260 265 270
Leu Cys Leu Thr Glu Arg Gln Ile Lys Ile Trp Phe Gln Asn Arg Arg
275 280 285
Met Lys Trp Lys Lys Glu Asn
290 295
[0388] Physical Characteristics of C3APL
Molecular Weight 34098.03 Daltons 295 Amino Acids 48 Strongly Basic(+) Amino Acids (K,R) 28 Strongly Acidic(−) Amino Acids (D,E) 89 Hydrophobic Amino Acids (A, I, L, F, W, V) 94 Polar Amino Acids (N, C, Q, S, T, Y) 9.847 Isolectric Point 20.524 Charge at PH 7.0 Davis, Botstein, Roth Melting Temp C. 79.48
EXAMPLE 2
DNA and Protein Sequence Details of C3APS
[0398] Nucleotide sequence of C3APS (SEQ ID NO: 5). The start site, is in the GST sequence of the plasmid, not shown here.
[0000]
ggatcctcta gagtcgacct gcaggcatgc aatgcttatt ccattaatca aaaggcttat
60
tcaaatactt accaggagtt tactaatatt gatcaagcaa aagcttgggg taatgctcag
120
tataaaaagt atggactaag caaatcagaa aaagaagcta tagtatcata tactaaaagc
180
gctagtgaaa taaatggaaa gctaagacaa aataagggag ttatcaatgg atttccttca
240
aatttaataa aacaagttga acttttagat aaatctttta ataaaatgaa gacccctgaa
300
aatattatgt tatttagagg cgacgaccct gcttatttag gaacagaatt tcaaaacact
360
cttcttaatt caaatggtac aattaataaa acggcttttg aaaaggctaa agctaagttt
420
ttaaataaag atagacttga atatggatat attagtactt cattaatgaa tgtctctcaa
480
tttgcaggaa gaccaattat tacacaattt aaagtagcaa aaggctcaaa ggcaggatat
540
attgacccta ttagtgcttt tcagggacaa cttgaaatgt tgcttcctag acatagtact
600
tatcatatag acgatatgag attgtcttct gatggtaaac aaataataat tacagcaaca
660
atgatgggca cagctatcaa tcctaaagaa ttccgccaga tcaagatttg gttccagaat
720
cgtcgcatga agtggaagaa ggtcgactcg agcggccgca tcgtgactga ctga
774
[0399] The APS transport sequence (SEQ ID NO.: 45) is as follows:
[0000]
Arg Gln Ile Lys Ile Trp Phe Gln Asn Arg Arg Met
1 5 10
Lys Trp Lys Lys Val Asp Ser
15
[0400] Amino Acid Sequence for C3APS (SEQ ID NO: 6)
[0000]
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Ile Asn
1 5 10 15
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Ile Asp Gln
20 25 30
Ala Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys
35 40 45
Ser Glu Lys Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala Ser Glu Ile
50 55 60
Asn Gly Lys Leu Arg Gln Asn Lys Gly Val Ile Asn Gly Phe Pro Ser
65 70 75 80
Asn Leu Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Lys Met
85 90 95
Lys Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp Pro Ala Tyr
100 105 110
Leu Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr Ile
115 120 125
Asn Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp
130 135 140
Arg Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val Ser Gln
145 150 155 160
Phe Ala Gly Arg Pro Ile Ile Thr Gln Phe Lys Val Ala Lys Gly Ser
165 170 175
Lys Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Gln Gly Gln Leu Glu
180 185 190
Met Leu Leu Pro Arg His Ser Thr Tyr His Ile Asp Asp Met Arg Leu
195 200 205
Ser Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met Gly Thr
210 215 220
Ala Ile Asn Pro Lys Glu Phe Arg Gln Ile Lys Ile Trp Phe Gln Asn
225 230 235 240
Arg Arg Met Lys Trp Lys Lys Val Asp Ser Ser Gly Arg Ile Val Thr
245 250 255
Asp
[0401] Physical Characteristics of C3APS
Molecular Weight 29088.22 Daltons 257 Amino Acids 38 Strongly Basic(+) Amino Acids (K,R) 23 Strongly Acidic(−) Amino Acids (D,E) 79 Hydrophobic Amino Acids (A, I, L, F, W, V) 83 Polar Amino Acids (N, C, Q, S, T, Y) 9.745 Isolectric Point 15.211 Charge at PH 7.0 Davis, Botstein, Roth Melting Temp C. 78.34
EXAMPLE 3
Method for Making the C3APLT and C3APS Proteins
[0411] C3APL (amino acid sequence: SEQ ID NO.: 4) and C3APLT (amino acid sequence; SEQ ID NO: 37) are the names given to the proteins encoded by cDNAs made by ligating the functional domain of C3 transferase and the homeobox region of the transcription factor called antennapedia (Bloch-Gallego (1993) 120: 485-492) in the following way. A cDNA encoding C3 (Dillon and Feig (1995) 256: 174-184) cloned in the plasmid vector pGEX-2T was used for the C3 portion of the chimeric protein. The stop codon at the 3′ end of the DNA was replaced with an EcoR I site by polymerase chain reaction using the primers 5′GAA TTC TTT AGG ATT GAT AGC TGT GCC 3′ (SEQ ID NO: 1) and 5′GGT GGC GAC CAT CCT CCA AAA 3′ (SEQ ID NO: 2). The PCR product was sub-cloned into a pSTBlue-1 vector (Novagen, city), then cloned into a pGEX-4T vector using BamH I and Not I restriction site. This vector was called pGEX-4T/C3. The pGEX-4T vector has a 5′ glutathione S transferase (GST) sequence for use in affinity purification. The antennapedia sequence used to add to the 3′ end of C3 in pGEX-4T/C3 was created by PCR from the pET-3a vector (Bloch-Gallego (1993) 120: 485-492, Derossi (1994) 269: 10444-10450). The primers used were 5′GAA TCC CGC AAA CGC GCA AGG CAG 3′ (SEQ ID NO: 7) and 5′TCA GTT CTC CTT CTT CCA CTT CAT GCG 3′ (SEQ ID NO: 8). The PCR product obtained from the reaction was subcloned into a pSTBlue-1 blunt vector, then cloned into the pGEX-4T/C3, using the restriction sites EcoR I and Sal I, creating pGEX-4T/C3APL and C3APLT. C3APLT was selected for the presence of a frameshift mutation giving a transport region moiety rich in prolines.
[0412] A shorter version of the antennapedia (pGEX-4T/C3AP-short) (amino acid sequence of C3APS; SEQ ID NO.: 6) was also made. This chimeric sequence was made by ligating oligonucleotides encoding the short antennapedia peptide (Maizel (1999) 126: 3183-3190) into the pGEX-4T/C3 vector cut with EcoR I and Sal I. For pGEX-4T/C3AP-short the sequences of the oligos made were 5′AAT TCC GCC AGA TCA AGA TTT GGT TCC AGA ATC GTC GCA TGA AGT GGA AGA AGG 3′ (SEQ ID NO: 9) and 5′GGC GGT CTA GTT CTA AAC CAA GCT CTT AGC AGC GTA GTT CAC CTT CTT CCA GCT 3′ (SEQ ID NO: 10). The two strands were annealed together by mixing equal amounts of the oligonucleotides, heating at 72° C. for 5 minutes and then leaving them at room temperature for 15 minutes. The oligonucleotides were ligated into the pGEX4T/C3 vector and clones were picked and analyzed.
[0413] To prepare recombinant C3APLT (SEQ ID NO.: 37) and C3APS (SEQ ID NO.: 6) proteins, the plasmids containing the corresponding cDNAs (pGEX-4T/C3APLT and pGEX-4T/C3AP-short) were transformed into bacteria, strain XL-1 blue competent E. coli . The bacteria were grown in L-broth (10 g/L Bacto-Tryptone, 5 g/L Yeast Extract, 10 g/L NaCl) with ampicillin at 50 ug/ml (BMC-Roche), in a shaking incubator for 1 hr at 37° C. and 300 rpm. Isopropyl .beta.-D-thiogalactopyranoside (IPTG), (Gibco) was added to a final concentration of 0.5 mM to induce the production of recombinant protein and the culture was grown for a further 6 hours at 37° C. and 250 rpm. Bacteria pellets were obtained by centrifugation in 250 ml centrifuge bottles at 7000 rpm for 6 minutes at 4° C. Each pellet was re-suspended in 10 ml of Buffer A (50 mM Tris, pH 7.5, 50 mM NaCl, 5 mM MgCl2, 1 mM DTT) plus 1 mM PMSF. All re-suspended pellets were pooled and transferred to a 100 ml plastic beaker on ice. The remaining Buffer A with PMSF was added to the pooled sample. The bacteria sample was sonicated 6.times.20 seconds using a Branson Sonifier 450 probe sonicator. Both the bacteria and probe were cooled on ice 1 minute between sonications. The sonicate was centrifuged in a Sorvall SS-34 rotor at 16,000 rpm for 12 minutes at 4° C. to clarify the supernatant. The supernatant was transferred into fresh SS-34 tubes and re-spun at 12,000 rpm for 12 minutes at 4° C. Up to 20 ml of Glutathione-agarose beads (Sigma) were added to the cleared lysate and placed on a rotating plate for 2-3 hours. The beads were washed 4 times with buffer B, (Buffer A, NaCl is 150 mM, no PSMF) then 2 times with Buffer C (Buffer B+2.5 mM CaCl2). The final wash was poured out till the beads created a thick slurry. To remove the glutathione S transferase sequence from the recombinant protein, 20 U of Thrombin (Bovine, Plasminogen-free, Calbiochem) was added, the beads were left on a rotator overnight at 4° C. After cleavage with thrombin the beads were loaded into an empty 20 ml column. Approximately 20 aliquots of 1 ml were collected by elution with PBS. Samples of each aliquot of 0.5 ul were spotted on nitrocellulose and stained with Amido Black to determine the protein peak. Aliquots containing fusion proteins were pooled and 100 □l (100 microliter) p-aminobenzamidine agarose beads (Sigma) were added and left mixing for 45 minutes at 4° C. This last step removed the thrombin from the recombinant protein sample. The recombinant protein was centrifuged to remove the beads and then concentrated using a centriprep-10 concentrator (Amicon). The concentrated recombinant protein was desalted with a PD-10 column (Pharmacia, containing Sephadex G-25M) and ten 0.5 ml aliquots were collected. A dot-blot was done on these samples to determine the protein peak, and the appropriate aliquots pooled, filter-sterilized, and stored at −80° C. A protein assay (DC assay, Biorad) was used to determine the concentration of recombinant protein. Purity of the sample was determined by SDS-PAGE, and bioactivity bioassay with PC-12 cells.
EXAMPLE 4
Testing of Efficacy of C3APLT and C3APS in Tissue Culture
[0414] To test the ability of C3APLT and C3APS to overcome growth inhibition, PC-12 cells were plated on myelin, a growth inhibitory substrate. The myelin was purified from bovine brain (Norton and Poduslo (1973) 21: 749-757). In some other experiments chondroitin sulfate proteoglycan (CSPG) substrates were made from a purchased protein composition (Chemicon). Before coating coverslips or wells of a 96 well plate, they were coated with poly-L-lysine (0.025 □g/ml; 0.025 microgram/milliliter) (Sigma, St. Louis, Mo.), washed with water and allowed to dry. Myelin stored as a 1 mg/ml solution at −80° C. was thawed at 37° C., and vortexed. The myelin was plated at 8 ug/well in a 8 well chamber Lab-Tek slides (Nuc, Naperville, Ill.). The myelin solution was left to dry overnight in a sterile tissue culture hood. The next morning the substrate was washed gently with phosphate buffered saline, and then cells in media were added to the substrate. PC-12 cells (Lehmann et al., 1999) were grown in DMEM with 10% horse serum (HS) and 5% fetal bovine serum (FBS). Two days prior to use the PC-12 cells were differentiated by 50 ng/ml of nerve growth factor (NGF). After the cells were primed, 5 ml of trypsin was added to the culture dish to detach the cells, the cells were pelleted and re-suspended in 2 ml of DMEM with 1% HS and 50 ng/ml of nerve growth factor. Approximately, 5000 to 7000 cells were then plated on 8 well chamber Lab-Tek slides (Nuc, Naperville, Ill.) coated myelin. The cells were placed on the test substrates at 37° C. for 3-4 hours to allow the cells to settle. The original media was carefully removed by aspiration, taking care not to disrupt the cells and replaced with DMEM with 1% HS, 50 ng/ml of NGF and varying amounts of the C3, C3APLT, or C3APS, depending on the dose desired. After two days, the cells were fixed (4% paraformaldehyde and 0.5% glutaraldehyde). For control experiments with unmodified C3, NGF primed PC-12 cells were trypsinized to detach them from the culture dish, the cells were washed once with scrape loading buffer (114 mM KCL, 15 mM NaCl, 5.5 mM MgCl2, and 10 mM Tris-HCL) and then the cells were scraped with a rubber policeman into 0.5 ml of scraping buffer in the presence of 25 or 50 □g/ml (microgram/milliliter) of C3. The cells were pelleted and resuspended in 2 ml of DMEM, 1% HS and 50 ng/ml nerve growth factor before plating. At least four experiments were analyzed for each treatment. For each well, twelve images were collected with a 20.times. objective using a Zeiss Axiovert microscope. For each image, the numbers of cells with and without neurites were counted and the lengths of the neurites were determined. Since myelin is phase dense, cells plated on myelin substrates were immuno-stained with anti-.beta.III tubulin antibody before analysis. Quantitative analysis of neurite outgrowth was with the aid of Northern Eclipse software (Empix Imaging, Mississauga, Ontario, Canada). Data analysis and statistics were with Microsoft Excel.
[0415] For a fast bioassay, the compounds were tested in tissue culture as described above, except that the cells were plated on the tissue culture plastic rather than on inhibitory substrates. For these experiments the plates were fixed and the neurites counted five hours after plating the cells. The test compounds (C3APLT and C3Basic3) were able to promote faster growth on tissue culture plastic than cells plated without treatment ( FIG. 11 ).
[0416] To examine ADP ribosylation by C3, C3APLT, and C3APS, the compounds were added to PC-12 cell cultures, as described above. The cells were harvested by centrifugation, cell homogenates prepared and the proteins separated by SDS polyacrylamide gel electrophoresis. The proteins were then transferred to nitrocellulose and the Western blots probed with anti-RhoA antibody (Santa Cruz).
EXAMPLE 5
Testing Ability of C3APLT and C3APS to Override Inhibition of Multiple Growth Inhibitory Proteins
[0417] Myelin substrates were made as described in Example 4 and plated on tissue culture chamber slides. P1 to P3 rat pups were decapitated, the heads washed in ethanol and the eye removed and placed in a petri dish with Hanks buffered saline solution (HBSS, from Gibco). A hole was cut in the cornea, the lens removed, and the retina squeezed out. Typically, four retinas per preparation were used. The retinas were removed to a 15 ml tube and the volume brought to 7 ml. A further 7 ml of dissociation enzymes and papain were added. The dissociation enzyme solution was made as follows: 30 mg DL cysteine was added to a 15 ml tube (Sigma DL cystein hydrochloride), and 70 ml HBSS, 280 ul of 10 mg/ml bovine serum albumin were added and the solution mixed and pH adjusted to 7 with 0.3 N NaOH. The dissociate solution was filter-sterilized and kept frozen in 7 ml aliquots, and before use 12.5 units papain per ml (Worthington) was added. After adding the dissociation solution to the retina, the tube was incubated for 30 minutes on a rocking tray at 37° C. The retinas were then gently triturated, centrifuged and washed with HBSS. The HBSS was replaced with growth medium (DMEM (Gibco), 10% fetal bovine serum, and 50 ng/ml brain derived neurotrophic factor (BDNF) vitamins, penicillin-streptomycin, in the presence or absence of C3APLT or C3APS. Cells were plated on test substrates of myelin or CSPG in chamber slides prepared as described in Example 4, above. A quantitative analysis was completed as described for Example 4 above. Neurons were visualized by fluorescent microscopy with anti-.beta.III tubulin antibody, which detects growing retinal ganglion cells (RGCs). Results are presented in FIG. 6 .
EXAMPLE 6
Treatment of Injured Mouse Spinal Cord with C3APLT and Measurement of Recovery of Motor Function in Treated Mice
[0418] Adult Balb-c mice were anaesthetized with 0.6 ml/kg hypnorm, 2.5 mg/kg diazepam and 35 mg/kg ketamine. This does gives about 30 minutes of anaesthetic, which is sufficient for the entire operation. A segment of the thoracic spinal column was exposed by removing the vertebrae and spinus process with microrongeurs (Fine Science Tools). A spinal cord lesion was then made dorsally, extending past the central canal with fine scissors, and the lesion was recut with a fine knife. This lesion renders all of the control animals paraplegic. The paravertebral muscle were closed with reabsorbable sutures, and the skin was closed with 2.0 silk sutures. After surgery, the bladder was manually voided every 8-10 hours until the animals regained control, typically 2-3 days. Food was placed in the cage for easy access, and sponge-water used for easy accessibility of water after surgery. Also, animals received subcutaneous injection Buprenorphine (0.05 to 0.1 mg/kg) every 8-12 hours for the first 3 days. Any animals that lost 15-20% of body weight were killed.
[0419] Rho antagonists (C3 or C3-like proteins) were delivered locally to the site of the lesion by a fibrin-based tissue adhesive delivery system (McKerracher, Canadian patent application No. 2,325,842). Recombinant C3APLT was mixed with fibrinogen and thrombin in the presence of CaCl2. Fibrinogen is cleaved by thrombin, and the resulting fibrin monomers polymerize into a three-dimensional matrix. We added C3APLT as part of a fibrin adhesive, which polymerized within about 10 seconds after being placed in the injured spinal cord. We tested C3APLT applied to the spinal cord lesion site after the lesion was made. For control we injected fibrin adhesive alone, or transected the cord without further treatment. For behavioral testing, the BBB scoring method was used to examine locomotion in an open field environment (Basso (1995) 12: 1-21). Results are presented in FIG. 7 . The environment was a rubber mat approximately 4′.times.3′ in size, and animals were placed on the mat and videotaped for about 4 minutes. Care was taken not to stimulate the peroneal region or touch the animals excessively during the taping session. The video tapes were digitized and observed by two observers to assign BBB scores. The BBB score, modified for mice, was as follows:
[0000]
Score
Description
1
No observable hindlimb (HL) movement.
2
Slight movement of one or two joints.
3
Extensive movement of one joint and/or slight movement of one other joint.
4
Extensive movement of two joints.
5
Slight movement of all three joints of the HL.
6
Slight movement of two joints and extensive movement of the third.
7
Extensive movement of two joints and slight movement of the third.
8
Extensive movement of all three joints of the HL walking with no weight support.
9
Extensive movement of all three joints, walking with weight support.
10
Frequent to consistent dorsal stepping with weight support.
11
Frequent plantar stepping with weight support.
12
Consistent plantar stepping with weight support, no coordination.
13
Consistent plantar stepping with consistent weight support, occasional FL-HL
coordination.
14
Consistent plantar stepping with consistent weight support, frequent FL-HL
coordination.
15
Consistent plantar stepping with consistent weight support, consistent FL-HL
coordination; predominant paw position during locomotion is rotated internally or
externally, or consistent FL-HL coordination with occasional dorsal stepping.
16
Consistent plantar stepping with consistent weight support, consistent FL-HL
coordination; predominant paw position is parallel to the body; frequent to
consistent toe drag, or curled toes, trunk instability.
17
Consistent plantar stepping with consistent weight support, consistent FL-HL
coordination; predominant paw position is parallel to the body, no toe drag, some
trunk instability.
18
Consistent plantar stepping with consistent weight support, consistent FL-HL
coordination; predominant paw position is parallel to the body, no toe drag and
consistent stability in the locomotion.
EXAMPLE 7
Treatment of Injured Mouse Spinal Cord with C3APLT and Assessment of Anatomical Recovery
[0420] Mice that received a spinal cord injury and treated as controls or with C3APLT, as described for Example 6 were assessed for morphological changes to the scar and for axon regeneration. To study axon regeneration, the corticospinal axons were identified by anterograde labeling. For anterograde labeling studies, the animals were anaesthetized as above, and the cranium over the motor cortex was removed. With the fine glass micropipetter (about 100 um in diameter) the cerebral cortex was injected with 2-4 ul of horse radish peroxidase conjugated to wheat germ agglutinin (2%), a marker that is taken up by nerve cells and transported anterogradely into the axon that extends into the spinal cord. After injection of the anterograde tracer, the cranium was replaced, and the skin closed with 5-0 silk sutures. The animals were sacrificed with chloral hydrate (4.9 mg/10 g) after 48 hours, and perfused with 4% paraformaldehyde in phosphate buffer as a fixative. The spinal cord was removed, cryoprotected with sucrose and cryostat sections placed on slides for histological examination.
EXAMPLE 8
DNA and Protein Sequence Details of C3-TL
[0421] The Tat coding sequence was obtained by polymerase chain reaction of the plasmid SVCMV-TAT (obtained form Dr. Eric Cohen, Universite de Montreal) that contains the entire HIV-1 Tat coding sequence. To isolate the transport sequence of the Tat protein, PCR was used. The first primer (5′GAATCCAAGCACCAGGAAGTCAGCC 3′ (SEQ ID NO.: 11)) and the second primer (5′ ACC AGCCACCACCTTCTGATA 3′ (SEQ ID NO.: 12)) used corresponded to amino acids 27 to 72 of the HIV Tat protein. Upon verification and purification, the PCR product was sub cloned into a pSTBlue-1 blunt vector. This transport segment of the Tat protein was then cloned into pGEX-4T/C3 at the 3′ end of C3, using the restriction sites EcoR I and Sac I. The new C3-Tat fusion protein was called C3-TL. Recombinant protein was made as described in Example 3.
[0422] DNA Sequence of C3-TL (SEQ ID NO.: 13)
[0000]
ggatcctcta gagtcgacct gcaggcatgc aatgcttatt ccattaatca aaaggcttat
60
tcaaatactt accaggagtt tactaatatt gatcaagcaa aagcttgggg taatgctcag
120
tataaaaagt atggactaag caaatcagaa aaagaagcta tagtatcata tactaaaagc
180
gctagtgaaa taaatggaaa gctaagacaa aataagggag ttatcaatgg atttccttca
240
aatttaataa aacaagttga acttttagat aaatctttta ataaaatgaa gacccctgaa
300
aatattatgt tatttagagg cgacgaccct gcttatttag gaacagaatt tcaaaacact
360
cttcttaatt caaatggtac aattaataaa acggcttttg aaaaggctaa agctaagttt
420
ttaaataaag atagacttga atatggatat attagtactt cattaatgaa tgtctctcaa
480
tttgcaggaa gaccaattat tacacaattt aaagtagcaa aaggctcaaa ggcaggatat
540
attgacccta ttagtgcttt tcagggacaa cttgaaatgt tgcttcctag acatagtact
600
tatcatatag acgatatgag attgtcttct gatggtaaac aaataataat tacagcaaca
660
atgatgggca cagctatcaa tcctaaagaa ttcaagcatc caggaagtca gcctaaaact
720
gcttgtacca attgctattg taaaaagtgt tgctttcatt gccaagtttg tttcataaca
780
aaagccttag gcatctccta tggcaggaag cggagacagc gacgaagagc tcatcagaac
840
agtcagactc atcaagcttc tctatcaaag cagtaa
876
[0423] The TL transport peptide sequence by itself is as follows: (SEQ ID NO.: 46)
[0000]
Lys His Pro Gly Ser Gln Pro Lys Thr Ala Cys Thr
1 5 10
Asn Cys Tyr Cys Lys Lys Cys Cys Phe His Cys Gln
15 20
Val Cys Phe Ile Thr Lys Ala Leu Gly Ile Ser Tyr
25 30 35
Gly Arg Lys Arg Arg Gln Arg Arg Ala His Gln Asn
40 45
Ser Gln Thr His Gln Ala Ser Leu Ser Lys Gln
50 55
[0424] The Protein Sequence of C3-TL (SEQ ID NO.: 14)
[0000]
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Ile Asn
1 5 10 15
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Ile Asp Gln
20 25 30
Ala Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys
35 40 45
Ser Glu Lys Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala Ser Glu Ile
50 55 60
Asn Gly Lys Leu Arg Gln Asn Lys Gly Val Ile Asn Gly Phe Pro Ser
65 70 75 80
Asn Leu Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Lys Met
85 90 95
Lys Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp Pro Ala Tyr
100 105 110
Leu Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr Ile
115 120 125
Asn Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp
130 135 140
Arg Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val Ser Gln
145 150 155 160
Phe Ala Gly Arg Pro Ile Ile Thr Gln Phe Lys Val Ala Lys Gly Ser
165 170 175
Lys Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Gln Gly Gln Leu Glu
180 185 190
Met Leu Leu Pro Arg His Ser Thr Tyr His Ile Asp Asp Met Arg Leu
195 200 205
Ser Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met Gly Thr
210 215 220
Ala Ile Asn Pro Lys Glu Phe Lys His Pro Gly Ser Gln Pro Lys Thr
225 230 235 240
Ala Cys Thr Asn Cys Tyr Cys Lys Lys Cys Cys Phe His Cys Gln Val
245 250 255
Cys Phe Ile Thr Lys Ala Leu Gly Ile Ser Tyr Gly Arg Lys Arg Arg
260 265 270
Gln Arg Arg Arg Ala His Gln Asn Ser Gln Thr His Gln Ala Ser Leu
275 280 285
Ser Lys Gln
290
[0425] Physical Characteristics
Molecular Weight 32721.40 Daltons 291 Amino Acids 43 Strongly Basic(+) Amino Acids (K,R) 21 Strongly Acidic(−) Amino Acids (D,E) 82 Hydrophobic Amino Acids (A, I, L, F, W, V) 104 Polar Amino Acids (N, C, Q, S, T, Y) 9.688 Isolectric Point 22.655 Charge at PH 7.0 Total Number of Bases Translated is 876
[0000]
% A = 37.44
[328]
% G = 17.58
[154]
% T = 28.31
[248]
% C = 16.67
[146]
EXAMPLE 9
DNA and Protein Sequence Details of C3-TS
[0435] A shorter Tat construct was also made (C3-TS). To make the shorter C3 Tat fusion protein the following oligonucleotides were 5′AAT TCT ATG GTC GTA AAA AAC GTC GTC AAC GTC GTC GTG 3′ (SEQ ID NO.: 15) and 5′ GAT ACC AGC ATT TTT TGC AGC AGT TGC AGC AGC ACA GCT 3′ (SEQ ID NO.: 16). The two oligonucleotide strands were annealed together by combining equal amounts of the oligonucleotides, heating at 72° C. for 5 minutes and then letting the oligonucleotide solution cool at room temperature for 15 minutes. The oligonucleotides were ligated into the pGEX4T/C3 vector at the 3′ end of C3. The construct was sequenced. All plasmids were transformed into XL-1 blue competent cells. Recombinant protein was made as described in Example 3.
[0436] Nucleotide Sequence of C3-TS (SEQ ID NO.: 17)
[0000]
ggatcctcta gagtcgacct gcaggcatgc aatgcttatt ccattaatca aaaggcttat
60
tcaaatactt accaggagtt tactaatatt gatcaagcaa aagcttgggg taatgctcag
120
tataaaaagt atggactaag caaatcagaa aaagaagcta tagtatcata tactaaaagc
180
gctagtgaaa taaatggaaa gctaagacaa aataagggag ttatcaatgg atttccttca
240
aatttaataa aacaagttga acttttagat aaatctttta ataaaatgaa gacccctgaa
300
aatattatgt tatttagagg cgacgaccct gcttatttag gaacagaatt tcaaaacact
360
cttcttaatt caaatggtac aattaataaa acggcttttg aaaaggctaa agctaagttt
420
ttaaataaag atagacttga atatggatat attagtactt cattaatgaa tgtctctcaa
480
tttgcaggaa gaccaattat tacacaattt aaagtagcaa aaggctcaaa ggcaggatat
540
attgacccta ttagtgcttt tcagggacaa cttgaaatgt tgcttcctag acatagtact
600
tatcatatag acgatatgag attgtcttct gatggtaaac aaataataat tacagcaaca
660
atgatgggca cagctatcaa tcctaaagaa ttctatggtg ctaaaaaacg tcgtcaacgt
720
cgtcgtgtcg actcgagcgg cccgcatcgt gactga
756
[0437] The TS transport peptide sequence by itself is as follows: (SEQ ID NO.: 47)
[0000]
Tyr Gly Ala Lys Lys Arg Arg Gln Arg Arg Arg Val
1 5 10
Asp Ser Ser Gly Pro His Arg Asp
15 20
[0438] The Protein Sequence of C3-TS (SEQ ID NO.: 18)
[0000]
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Ile Asn
1 5 10 15
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Ile Asp Gln
20 25 30
Ala Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys
35 40 45
Ser Glu Lys Glu Ala Ile Val Ser Tyr Ile Lys Ser Ala Ser Glu Thr
50 55 60
Asn Gly Lys Leu Arg Gln Asn Lys Gly Val Ile Asn Gly Phe Pro Ser
65 70 75 80
Asn Leu Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Lys Met
85 90 95
Lys Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp Pro Ala Tyr
100 105 110
Leu Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr Ile
115 120 125
Asn Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp
130 135 140
Arg Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val Ser Gln
145 150 155 160
Phe Ala Gly Arg Pro Ile Ile Thr Gln Phe Lys Val Ala Lys Gly Ser
165 170 175
Lys Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Gln Gly Gln Leu Glu
180 185 190
Met Leu Leu Pro Arg His Ser Thr Tyr His Ile Asp Asp Met Arg Leu
195 200 205
Ser Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met Gly Thr
210 215 220
Ala Ile Asn Pro Lys Glu Phe Tyr Gly Ala Lys Lys Arg Arg Gln Arg
225 230 235 240
Arg Arg Val Asp Ser Ser Gly Pro His Arg Asp
245 250
[0439] Physical Characteristics
Molecular Weight 26866.62 Daltons 238 Amino Acids 36 Strongly Basic(+) Amino Acids (K,R) 21 Strongly Acidic(−) Amino Acids (D,E) 71 Hydrophobic Amino Acids (A, I, L, F, W, V) 78 Polar Amino Acids (N, C, Q, S, T, Y) 9.802 Isolectric Point 15.212 Charge at PH 7.0 Total Number of Bases Translated is 717
[0000]
% A = 38.91
[279]
% G = 17.43
[125]
% T = 28.45
[204]
% C = 15.20
[109]
EXAMPLE 10
[0449] The following example illustrates how a coding sequence can be modified without affecting the efficacy of the translated protein. The example shows modifications to C3Basic3 that would not affect the activity. Sequences may include the entire GST sequence, as shown here that includes the start site, which would not be removed enzymatically. Also, the transport sequence shown in this example has changes in amino acid composition surrounding the active sequence due to a difference in the cloning strategy, and the His tag has been omitted. However, the active region is: R R K Q R R K R R (SEQ ID NO:53). This sequence is contained in the C3Basic3, and is the active transport sequence in the sequence below. Also note that the C-terminal region of the protein after this active region differs from C3Basic3. That is because the cloning strategy was changed, the restriction sites differ, and therefore non-essential amino acids 3′ terminal to the transport sequence are transplanted and included in the protein.
[0450] Nucleic Acid Sequence: (SEQ ID NO.: 19)
1413 base pairs single strand linear sequence
[0000]
atgtccccta tactaggtta ttggaaaatt aagggccttg tgcaacccac tcgacttctt
60
ttggaatatc ttgaagaaaa atatgaagag catttgtatg agcgcgatga aggtgataaa
120
tggcgaaaca aaaagtttga attgggtttg gagtttccca atcttcctta ttatattgat
180
ggtgatgtta aattaacaca gtctatggcc atcatacgtt atatagctga caagcacaac
240
atgttgggtg gttgtccaaa agagcgtgca gagatttcaa tgcttgaagg agcggttttg
300
gatattagat acggtgtttc gagaattgca tatagtaaag actttgaaac tctcaaagtt
360
gattttctta gcaagctacc tgaaatgctg aaaatgttcg aagatcgttt atgtcataaa
420
acatatttaa atggtgatca tgtaacccat cctgacttca tgttgtatga cgctcttgat
480
gttgttttat acatggaccc aatgtgcctg gatgcgttcc caaaattagt ttgttttaaa
540
aaacgtattg aagctatccc acaaattgat aagtacttga aatccagcaa gtatatagca
600
tggcctttgc agggctggca agccacgttt ggtggtggcg accatcctcc aaaatcggat
660
ctggttccgc gtggatcctc tagagtcgac ctgcaggcat gcaatgctta ttccattaat
720
caaaaggctt attcaaatac ttaccaggag tttactaata ttgatcaagc aaaagcttgg
780
ggtaatgctg agtataaaaa gtatggacta agcaaatcag aaaaagaagc tatagtatca
840
tatactaaaa gcgctagtga aataaatgga aagctaagac aaaataaggg agttatcaat
900
ggatttcctt caaatttaat aaaacaagtt gaacttttag ataaatcttt taataaaatg
960
aagacccctg aaaatattat gttatttaga ggcgaggagc ctgcttattt aggaacagaa
1020
tttcaaaaca ctcttcttaa ttcaaatggt acaattaata aaacggcttt tgaaaaggct
1080
aaagctaagt ttttaaataa agatagactt gaatatggat atattagtac ttcattaatg
1140
aatgtttctc aatttgcagg aagaccaatt attacaaaat ttaaagtagc aaaaggctca
1200
aaggcaggat atattgagcc tattagtgct tttcagggac aacttgaaat gttgcttcct
1260
agacatagta cttatcatat agacgatatg agattgtctt ctgatggtaa acaaataata
1320
attacagcaa caatgatggg cacagctatc aatcctaaag aattcagaag gaaacaaaga
1380
agaaaaagaa gactgcaggc ggccgcatcg tga
1413
[0454] Amino Acid Sequence (SEQ ID NO: 20)
479 amino acids linear, single strand
[0000]
Met Ser Pro Ile Leu Gly Tyr Trp Lys Ile Lys Gly Leu Val Gln Pro
1 5 10 15
Thr Arg Leu Leu Leu Glu Tyr Leu Glu Glu Lys Tyr Glu Glu His Leu
20 25 30
Tyr Glu Arg Asp Glu Gly Asp Lys Trp Arg Asn Lys Lys Phe Glu Leu
35 40 45
Gly Leu Glu Phe Pro Asn Leu Pro Tyr Tyr Ile Asp Gly Asp Val Lys
50 55 60
Leu Thr Gln Ser Met Ala Ile Ile Arg Tyr Ile Ala Asp Lys His Asn
65 70 75 80
Met Leu Gly Gly Cys Pro Lys Glu Arg Ala Glu Ile Ser Met Leu Glu
85 90 95
Gly Ala Val Leu Asp Ile Arg Tyr Gly Val Ser Arg Ile Ala Tyr Ser
100 105 110
Lys Asp Phe Glu Thr Leu Lys Val Asp Phe Leu Ser Lys Leu Pro Glu
115 120 125
Met Leu Lys Met Phe Glu Asp Arg Leu Cys His Lys Thr Tyr Leu Asn
130 135 140
Gly Asp His Val Thr His Pro Asp Phe Met Leu Tyr Asp Ala Leu Asp
145 150 155 160
Val Val Leu Tyr Met Asp Pro Met Cys Leu Asp Ala Phe Pro Lys Leu
165 170 175
Val Cys Phe Lys Lys Arg Ile Glu Ala Ile Pro Gln Ile Asp Lys Tyr
180 185 190
Leu Lys Ser Ser Lys Tyr Ile Ala Trp Pro Leu Gln Gly Trp Gln Ala
195 200 205
Thr Phe Gly Gly Gly Asp His Pro Pro Lys Ser Asp Leu Val Pro Arg
210 215 220
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Ile Asn
225 230 235 240
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Thr Asp Gln
245 250 255
Ala Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys
260 265 270
Ser Glu Lys Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala Ser Glu Thr
275 280 285
Asn Gly Lys Leu Arg Gln Asn Lys Gly Val Ile Asn Gly Phe Pro Ser
290 295 300
Asn Leu Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Lys Met
305 310 315 320
Lys Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp Pro Ala Tyr
325 330 335
Leu Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr Ile
340 345 350
Asn Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp
355 360 365
Arg Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val Ser Gln
370 375 380
Phe Ala Gly Arg Pro Ile Ile Thr Arg Phe Lys Val Ala Lys Gly Ser
385 390 395 400
Lys Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Gln Gly Gln Leu Glu
405 410 415
Met Leu Leu Pro Arg His Ser Thr Tyr His Asp Asp Met Arg Leu Ser
420 425 430
Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met Gly Thr Ala
435 440 445
Ile Asn Pro Lys Glu Phe Arg Arg Lys Gln Arg Arg Lys Arg Arg Leu
450 455 460
Gln Ala Ala Ala Ser
465
[0458] Physical Characteristics
Molecular Weight 53813.02 Daltons 470 Amino Acids 68 Strongly Basic(+) Amino Acids (K,R) 55 Strongly Acidic(−) Amino Acids (D,E) 149 Hydrophobic Amino Acids (A, I, L, F, W, V) 121 Polar Amino Acids (N, C, Q, S, T, Y) 9.137 Isolectric Point 14.106 Charge at PH 7.0 Total Number of Bases Translated is 1413
[0000]
% A = 34.61
[489]
% G = 19.75
[279]
% T = 29.51
[417]
% C = 15.99
[226]
% Ambiguous = 0.14
[2]
% A + T = 64.12
[906]
% C + G = 35.74
[505]
Davis, Botstein, Roth Melting Temp C. 79.20
EXAMPLE 11
Additional Chimeric C3 Proteins that would be Effective to Stimulate Repair in the CNS
[0469] The following sequences could be added to the amino terminal or carboxy terminal of C3 or a truncated C3 that retains its enzymatic activity.
(1) Sequences of polyarginine as described (Wender, et al. (2000) 97: 13003-8.). These could be from 6 to 9 or more arginines. (2) Sequences of poly-lysine (3) Sequences of poly-histidine (4) Sequences of arginine and lysine mixed. (5) Basic stretches of amino acids containing non-basic amino acids stretch where the sequence added retains transport characteristics. (6) Sequences of 5-15 amino acids containing at least 50% basic amino acids (7) Sequences longer than 15-30 amino acids containing at least 30% basic amino acids. (8) Sequences longer than 50 amino acids containing at least 18% basic amino acids. (9) Any of the above where the amino acids are chemically modified, such as by addition of cyclohexyl side chains, other side chains, different alkyl spacers. (10) Sequences that have proline residues with helix-breaking propensity to act as effective transporters.
EXAMPLE 12
Additional Chimeric C3 Proteins that would be Effective to Stimulate Repair in the CNS
[0480] C3Basic1: C3 fused to a randomly designed basic tail
[0481] C3Basic2: C3 fused to a randomly designed basic tail
[0482] C3 Basic3: C3 fused to the reverse Tat sequence
[0483] We have designed the following DNA encoding a chimeric C3 with membrane transport properties. The protein is designated C3Basic1. This sequence was designed with C3 fused to a random basic sequence. The construct was made to encode the peptide given below.
[0000]
(SEQ ID NO.: 21)
Lys Arg Arg Arg Arg Arg Pro Lys Lys Arg Arg Arg
1 5 10
Ala Lys Arg Arg
15
[0484] The construct was made by synthesizing the two oligonucleotides given below, annealing them together, and ligating them into the pGEX-4T/C3 vector with an added histidine tag.
[0000]
(SEQ ID NO: 22)
aagagaaggc gaagaagacc taagaagaga cgaagggcga
48
agaggaga
(SEQ ID NO: 23)
ttctcttccg cttcttctgg attcttctct gcttcccgct
48
tctcctct
[0485] DNA Sequence of C3Basic1 (SEQ ID NO: 24)
[0000]
ggatcctcta gagtcgacct gcaggcatgc aatgcttatt ccattaatca aaaggcttat
60
tcaaatactt accaggagtt tactaatatt gatcaagcaa aagcttgggg taatgctcag
120
tataaaaagt atggactaag caaatcagaa aaagaagcta tagtatcata tactaaaagc
180
gctagtgaaa taaatggaaa gctaagacaa aataagggag ttatcaatgg atttccttca
240
aatttaataa aacaagttga acttttagat aaatctttta ataaaatgaa gacccctgaa
300
aatattatgt tatttagagg cgacgaccct gcttatttag gaacagaatt tcaaaacact
360
cttcttaatt caaatggtac aattaataaa acggcttttg aaaaggctaa agctaagttt
420
ttaaataaag atagacttga atatggatat attagtactt cattaatgaa tgtttctcaa
480
tttgcaggaa gaccaattat tacaaaattt aaagtagcaa aaggctcaaa ggcaggatat
540
attgacccta ttagtgcttt tcagggacaa cttgaaatgt tgcttcctag acatagtact
600
tatcatatag acgatatgag attgtcttct gatggtaaac aaataataat tacagcaaca
660
atgatgggca cagctatcaa tcctaaagaa ttcaagagaa ggcgaagaag acctaagaag
720
agacgaaggg cgaagaggag acaccaccac caccaccacg tcgactcgag cggccgcatc
780
gtgactgact ga
792
[0486] Protein Sequence of C3Basic1 (SEQ ID NO: 25)
[0000]
GSSRVDLQACNAYSTNQKAYSNTYQEFTNDQAKAWGNAQYKKYGLSKSEK
EAIVSYTKSASEINGKLRQNKGVINGFPSNUKQVELLDKSFNKMKTPENI
MLFRGDDPAYLGTEFQNTLLNSNGTINKTAFEKAKAKFLNKDRLEYGYIS
TSLMNVSQFAGRPIITKFKVAKGSKAGYDPISAFQGQLEMLLPRHSTYHD
DMRLSSDGKIIITATMMGTAINPKEFKRRRRRPKKRRRAKRRHHHHHHVD
SSGRIVTD.
[0487] Physical Characteristics
Molecular Weight 29897.03 Daltons 263 Amino Acids 44 Strongly Basic(+) Amino Acids (K,R) 23 Strongly Acidic(−) Amino Acids (D,E) 75 Hydrophobic Amino Acids (A, I, L, F, W, V) 79 Polar Amino Acids (N, C, Q, S, T, Y) 10.024 Isolectric Point 22.209 Charge at PH 7.0 Davis, Botstein, Roth Melting Temp C. 78.56
EXAMPLE 13
Additional Chimeric C3 Protein that would be Effective to Stimulate Repair in the CNS
[0497] We have designed the following DNA encoding a chimeric C3 with membrane transport properties. The protein is designated C3Basic2. This sequence was designed with C3 fused to a random basic sequence. The construct was made to encode the peptide given below.
[0000]
(SEQ ID NO.:26)
Lys Arg Arg Arg Arg Lys Lys Arg Arg Gln Arg Arg
1 5 10
Arg
[0498] The construct was made by synthesizing the two oligonucleotides given below, annealing them together, and ligating them into the pGEX4T/C3 vector with an added histidine tag.
[0000]
(SEQ ID NO.: 27)
aagcgtcgac gtagaaagaa acgtagacag cgtagacgt
39
(SEQ ID NO.: 28)
ttcgcagctg catctttctt tgcatctgtc gcatctgca
39
[0499] DNA Sequence of C3Basic2 (SEQ ID NO.: 29)
[0000]
5′ GGA TCC TCT AGA GTC GAC CTG CAG GCA TGC AAT GCT
TAT TCC ATT AAT CAA AAG GCT TAT TCA AAT ACT TAC
CAG GAG TTT ACT AAT ATT GAT CAA GCA AAA GCT TGG
GGT AAT GCT CAG TAT AAA AAG TAT GGA CTA AGC AAA
TCA GAA AAA GPA GCT ATA GTA TCA TAT ACT AAA AGC
GCT AGT GAA ATA AAT GGA AAG CTA AGA CAA AAT AAG
GGA GTT ATC AAT GGA TTT CCT TCA AAT TTA ATA AAA
CAA GTT GAA CTT TTA GAT PAA TCT TTT AAT AAA ATG
AAG ACC CCT GAA AAT ATT ATG TTA TTT AGA GGC GAC
GAC CCT GCT TAT TTA GGA ACA GPA TTT CPA AAC ACT
CTT CTT AAT TCA AAT GGT ACA ATT AAT AAA ACG GCT
TTT GAA AAG GCT AAA GCT AAG TTT TTA AAT AAA GAT
AGA CTT GAA TAT GGA TAT ATT AGT ACT TCA TTA ATG
AAT GTT TCT CAA TTT GCA GGA AGA CCA ATT ATT ACA
AAA TTT AAA GTA GCA AAA GGC TCA AAG GCA GGA TAT
ATT GAC CCT ATT AGT GCT TTT CAG GGA CAA CTT GAA
ATG TTG CTT CCT AGA CAT AGT ACT TAT CAT ATA GAC
GAT ATG AGA TTG TCT TCT GAT GGT AAA CAA ATA ATA
ATT ACA GCA ACA ATG ATG GGC ACA GCT ATC AAT CCT
AAA GAA TTC AAG CGT CGA CGT AGA AAG AAA CGT AGA
CAG CGT AGA CGT CAC CAC CAC CAC CAC CAC GTC GAC
TCG AGC GGC CGC ATC GTG ACT GAC TGA 3′
[0500] Protein Sequence of C3Basic2 (SEQ ID NO.: 30)
[0000]
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Ile Asn
1 5 10 15
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Asp Gln Ala
20 25 30
Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys Ser
35 40 45
Glu Lys Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala Ser Glu Thr Asn
50 55 60
Gly Lys Leu Arg Gln Asn Lys Gly Val Thr Asn Gly Phe Pro Ser Asn
65 70 75 80
Leu Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Xaa Met Lys
85 90 95
Thr Pro Glu Asn Thr Met Leu Phe Arg Gly Asp Asp Pro Ala Tyr Leu
100 105 110
Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr Ile Asn
115 120 125
Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp Arg
130 135 140
Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val Ser Gln Phe
145 150 155 160
Ala Gly Arg Pro Ile Ile Thr Lys Phe Lys Val Ala Lys Gly Ser Lys
165 170 175
Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Gln Gly Gln Leu Glu Met
180 185 190
Leu Leu Pro Arg His Ser Thr Tyr His Thr Asp Asp Met Arg Leu Ser
195 200 205
Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met Gly Thr Ala
210 215 220
Thr Asn Pro Lys Glu Phe Lys Arg Arg Arg Arg Lys Lys Arg Arg Gln
225 230 235 240
Arg Arg Arg His His His His His His Val Asp Ser Ser Gly Arg Ile
245 250 255
Val Thr Asp
[0501] Physical Characteristics
Molecular Weight 29572.61 Daltons 260 Amino Acids 42 Strongly Basic(+) Amino Acids (K,R) 23 Strongly Acidic(−) Amino Acids (D,E) 74 Hydrophobic Amino Acids (A, I, L, F, W, V) 80 Polar Amino Acids (N, C, Q, S, T, Y) 9.956 Isolectric Point 20.210 Charge at PH 7.0 Davis, Botstein, Roth Melting Temp C. 78.45
EXAMPLE 14
Additional Chimeric C3 Protein that would be Effective to Stimulate Repair in the CNS
[0511] We have designed the following DNA encoding a chimeric C3 with membrane transport properties. The protein is designated C3Basic3. This sequence was designed with C3 fused to a reverse Tat sequence. The construct was made to encode the peptide given below
[0000]
Arg Arg Lys Gln Arg Arg Lys Arg Arg
(SEQ ID NO:31)
1 5
[0512] The construct was made by synthesizing the two oligonucleotides given below, annealing them together, and ligating them into the pGEX4T/C3 vector with an added histidine tag, then subcloning in pGEX-4T/C3.
[0000]
agaaggaaac aaagaagaaa aagaaga
27
(SEQ ID NO.: 32)
tcttcctttg tttcttcttt ttcttct
27
(SEQ ID NO.: 33)
[0513] DNA Sequence of C3Basic3 (SEQ ID NO.: 34)
[0000]
ggatcctcta gagtcgacct gcaggcatgc aatgcttatt ccattaatca aaaggcttat
60
tcaaatactt accaggagtt tactaatatt gatcaagcaa aagcttgggg taatgctcag
120
tataaaaagt atggactaag caaatcagaa aaagaagcta tagtatcata tactaaaagc
180
gctagtgaaa taaatggaaa gctaagacaa aataagggag ttatcaatgg atttccttca
240
aatttaataa aacaagttga acttttagat aaatctttta ataaaatgaa gacccctgaa
300
aatattatgt tatttagagg cgacgaccct gcttatttag gaacagaatt tcaaaacact
360
cttcttaatt caaatggtac aattaataaa acggcttttg aaaaggctaa agctaagttt
420
ttaaataaag atagacttga atatggatat attagtactt cattaatgaa tgtttctcaa
480
tttgcaggaa gaccaattat tacaaaattt aaagtagcaa aaggctcaaa ggcaggatat
540
attgacccta ttagtgcttt tcagggacaa cttgaaatgt tgcttcctag acatagtact
600
tatcatatag acgatatgag attgtcttct gatggtaaac aaataataat tacagcaaca
660
atgatgggca cagctatcaa tcctaaagaa ttcagaagga aacaaagaag aaaaagaaga
720
caccaccacc accaccacgt cgactcgagc ggccgcatcg tgactgactg a
771
[0514] Protein Sequence of C3Basic3 (SEQ ID NO.: 35)
[0000]
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Thr Asn
1 5 10 15
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Ile Asp Gln
20 25 30
Ala Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys
35 40 45
Ser Glu Lys Ile Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala Ser Glu
50 55 60
Ile Asn Gly Lys Leu Arg Gln Asn Lys Gly Val Ile Asn Gly Phe Pro
65 70 75 80
Ser Asn Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Lys Met
85 90 95
Lys Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp Pro Ala Tyr
100 105 110
Leu Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr Thr
115 120 125
Asn Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp
130 135 140
Arg Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val Ser Gln
145 150 155 160
Phe Ala Gly Arg Leu Pro Ile Ile Thr Arg Phe Lys Val Ala Lys Gly
165 170 175
Ser Lys Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Gln Gly Gln Leu
180 185 190
Glu Met Leu Leu Ala Arg His Ser Thr Tyr His Ile Asp Asp Met Arg
195 200 205
Leu Ser Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met Gly
210 215 220
Thr Ala Ile Asn Pro Lys Glu Phe Arg Arg Lys Gln Arg Arg Lys Arg
225 230 235 240
Arg His His His His His His Val Asp Ser Ser Gly Arg Ile Val Thr
245 250 255
Asp
[0515] Physical Characteristics
Molecular Weight 29441.47 Daltons 260 Amino Acids 39 Strongly Basic(+) Amino Acids (K,R) 23 Strongly Acidic(−) Amino Acids (D,E) 76 Hydrophobic Amino Acids (A, I, L, F, W, V) 80 Polar Amino Acids (N, C, Q, S, T, Y) 9.833 Isolectric Point 17.211 Charge at PH 7.0 Davis, Botstein, Roth Melting Temp C. 78.29
EXAMPLE 15
Sequences for C3APLT
[0525] One of the clones that was selected from the subcloning of C3APL into pGEX encoded a protein that was not the expected size but had good biological activity. This clone that had a frameshift mutation leading to a truncation, and this clone was called C3APLT. The clone was resequenced and the chromatograms analyzed to confirm the sequence. To confirm the sequences of C3APLT, the coding sequence from both strands of pGEX-4T/C3APLT were sequenced by double strand sequencing of the full length of the clone (BioS&T, Montreal, Quebec).
[0526] The DNA Sequence for C3APLT is as follows: (SEQ ID NO.: 36)
[0000]
ggatcctcta gagtcgacct gcaggcatgc aatgcttatt ccattaatca aaaggcttat
60
tcaaatactt accaggagtt tactaatatt gatcaagcaa aagcttgggg taatgctcag
120
tataaaaagt atggactaag caaatcagaa aaagaagcta tagtatcata tactaaaagc
180
gctagtgaaa taaatggaaa gctaagacaa aataagggag ttatcaatgg atttccttca
240
aatttaataa aacaagttga acttttagat aaatctttta ataaaatgaa gacccctgaa
300
aatattatgt tatttagagg cgacgaccct gcttatttag gaacagaatt tcaaaacact
360
cttcttaatt caaatggtac aattaataaa acggcttttg aaaaggctaa agctaagttt
420
ttaaataaag atagacttga atatggatat attagtactt cattaatgaa tgtttctcaa
480
tttgcaggaa gaccaattat tacaaaattt aaagtagcaa aaggctcaaa ggcaggatat
540
attgacccta ttagtgcttt tgcaggacaa cttgaaatgt tgcttcctag acatagtact
600
tatcatatag acgatatgag attgtcttct gatggtaaac aaataataat tacagcaaca
660
atgatgggca cagctatcaa tcctaaagaa ttcgtgatga atcccgcaaa cgcgcaaggc
720
agacatacac ccggtaccag actctagagc tagagaagga gtttcacttc aatcgctact
780
tgacccgtcg gcgaaggatc gagatcgccc acgccctgtg cctcacggag cgccagataa
840
agatttggtt ccagaatcgg cgcatgaagt ggaagaagga gaactga
887
[0527] The APLT transport peptide sequence by itself is as follows (SEQ ID NO.: 48):
[0000]
Val Met Asn Pro Ala Asn Ala Gln Gly Arg His Thr
1 5 10
Pro Gly Thr Arg Leu
15
[0528] The Protein Sequence for C3APLT is as follows: (SEQ ID NO.: 37)
[0000]
Gly Ser Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr Ser Ile Asn
1 5 10 15
Gln Lys Ala Tyr Ser Asn Thr Tyr Gln Glu Phe Thr Asn Ile Asp Gln
20 25 30
Ala Lys Ala Trp Gly Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys
35 40 45
Ser Glu Lys Ile Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala Ser Glu
50 55 60
Ile Asn Gly Lys Leu Arg Gln Asn Lys Gly Val Ile Asn Gly Phe Pro
65 70 75 80
Ser Asn Leu Ile Lys Gln Val Glu Leu Leu Asp Lys Ser Phe Asn Lys
85 90 95
Met Lys Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp Pro Ala
100 105 110
Tyr Leu Gly Thr Glu Phe Gln Asn Thr Leu Leu Asn Ser Asn Gly Thr
115 120 125
Ile Asn Lys Thr Ala Phe Glu Lys Ala Lys Ala Lys Phe Leu Asn Ile
130 135 140
Lys Asp Arg Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn Val
145 150 155 160
Ser Gln Phe Ala Gly Arg Pro Ile Ile Thr Lys Phe Lys Val Ala Lys
165 170 175
Gly Ser Lys Ala Gly Tyr Ile Asp Pro Ile Ser Ala Phe Ala Gly Gln
180 185 190
Leu Glu Met Leu Leu Pro Arg His Ser Thr Tyr His Ile Asp Asp Met
195 200 205
Arg Leu Ser Ser Asp Gly Lys Gln Ile Ile Ile Thr Ala Thr Met Met
210 215 220
Gly Thr Ala Thr Asn Pro Lys Glu Phe Val Met Asn Pro Ala Asn Ala
225 230 235 240
Gln Gly Arg His Thr Pro Gly Thr Arg Leu
245 250
[0529] Physical Characteristics
Molecular Weight 27574.42 Daltons 248 Amino Acids 33 Strongly Basic(+) Amino Acids (K,R) 21 Strongly Acidic(−) Amino Acids (D,E) 76 Hydrophobic Amino Acids (A, I, L, F, W, V) 80 Polar Amino Acids (N, C, Q, S, T, Y) 9.636 Isoelectric Point 12.379 Charge at PH 7.0
EXAMPLE 16
Sequence for C3-07
Subcloning and Sequences for C3APLT in pET
[0538] C3 has been reported to be stably expressed in E. coli by both pGEX-series and pET-series vectors (e.g., Dillon and Feig, 1995 Meth. Enzymol. 256: 174-184. Small GTPases and Their Regulators. Part B. Rho Family. W. E. Balch, C. J. Der, and A. Hall, eds.; Lehmann et al., 1999 supra; Han et al., 2001. J. Mol. Biol. 395: 95-107). The fusion proteins were expressed well in the pGEX vector, for synthesis and testing. However, for large-scale production it is more efficient to synthesize recombinant proteins without an affinity tag that increases the size of the protein produced. Also, it is more economical to synthesize proteins in large scale by affinity chromatography using automated FPLC systems. The polymerase chain reaction was used to transfer recombinant construct C3APLT into the pET T7 polymerase based system E. coli expression system (reviewed by Studier et al., 1990. Meth. Enzymol. 185: 60-89. Gene Expression Technology. D. V. Goeddel, ed.). A similar PCR approach is suitable for others in the fusion protein series of C3-based constructs with transport sequences. The pET3a vector DNA was obtained from Dr. Jerry Pelletier, McGill University. PCR primers were obtained from Invitrogen. The upper (5′) primer was 5′-GGA TCT GGT TCC GCG TCA TAT GTC TAG AGT CGA CCT G-3 (37 b) (SEQ ID NO.:38). Underlined is the Nde I site that was introduced into the primer to replace the BamHI site in pGEX4T-C3APLT. The lower primer was 5′-CGC GGA TCC ATT AGT TCT CCT TCT TCC ACT TC-3′ (32 b) (SEQ ID NO.:39). This primer introduced two changes in the coding strand DNA of pGEX4T-C3APLT, replacing the EcoRI site from pGEX4T-C3APLT with a BamH I site (underlined) and replacing a TGA stop codon with the strong stop sequence TAAT (the italicized ATTA sequence in the complementary primer). Compared to pGEX4T-C3APLT, the predicted N-terminal sequence of pET3a-C3APLT is Met-Ser rather than Gly-Ser-Ser, a loss of one serine and a substitution of Met for Gly. There were no changes in amino acid sequence at the C-terminus of C3APLT.
[0539] The target C3APLT gene was amplified using Pfu polymerase (Invitrogen/Canadian Life Technologies) with buffer, DNA and deoxyribonucleotide concentrations recommended by the manufacturer. The PCR was carried out as follows: 95° C. for 5 minutes, 10 cycles of 94° C. for 2 minutes followed by 56° C. for 2 minutes then extension at 70° C. for 2 minutes, then 30 cycles of 94° C. for 2 minutes followed by 70° C. Completed reactions were stored at 4° C. The QIAEXII kit (Qiagen) was used to purify the agarose gel slice containing DNA band. The purified PCR product DNA and the vector were digested with BamH I and Nde I (both obtained from New England BioLabs) following the instructions of the manufacturer. The digestion products were separated from extraneous DNA by agarose gel electrophoresis and purified with the QIAEXII kit. The insert and vector DNA were incubated together overnight at 16° C. with T4 DNA ligase according to directions provided by the manufacturer (New England BioLabs). Competent E. coli (DH5.alpha., obtained from Invitrogen/Canadian Life Technologies) were transformed with the ligation mixture.
[0540] DNA was prepared from purified colonies using the Qiagen plasmid midi kit, and the entire insert and junction sequences were verified by double strand sequencing of the full length of the clone (BioS&T, Montreal, Quebec) with forward primer 5′ AAA TTA ATA CGA CTC ACT ATA GGG 3′ (24 bases) (SEQ ID NO.: 40) and reverse T7 terminator sequencing primer 5′ GCT AGT TAT TGC TCAGCG G 3′ (19 bases) (SEQ ID NO.: 41). The sequence of the C3APLT cDNA in pET is given in SEQ ID NO.: 42. The amino acid sequence is given in SEQ. ID NO.: 43.
EXAMPLE 17
Modifications of Sequences
[0541] Any of sequences given in Examples 1, 2, 8, 9, 10, 11, 12 and 13, 15 and 16 could be modified to retain C3 enzymatic activity and effective transport sequences. For example amino acids encoded from DNA at the 3′ end of the sequence that represents the translation of the restriction sites used in cloning may be removed without affecting activity. Some of the amino terminal amino acids may also be removed without affecting activity. The minimal amount of sequence needed for biological activity of the C3 portion of the fusion protein is not known but could be easily determined by known techniques. For example, increasingly more of the 5′ end of the cDNA encoding C3 could be removed, and the resulting proteins made and tested for biological activity. Similarly, increasing amounts of the 3′ end could be removed and the fragments tested for biological activity. Next, fragments testing the central region could be tested for retention of C3 activity. Therefore, the C3 portion of the protein could be truncated to include just the amino acids needed for activity. Alternatively mutations could be made in the coding regions of C3, and the resulting proteins tested for activity. The transport sequences could be modified to add or remove one or more amino acids or to completely change the transport peptide, but retain the transport characteristics in terms of effective dose compared to C3 in our tissue culture bioassay (Example 4). New transport sequences could be tested for biological activity to improve the efficiency of C3 activity by plating neurons and testing them on inhibitory substrates, as described in Example 4.
[0542] As discussed previously, it has been determined in tissue culture studies, that the minimum amount of C3 that can be used to induce growth on inhibitory substrates is 25 ug/ml (Lehmann, et al. (1999) J. Neurosci. 19: 7537-7547; Morii, N and Narumiya, S. (1995) Methods in Enzymology, Vol 256 part B, pg. 196-206. If the cells are not triturated, even this dose is ineffective ( FIG. 1 ). In the context of the present invention it has been determined, for example, that at least 40 □g (40 microgram) of C3/20 g mouse needs to be applied to injured mouse spinal cord or rat optic nerve (McKerracher, Canadian patent application No.: 2,325,842). Calculating doses that would be required to treat an adult human on an equivalent dose per weight scale up used for rat and mice experiments, it would be necessary to apply 120 mg/kg of C3 (i.e. alone) to the injured human spinal cord. This large amount of recombinant C3 protein needed, creates significant problems for manufacturing, due to the large-scale protein purification and cost. It also limits the dose ranging that can be tested because of the large amount of protein needed for minimal effective doses.
[0543] Fusion proteins of the present invention are much more effective than C3 (i.e., alone) in promoting neurite outgrowth on myelin substrate. For example, concentrations of C3APLT and C3APS, 10,000 and 1,000 times less than the concentration needed for C3 may be used with comparable (similar) effects without exhibiting toxic effects (e.g., on PC-12 cells). C3-TL and C3-TS are also able to promote neurite growth on myelin substrates at doses significantly less than C3. In vivo results also indicate that lower dose of the fusion proteins may be required to promote regeneration and functional recovery after spinal cord injury in mice. Thus, fusion proteins of the present invention represent a significant improvement and advantage over C3 in both manufacture cost and doses required for treatment.
EXAMPLE 18
General Method for Determination of Inhibition of Angiogenesis
[0544] The formation of new blood vessels can be studied in a cell culture model by growing endothelial cells in the presence of a matrix of basement membrane (Matigel). Human umbilical vein endothelial cells (HUVEC) are harvested from stock cultures by trypinization, and are resuspended in growth medial consisting of EBM-2 (Clonetics), FBS, hydrocortisone, hFGF, VEGF, R3-IGF-1, ascorbic acid, hEGF, GA-1000, heparin. Matrigel (12.5 mg/mL) is thawed at 4° C., and 50 mL of Matrigel is added to each well of a 96 well plate, and allowed to solidify for 10 min. at 37° C. Cells in growth medium at a concentration of 15,000 cells/well are added to each well, and are allowed to adhere for 6 hours. A fusion protein of this invention, e.g., C3APLT, in phosphate buffered saline (PBS) is added to the well at about 10 mg/ml, and in other wells PBS is added as control. The cultures are allowed to grow for a further 6 to 8 hours. The growth of tubes can be visualized by microscopy at a magnification of 50×, and the mean length of the capillary network is quantified using Northern Eclipse software. Treatment of the cells in the Matrigel assay with a fusion protein of this invention (e.g., C3APLT) reduces tube formation (see FIG. 13 ).
EXAMPLE 19
A Lyophilized Formulation
[0545] A solution comprising a unit dosage amount of a composition of this invention comprising a fusion protein such as C3APLT dissolved in an pharmaceutically acceptable isotonic aqueous medium comprising a pharmaceutically acceptable buffer salt and/or a readily water-soluble pharmaceutically acceptable carbohydrate (preferably a pharmaceutically acceptable non-reducting sugar or a cyclodextrin) is sterile-filtered (e.g. through a 0.2 micron filter) under aseptic conditions, the filtrate is placed in a sterilized vial, the filtrate is frozen, the frozen aqueous solution is lyophilized aseptically at reduced pressure in a pharmaceutically acceptable lyophilizer to leave a dried matrix comprising the fusion protein in the vial, the vial is returned to atmospheric pressure under a sterile inert atmosphere, the vial is sealed with a sterile stopper (e.g. together with a crimp cap). The sealed vial is labeled with its contents and dosage amount and placed in a kit together with a second sealed sterile vial which contains sterilized water for injection in an amount useful to transfer into the first vial containing the lyophilized fusion protein in order to reconstitute the fusion protein matrix to a solution as a unit dosage form. In another embodiment, the fusion protein can be dissolved in a starting volume of aqueous medium which comprises a hypertonic aqueous medium, the solution sterile filtered, the filtrate filled into a vial, and lyophilized to form a dried matrix. This dried matrix can be dissolved or reconstituted in a larger-than-original volume of sterile water, the larger volume sufficient to form an isotonic solution for injection such as by intravenous injection and/or infusion. Alternatively, a hypertonic solution can be used for administration by infusion into a drip bag containing a larger volume of isotonic aqueous medium such that the hypertonic solution is substantially diluted. Optionally, a vial containing a volume of sterile water in an amount suitable to reconstitute the matrix to a unit dosage form is distributed as a kit with the lyophilized protein. Preferably the reconstituted composition comprises an isotonic solution. The fusion protein can be used for intravenous delivery, and/or infusion, and/or direct injection into tissue of the eye or tissue proximal to the eye with this formulation.
EXAMPLE 20
Construction of an Inactive Mutant Variant of C3-07, C3-07Q189A
[0546] C3-07 is a derivative of C3APLT lacking the GST sequence. C3-07 was prepared by polymerase chain reaction and subcloned into pET9a vector to create C3-07. C3-07 differs from C3-05 by silent amino acid changes which can be described as a deletion of the terminal glycine in C3-05 which provides a truncated fragment of C3-05 terminating in a serine plus a mutation (i.e., substitution) of that terminal serine in the truncated fragment by a methione to provide C3-07. C3-07Q189A was made by intentionally producing a mutation in C3-07 near the ADP-ribosyl transferase catalytic site in the fusion protein, thereby substantially reducing ADP-ribosylation activity. Two oligonucleotides were designed to change the amino acid 189 glutamine at the active site (gln, Q, coded by CAA) to 189 alanine (ala, A, coded by GCA) by site-directed-mutagenesis using the QuikChange (Stratagene). Polymerase chain reaction was carried out in a thermo cycler using 50 ng of “pET9a-BA-207” which is sometimes also referred to as “pET9a-BA05”, 133 ng of 41-mer mutant primer ZSM3, and 137 ng of 41-mer mutant primer ZSM4. The cycle program for the Q189A mutant was as follows: 95° C. for 30 sec, 18 cycles of 95° C. for 30 sec., 55° C. for 1 min., and 68° C. for 10 min., and hold at 4° C.
[0000]
Primer ZSM3
5′- GCT TTT GCA GGA { GC }A CTT GAA ATG TTG CTT CCT
AGA CAT AG′
Primer ZSM4
5′- CT ATG T CT A GG AAG CAA CAT TTC AAG T{ GC } TCC
TGC AAA AGC -3′
[0547] The bracketed bold letters in the above sequence denote the change from the C3-07 sequence.
[0548] The amino acid sequence of C3-07 is SEQ ID NO.: 43.
[0549] The cDNA sequence of C3-07 is SEQ ID NO.: 42.
[0550] DpnI digestion was done according to the manufacturer's instructions and 1 μL of this product was used to transform XL1-Blue competent cells. These plates were then incubated overnight at 37° C. Clones of Putative C3-07Q189A were selected and their plasmid DNA amplified and purified using the Qiagen Midi Kit. The purified plasmids were analyzed by restriction digestion analyses. The DNA from three candidate clones was sequenced at BioS&T (Lachine, Quebec) using the T7 and T7T primers. Mutant ZSMT2-2 was confirmed to contain the mutation and the DNA was used to transform BL21 (DE3) cells and prepare a research cell bank (RCB).
[0551] Purified C3-07Q189A was prepared from E. coli . First, a flask of 0.5 L Luria Broth with glucose was inoculated with 2 vials of research cell bank (RCB) of pET9a-C3-07Q189A and grown overnight. The starter culture was diluted 10-fold into 8 flasks each containing 500 mL growth medium. The flasks were incubated at 37° C. and after 1 hour 20 min, isopropylthio-B-D-galactoside (IPTG) was added to increase the expression of C3-07Q189A. After a further 4 hours, the cells were harvested by centrifugation and stored at −80° C. until required. A sample of the harvested culture was analyzed for C3-07Q189A content. Next, the cells were thawed and subjected to primary recovery, which in the research scale process for production of C3-07 is sonication in extraction buffer. The crude extract was treated with positively-charged polymer to remove nucleic acids and with ammonium sulfate to remove some proteins and reduce the volume. Excess salt was removed. The protein was further purified by passing over four chromatography columns. The final purification and isolation steps consisted of concentration of the resulting purified protein solution (ultrafiltration can be used), filtration of the protein solution (e.g., through a 0.2 micrometer filtration membrane which can be useful to sterilize the protein solution), dispensing of the solution into sterile tubes, freezing the protein solution, and lyophilization of the frozen solution to leaving the protein formulated in the form of a powder. After the C3-07Q189A was purified, the fusion protein was analyzed to determine the amount of protein which was produced, its purity, its potency and its biological activity (e.g., ADP-ribosyl transferase related activity for neurite outgrowth). Purity was measured by scanning densitometry of SDS-polyacrylamide gels stained with Coomassie Blue. The activity of C3-07Q189A was determined using an NG108 cell 4 hour neurite outgrowth bioassay. The procedure for the bioassay comprises incubation of h NG-108 cells for 4 hours with an aliquot of a buffered solution containing C3-07Q189A. A simultaneous and otherwise identical bioassay was run as a positive control, wherein C3APLT or C3-07 was used in place of C3-07Q189A. The cells were then fixed with paraformaldehyde, stained with cresyl violet, and the percentage of cells in each well that demonstrated neurites greater than one cell body in length was determined by counting under the microscope. Each data point was determined in triplicate.
[0552] The amino acid sequence of C3-07Q189A is as follows:
[0553] Protein sequence for C3-07Q189A
[0000]
(SEQ ID NO:55)
Met Ser Arg Val Asp Leu Gln Ala Cys Asn Ala Tyr
1 5 10
Ser Ile Asn Gln Lys Ala Tyr Ser Asn Thr Tyr Gln
15 20
Glu Phe Thr Asn Ile Asp Gln Ala Lys Ala Trp Gly
25 30 35
Asn Ala Gln Tyr Lys Lys Tyr Gly Leu Ser Lys Ser
40 45
Glu Lys Glu Ala Ile Val Ser Tyr Thr Lys Ser Ala
50 55 60
Ser Glu Ile Asn Gly Lys Leu Arg Gln Asn Lys Gly
65 70
Val Ile Asn Gly Phe Pro Ser Asn Leu Ile Lys Gln
75 80
Val Glu Leu Leu Asp Lys Ser Phe Asn Lys Met Lys
85 90 95
Thr Pro Glu Asn Ile Met Leu Phe Arg Gly Asp Asp
100 105
Pro Ala Tyr Leu Gly Thr Glu Phe Gln Asn Thr Leu
110 115 120
Leu Asn Ser Asn Gly Thr Ile Asn Lys Thr Ala Phe
125 130
Glu Lys Ala Lys Ala Lys Phe Leu Asn Lys Asp Arg
135 140
Leu Glu Tyr Gly Tyr Ile Ser Thr Ser Leu Met Asn
145 150 155
Val Ser Gln Phe Ala Gly Arg Pro Ile Ile Thr Gln
160 165
Phe Lys Val Ala Lys Gly Ser Lys Ala Gly Tyr Ile
170 175 180
Asp Pro Ile Ser Ala Phe Gln Gly Ala Leu Glu Met
185 190
Leu Leu Pro Arg His Ser Thr Tyr His Ile Asp Asp
195 200
Met Arg Leu Ser Ser Asp Gly Lys Gln Ile Ile Ile
205 210 215
Thr Ala Thr Met Met Gly Thr Ala Ile Asn Pro Lys
220 225
Glu Phe Val Met Asn Pro Ala Asn Ala Gln Gly Arg
230 235 240
His Thr Pro Gly Thr Arg Leu
245
[0554] The cDNA sequence of C3-07Q189A is as follows:
[0555] cDNA sequence for C3-07Q189A
[0000]
(SEQ ID NO:54)
atgtctagag tcgacctgca ggcatgcaat gcttattcca ttaatcaaaa ggcttattca
60
aatacttacc aggagtttac taatattgat caagcaaaag cttggggtaa tgctcagtat
120
aaaaagtatg gactaagcaa atcagaaaaa gaagctatag tatcatatac taaaagcgct
180
agtgaaataa atggaaagct aagacaaaat aagggagtta tcaatggatt tccttcaaat
240
ttaataaaac aagttgaact tttagataaa tcttttaata aaatgaagac ccctgaaaat
300
attatgttat ttagaggcga cgaccctgct tatttaggaa cagaatttca aaacactctt
360
cttaattcaa atggtacaat taataaaacg gcttttgaaa aggctaaagc taagttttta
420
aataaagata gacttgaata tggatatatt agtacttcat taatgaatgt ttctcaattt
480
gcaggaagac caattattac aaaatttaaa gtagcaaaag gctcaaaggc aggatatatt
540
gaccctatta gtgcttttgc aggagcactt gaaatgttgc ttcctagaca tagtacttat
600
catatagacg atatgagatt gtcttctgat ggtaaacaaa taataattac agcaacaatg
660
atgggcacag ctatcaatcc taaagaattc gtgatgaatc ccgcaaacgc gcaaggcaga
720
catacacccg gtaccagact ctag
744
EXAMPLE 21
General Procedure to Determine the Relative Neuroprotection Ability in the Retina of a Fusion Protein of this Invention
[0556] C3-APLT and C3-07 are examples of fusion proteins of this invention, each protein having ADP-riboysyl transferase activity and each having an ADP-riboysyl transferase active site.
[0557] In the visual system, retinal ganglion cells die after optic nerve injury. The severity (i.e., the number of cells which die) and rate of cell death depends on the proximity of axonal injury to the eye. To study the effects of inactivation of Rho on RGC survival we have made use of two cell-membrane penetrating (i.e., cell-membrane permeable) derivatives of C3 transferase: C3-APLT and C3-07.
[0558] Rats were anaesthetised under 2-3% isoflurane. RGCs were retrogradely labelled from the superior colliculus with Fluorogold (Fluorchrome Inc, Denver, Colo.). The right midbrain of a rat was exposed by making a small circular opening in the bone, followed by aspiration of cortex, and removal of the pia matter overlying the superior colliculi. A small piece of Gelfoam soaked in an aqueous medium comprising 2% fluorgold and 10% DMSO was applied to the surface of the right superior colliculus. Seven days after Fluorogold application, the left optic nerve was transected 1 mm from the eye. The optic nerve was accessed within the orbit by making an incision parasagitally in the skin covering the superior rim of the orbit bone, taking care to leave the supraorbital vein intact. Following partial resection or reflection of the lacrimal gland, the superior extraocular muscles were spread with a small retractor or 6-0 silk suture. The optic nerve was exposed, and the surrounding sheath was cut longitudinally to avoid cutting blood vessels while exposing the optic nerve. The pia mater of the optic nerve was nicked, the optic nerve moved gently to dislodge it, and then scissors were slipped tangentially under the optic nerve to give a clean cut 1 mm from the eye. In animals used for studies on cytokine levels, a microcrush lesion was used. For these studies the pia was left intact, and the optic nerve was lifted out from the sheath and crushed 1 mm from the globe by constriction with a 10.0 suture held for 60 seconds.
[0559] Anesthetised animals received single injections of C3APLT or C3-07 in aqueous buffer immediately after the optic nerve was cut, or 4 days later. Intraocular injections were made with a 10 μl syringe attached to a glass micropipette. A hole was made in the superior nasal retina approximately 4 mm from the optic disc with a 30 g needle before introduction of the glass pipette to inject 5 μl of fusion protein (e.g., C3-07) or buffer control. The needle was withdrawn slowly to allow diffusion of the solution into the vitreous spaces. The sclera was then sealed with tissue adhesive (Indermil, Tyco Heathcare, Mansfield, USA). Care was taken not to damage the lens during injection to avoid cataract formation and consequential increased survival of the RGCs. The skin was closed, and the integrity of the retinal vasculature was evaluated by a postoperative opthalmoscopic examination. Rats with compromised vasculature or rats that developed cataracts were not included in the experimental results.
[0560] Fluorogold labeled retinas were prepared for counting 7 or 14 days after axotomy. Animals were perfused with 4% paraformaldehyde (PFA), and their eyes were removed and postfixed in 4% PFA after puncture of the cornea. The eyes were then rinsed with phosphate buffered saline (PBS) for 1 hour. Incisions were made in each eye in the four retinal quadrants, and the retinas were removed and flat-mounted on glass slides. Excess vitreous was blotted away with paper wicks. Coverslips were placed on the slides over the mounted retinas, and RGCs were examined with an ultraviolet filter (365/420). Labeled RGCs were counted under the microscope at 20× magnification with the aid of a rectangle insert in one ocular field of view of the microscope to provide a rectangular field area of 0.375 mm×0.1125 mm. Four standard rectangular areas of retina were counted at 1 and 2 mm from the disc. The number of labeled cells in each area was divided by 0.04125 (rectangular area counted in mm 2 ), and the average density for each retina was calculated as RGCs/mm 2 . Cells counts were conducted by the same investigator blind to the treatment. After axotomy, Fluorogold is also present in endothelial cells and microglial cells. These cells, identified by morphology were excluded from the counts of RGCs. Statistics were performed with Excel, and results from treated animals were compared with results from controls by T-test.
[0561] A single injection of FPLC-purified C3APLT was neuroprotective and rescued all RGCs at 7 days after axotomy, and a single injection of FPLC-purified C3-07 was neuroprotective and rescued all RGCs at 7 days after axotomy. To determine if RGC cell survival following C3-07 injection might be increased because of properties of C3-07 other than its Rho ribosylation activity, we tested the effect of C3-07Q189A on RGC cell survival. The mutant protein, C3-07Q189A, was purified by FPLC, and 1 ug was injected immediately after axotomy in the manner used for C3-07. Cell survival following administration of C3-07Q189A was not significantly different from cell survival following axotomy alone, and was significantly different from the effect of C3-07 ( FIG. 14 ). Therefore, the neuroprotective activity of C3-07 is due to the presence of ADP-ribosyl transferase in the fusion protein and thus inactivation of Rho, not from other effects.
[0562] Ischemia can be produced in the retina of the albino Lewis rat by raising intraocular pressure by intraocular injection of saline (Unoki and LaVail, Invest Opthalmol Vis. Sci. 35:907, 1994). The survival of RGCs can be assessed by counting RGCs retrogradely labeled with Florogold in retinal wholemounts, as described above.
EXAMPLE 22
Procedure to Measure Efficacy to Prevent Photoreceptor Cell Death in Rat Models of Photoreceptor Degeneration
[0563] The rescue of photoreceptor cells can be demonstrated in Royal College of Surgeons (RCS) rats, which rats have an inherited retinal degeneration (Faktorovich et al., Nature 347:83, 1990). Intraocular injections of C3APLT in aqueous buffer are made with a 10 μl syringe attached to a glass micropipette. A hole is made in the superior nasal retina approximately 4 mm from the optic disc using a 30 g needle before introduction of the glass pipette to inject 5 μl of 1 ug C3-APLT or buffer control. The needle is withdrawn slowly to allow diffusion of the solution into the vitreous spaces, and the sclera is sealed with tissue adhesive. Care is taken not to damage the lens during injection because lens damage can lead to cataract formation and consequent increases in survival of the RGCs. The skin is closed, and the integrity of the retinal vasculature is evaluated by a postoperative opthalmoscopic examination. Rats with compromised vasculature or rats that develop cataracts are not included in the experimental results.
[0564] A histological analysis useful to assess photoreceptor survival in therapeutically treated or untreated RCS rats comprises the steps of vascular perfusion of an anesthetized animal, embedding of the animal's eye in paraffin, and staining of 6 micron thick sections with hemotoxyline and eosin or with toluidine blue. In the eyes of untreated RCS rats at 53 days after birth (P53) the outer nuclear layer, which contains the photoreceptor cells, is reduced in thickness to only a few rows of cells (approximately 20% of the thickness found in normal rats at the same age). A therapeutically effective dose of C3APLT administered by intravitreal administration (e.g., a single injection comprising one microgram of protein) can restore the thickness of the outer nuclear layer, and hence rescue photoreceptor cells.
[0565] Alternatively, rescue of photoreceptor cells can be demonstrated using 2-to-3 month old male Sprague-Dawley rats in a model of exposure to constant light (115-200 foot-candles) for 1 week following the procedures of LaVail et al., PNAS USA 89:11249, 1992, the disclosure of which is incorporated herein by reference. An aqueous buffer solution of C3APLT can be injected (1 ug of protein) into the subretinal space or into the vitreous humor 48 hours prior to the onset of continuous illumination. Histological examination and analysis of retinas following a fixed recovery period (usually 10 days) is used to assess the death or damage to and the rescue or survival of photoreceptor cells.
[0566] Retinal detachment also leads to the death of photoreceptor cells. An animal model described by Erickson et al., J Struct. Biol. 108:148, 1992, the disclosure of which is incorporated herein by reference, can demonstrate the effect of administration of C3APLT to enhance survival of retinal cells in vitro relative to administration of buffer control, a protein mutated to eliminate ADP-ribosylation activity, and to untreated controls.
EXAMPLE 23
Procedure to Measure Efficacy of a Fusion Protein of the Invention to Prevent Photoreceptor Cell Death in Transgenic Mouse Models of Photoreceptor Degeneration
[0567] Several mouse genetic models of photoreceptor degeneration (e.g., rd-mutant of b subunit of cGMP phosphodiesterasel rds-mutant of peripherin) can be employed using the modes of administration described above to demonstrate fusion protein-related (e.g., C3APLT-related) photoreceptor cell enhanced survival effects in vivo.
[0568] Rd-mutant mice and rds-mutant mice exhibit retinal degeneration within a few weeks after birth. Following intravitreal injection of a fusion protein (e.g., C3APLT) as described above, tissues are analysed by histological methods described above.
[0569] Retinal explants from rd-mutant mice cultured in a C3APLT-containing medium can be assayed for thickness of the outer nuclear layer using methods described in Caffe et al., Curr. Eye Res. 12:719, 1993, the disclosure of which is hereby incorporated by reference. Thus, mouse pups are enucleated 48 hours after birth and treated with proteinase K. After this enzyme treatment, the neural retina with the retinal pigmented epithelium (RPE) attached is recovered, placed into a multi-well culture dish, and incubated in 1.2 ml culture medium (e.g., R16) for up to 4 weeks at 37° C. with 5% CO2. Immunocytochemical staining for opsin of fixed (e.g., 4% paraformaldehyde) sections is used to assess the degeneration and rescue of photoreceptor cells. In the rd-mutant mouse the outer nuclear layer (photoreceptor cells) degenerate after 2-to-4 weeks in culture. The media can be supplemented with a dose range of C3APLT to achieve an effect on retinal cell function, such as rescue of the outer nuclear layer from degeneration. Survival effects can also be shown using the TUNEL method on sections of retina analysed in the models described above.
EXAMPLE 24
Procedure to Determine Efficacy of a Fusion Protein to Prevent Neovascularization of the Retina
[0570] Uncontrolled retinal angiogenesis can contribute to the pathology of a number of diseases of the retina such as wet macular degeneration, retinitis pigmentosa, Stargardt's Disease, diabetic retinopathy, hypertensive retinopathy, and occlusive retinopathy. Vascular endothelial growth factor (VEGF) production is increased by hypoxia in the retina, and neovascularization of the retina is thereby induced.
[0571] A mouse model of ischemia-induced retinal neovascularization employs newborn C57BL/6J mice which are exposed to 75% O2 from postnatal day (P) 7 to P12, along with their nursing mothers, followed by a return to room air. To accomplish this, the mice are weighed and placed at day P7 in a plexiglass box which serves as an oxygen chamber together with enough food and water for 5 days to P12. An oxygen flow rate of 1.5 L/min is maintained through the box for 5 days. The flow rate is checked twice daily with a Beckman oxygen analyzer (model D2, Irvine Calif.). The chamber is not opened during the 5 days of hyperoxia. An intraocular injection of a fusion protein (e.g., C3APLT) is performed at day P12 and the mice are removed to ambient air thereby inducing hypoxia. At day P17 the mice are sacrificed by cardiac perfusion with saline followed by 4% paraformaldehyde (PF), and their eyes are removed and fixed in PF overnight. The eyes are then rinsed, brought through a graded alcohol series, and then radial sections 6 um thick are cut. Sections through the optic nerve head are stained with periodic acid/Schiff reagent and hematoxylin. Sections 30 um apart are evaluated for a span of 300 um through the retina. All retinal vascular nuclei anterior to the internal limiting membrane are counted in each section. The mean of 10 counted sections is determined to give the average number of neovascular nuclei per section per eye. No vascular cell nuclei anterior to the limiting membrane are observed in normal, unmanipulated animals. The administration of a fusion protein substantially reduces the number of retinal vascular nuclei relative to the number observed in the absence of fusion protein. | The Rho family GTPases regulates axon growth and regeneration. Inactivation of Rho with C3, a toxin from Clostridium botulinum , can stimulate regeneration and sprouting of injured axons. The present invention provides novel chimeric C3-like Rho antagonists. These new antagonists are a significant improvement over C3 compounds because they are 3-4 orders of magnitude more potent to stimulate axon growth on inhibitory substrates than recombinant C3. The invention further provides evidence that these compounds promote repair when applied to the injured mammalian central nervous system. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention concerns a bottle with a rounded bottom fitted with a base and especially bottles of this kind intended to be subjected to pasteurization, deep-freezing and like processing using a heat-exchange fluid.
Such bottles are specifically designed for use in the foodstuffs, pharmaceuticals, industrial and like domains.
2. Description of the prior art
The bases usually used in association with round-bottomed bottles enable them to remain stable when stood on a support.
However, when a bottle of this kind contains a fluid to be pasteurized, there is observed during the pasteurization process a difference in temperature between the liquid in the part of the bottle above the base and the liquid in the part of the bottle surrounded by the base. The base acts as a insulator at the bottom of the container and the fluid at this level does not receive the same quantity of heat from a heat exchange fluid as that in the part of the bottle above the base. This constitutes a major disadvantage when such bottles are pasteurized because it is then necessary to extend the heating and/or cooling period in such a way as to obtain the required temperature. This entails the expenditure of additional energy and the overall cost of the operation is thereby significantly increased.
The objective of the present invention is to alleviate this disadvantage by providing a bottle provided with a passage for heat exchange fluid between the bottle and its base so as to improve the transfer of heat between the heat exchange fluid and the liquid contained in the bottle and especially the liquid in the part of the bottle surrounded by the base.
SUMMARY OF THE INVENTION
In one aspect the present invention consists in a bottle suitable for processing by means of a heat exchange fluid, as by pasteurization or the like, comprising a separate base attached to it and, between said base and the body of the lower part of the bottle, a passage for heat exchange fluid communicating with the exterior and having an inlet area and an outlet area.
In a second aspect the present invention consists in a bottle having a rounded bottom and a lateral wall and comprising a separate base attached to it and having a lateral wall surrounding and fixed to a lower portion of said lateral wall of said bottle, an annular support boss, and a bottom part comprising an area supporting the bottom of said bottle, the bottle further comprising, between said base and the body of the bottle, a passage for heat exchange fluid communicating with the exterior via an inlet area and an outlet area, the fluid passing over part of the bottom of the bottle as it flows through said passage.
In a third aspect, the present invention consists in a base for a container having a rounded bottom and a lateral wall, comprising a lateral wall adapted to surround and to be fixed to a lower portion of said lateral wall of said container, an annular support boss, a bottom part comprising an area adapted to support the bottom of said container, and inlet and outlet areas for a heat exchange fluid in said base arranged so that a flow of said fluid through said base passes across the bottom of said container.
By virtue of these provisions the bottle or the base for same facilitates the flow of a heat exchange fluid in contact with the lower part of the bottle and therefore improves the transfer of heat between the heat exchange fluid and the substance contained in the bottle. It is therefore possible to reduce the time for which the container is held at a particular temperature during any form of pasteurization, deep-freezing or like process.
Other objectives, characteristics and advantages of the invention will emerge from the following description given by way of example with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in elevation of a bottle and its base, the bottle being provided with a heat exchange fluid passage, constituting a first embodiment of the invention.
FIG. 2 is a partial view to a larger scale and in longitudinal cross-section of a bottle fitted with a base in accordance with a first embodiment of the invention.
FIG. 3 is partial view in cross-section on the line III--III in FIG. 2.
FIG. 4 is a view to a larger scale of the detail marked IV in FIG. 2.
FIG. 5 is a partially cut away view in elevation of a bottle and its base having a heat exchange fluid passage, constituting a second embodiment of the invention.
FIG. 6 is a view in cross-section and to a larger scale of part of the bottle and base shown in FIG. 5.
FIG. 7 is a view in cross-section of the line VII--VII in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Each of the two embodiments to be described provides a heat exchange fluid passage between a bottle and its base.
In the embodiment shown in FIGS. 1 through 4 a bottle or container 10 is fitted with a base 11. The bottle 10, which is known per se, contains any liquid 12 to be pasteurized and has a rounded bottom 13 and a cylindrical lateral wall 14. The base is in the form of a cup having a bottom part, a support boss 17 and a cylindrical lateral wall 16. The bottom part consists of a central part 15 spaced from the bottom of the bottle 10 and surrounded by an annular curved area 23 defining a support and centering area for the rounded bottom of the container 10.
The annular support boss 17 is pierced at its end by a plurality of orifices 18 constituting a fluid outlet. These orifices are circumferentially distributed and spaced from a bearing area 30 of the boss.
The lateral wall 16 of the base has in its upper part the annular fixing area 19 provided with a plurality of axially oriented recesses 20.
A passage 50 for heat exchange fluid is defined by the wall of the bottle between the fixing area 19 and the support area 23, on the one hand, and the wall of the base facing this wall, on the other hand.
As can be seen better in FIGS. 2 and 3, the recesses 20 alternate circumferentially with reinforcements 21 forming an integral part of the lateral wall 16.
A base of this kind is designed to cap the lower part of the bottle 10 and thus to cover its bottom.
The fixing area 19 cooperates with the support area 23 to hold the bottle 10 in a vertical position and center it within the base.
The lateral wall 16 is thicker at this point in order to reinforce the fixing area 19, to make it mechanically stronger.
The fixing area 19, more specifically the surface 22 of the reinforcements 21, is designed to come into contact with the lateral wall 14 of the bottle. This contact is generally strengthened by adhesive bonding, welding, clipping or interference fit means.
When the container provided with a heat exchange fluid passage in accordance with the invention is subjected to a pasteurization process, for example, a heat exchange fluid flows along the wall 14 of the bottle, enters the passage 50 through the recesses 20, flows along the wall of the bottle between the fixing area 19 and the bottle support area 23, separates from the bottom 13 of the bottle, falls into the boss 17 and is then evacuated from the passage 50 through the orifices 18.
Thus the part of the wall 14 of the bottle between the fixing area 19 and the support area 23 and surrounded by the base is directly in contact with the heat exchange fluid, which enables the transfer of heat to the liquid in the bottom of the bottle to be substantially increased.
Note that the fact that the base just described is hollow and that its lateral wall 16 is spaced from the wall 14 of the bottle 10 enables good circulation of the heat exchange liquid, which is not impeded at the points of evacuation since the outlet orifices 18, although situated in the lowest part of the support boss 17, are not closed off when the bottle is resting on a support. The heat exchange fluid can therefore be circulated in a continuous way. To permit more effective circulation of the heat exchange liquid over the bottom of the bottle 10 the total cross-section of the orifices 18 in the base is greater than or equal to the total cross-section of the recesses 20.
Note that the base fitted with a corresponding bottle may be subjected to other processes than pasteurization, such as deep-freezing, for example.
Although the surface 22 of the reinforcements 21 of the base as previously descirbed is in direct contact with the cylindrical wall 14 of the bottle there is no significant insulative effect near the contact area since this is small and does not significantly affect the distribution of heat within the liquid contained in the bottle 10.
The heat exchange fluid passage in accordance with the invention may also be formed not by adapting the base but by adapting the bottom of the bottle itself, as in the second embodiment of the present invention described hereinafter.
Parts that are identical or have an analogous function in the two embodiments have reference numbers differing by the addition of a hundreds digit.
As shown in FIGS. 5 through 7, a bottle 100 is formed with longitudinal recesses 120 in its lower part. These recesses extend between a cylindrical area 114 and a rounded area 104 of the bottle and through an annular area 119 in which a base 111 is fixed to the bottle.
The lower part of the bottle is further provided with a circumferential shoulder 101 defining a bearing area for the base 111, of known type, designed to cover the rounded bottom of the bottle and to be fixed to the bottle 100 through the intermediary of the annular fixing area 119. The base 111 comprises a member support boss 117 having a plurality of orifices 118 analogous to the plurality of orifices 18 in the first embodiment. This plurality of orifices 118 constitutes a fluid outlet area. Once fitted onto the bottle and fixed to it by any appropriate means (by adhesive bonding in particular), the recesses 120 have an upper part 140 situated above the junction of the base with the bottle.
There is thus created a passage 150 for a heat exchange fluid the inlet area of which is defined between the upper part 140 of the recess 120 and the part of the upper edge 141 of the base facing the recess 120.
The heat exchange fluid passge 150 extends from the inlet area along the recess 120 and then along part of the bottom 113 of the bottle, as far as the outlet area 118.
Note that the recesses 120 formed in the bottle 100 are easier to produce (as they are formed when the bottle is blown) than the recesses 20 in the thickness of the annular fixing area of the base in the first embodiment.
Note also that the total area of the heat exchange fluid passage inlet area is greater in the second embodiment than in the first embodiment.
The recesses 120 in the bottle constitute re-entrant areas the radial dimension of which is greater than or equal to several times the thickness of the base of the first embodiment. As the recesses formed in the base in the first embodiment are necessarily limited to a fraction of the total thickness of the wall of the base, in order for this wall to have sufficient mechanical strength, these recesses 20 necessarily constitute an inlet area of limited surface area.
It is also possible to increase the inlet area by providing recesses that are deeper in the radial direction, without this reducing the circumferential extend between the fixing areas and the cylindrical part of the lateral wall of the bottle.
Note also that since the total area of the inlet area in the second embodiment is greater than the total area of the inlet area in the first embodiment, the flowrate and circulation of the heat exchange fluid are enhanced in the second embodiment.
However, both of the two embodiments described provide a passage for a heat exchange fluid between a bottle and a base to improve the transfer of heat between the heat exchange fluid and the substance contained in the bottle.
In a third embodiment (not shown) the heat exchange fluid passage has, in addition to an outlet area formed in the base, an inlet area also formed in the base of the bottle but short of its fixing area.
In a variant that is not shown the outlet area of the heat exchange fluid passage is formed in the central part 15 of the base and recesses as described for the second embodiment are formed in the bottom part 113 facing the support area 123 to permit circulation of the heat exchange fluid. These recesses can likewise be formed in the support area of the base. These modifications may be incorporated in any of the embodiments previously described and offer the advantage of increasing the area of contact between the heat exchange fluid and the bottom of the bottle.
The present invention also encompasses all variants within the competence of those skilled in the art, such as, for example, the adaptation of a heat exchange fluid passage of this kind to polygonal containers, or plastics material and/or metal barrels. | A bottle has a rounded bottom, a lateral wall and a separate base. The base comprises a lateral wall which surrounds and is fixed to a lower portion of the lateral wall of the bottle. It also comprises an annular support boss and a bottom part comprising an area supporting the bottom of the bottle. The bottle comprises a passage for a heat exchange fluid. This passage includes inlet and outlet areas for the heat exchange fluid. The flow of the fluid through the passage passes across part of the bottom of the bottle. This facilitates effective pasteurization or deep-freezing of the bottle's contents. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 13/208,016 filed Aug. 11, 2011, which, in turn, claims the benefit of U.S. provisional application Ser. No. 61/372,766, filed on Aug. 11, 2010 and is a continuation-in-part application of Patent Cooperation Treaty Application Serial No. PCT/US10/32,037, filed Apr. 22, 2010, which, in turn, claims the benefit of U.S. provisional application Ser. No. 61/171,641, filed Apr. 22, 2009. All disclosures in these prior applications are hereby incorporated in their entirety by reference herein.
TECHNICAL FIELD
[0002] This disclosure is related generally to energy conversion devices capable of inputting electrical and/or mechanical energy and outputting electrical and/or mechanical energy. In particular, the energy conversion device is adapted for converting one form of input energy selected from a mechanical energy and electrical energy, into an output energy selected from a mechanical energy and electrical energy using a stationary and moveable magnetic component. This disclosure is further related generally to energy management systems capable of managing kinetic energy in the form of vibrating mechanical input. In particular, this disclosure is directed to energy management systems for absorbing transverse shock or vibration experienced by a moving vehicle.
SUMMARY
[0003] At least two nested magnetic components, such as toroidal magnetic components are provided, one active component creating a magnetic field and one passive component, from which the energy of the field is converted to mechanical energy or vice versa through relative movement between the active and passive component. The passive component may be a magnetic piston and the active component may be a coiled electrical winding.
[0004] For conversion of mechanical energy into electrical energy, external forces, originating from source of kinetic energy such as walking, running, driving, typing, or the movement of air or water, or the expansion or contraction of a fluid, may cause a floating magnet to oscillate relative to a winding or coil. For example, mechanical energy from wind, hydro or other moving fluid or from mechanical activity may be used to cause relative movement between the piston and the winding and energy generated by the relative motion may be transferred from the winding to and stored as electrical energy by an electrical storage device such as a battery or a capacitor. For conversion of electrical energy into mechanical energy, electrical energy from an external source causes the winding to create a magnetic field which causes the floating magnet to move. The mechanical energy is used directly or stored by a mechanical energy storage device such as a flywheel.
[0005] In one exemplary device, a winding or coil defines a longitudinal axis. Two fixed magnets, one disposed at each end of the longitudinal axis, act on a magnetic piston movably disposed relative to the winding and displaceable along the longitudinal axis. The relative motion between the piston and the winding may be horizontal or vertical or at any angle therebetween.
[0006] In another exemplary device, the energy conversion device has an elongated channel defined by a radial magnetic source, a winding disposed coaxial with the radial magnetic source two oppositely disposed axial magnets in fixed locations at opposing ends of the elongated channel and a piston disposed therebetween. The radial axial magnets may be rare earth magnets such as neodymium magnets.
[0007] In another exemplary device, a passive toroidal component is significantly larger than an active toroidal component.
[0008] In still another exemplary device, the piston may be a complex magnet having an axial magnetic component responsive to the oppositely disposed axial magnets, and a radial magnetic component responsive to the radial magnetic source to generally maintain the piston in a floating position within an elongated channel defined by the winding or coil. The opposing magnetic fields of the oppositely disposed axial magnets confine the floating piston within the channel and increase the number and speed of the oscillations. A cylinder may be provided defining the channel and may be wrapped tightly with a toroidal copper winding defining the winding. As the piston passes through the winding, its movement creates a moving magnetic field that is converted into electrical current flowing through the winding.
[0009] Additional magnets may be configured around the cylinder allowing the piston to float freely, reducing friction between the piston and the walls of the cylinder.
[0010] A kinetic energy management system is also disclosed for managing vibration experienced by a moving vehicle, where the vibration occurs in a direction generally transverse to the direction of movement of the vehicle,
[0011] One exemplary kinetic energy management system includes an electromechanical shock absorber device comprising a first main body movably attached to a second main body for reciprocal movement therebetween, the first main body having a winding or coil movable therewith and the second main body having a magnet moveable therewith. The magnet may be movable relative to the winding by the reciprocal relative movement of the first and second main bodies such as to generate a current in the winding. One of the first or second main bodies is adapted for engagement with a vehicular component that experiences the irregularities of a surface on which the vehicle travels and the other of the main bodies is adapted for engagement with a load bearing portion of the vehicle for which isolation from the vibrations due to irregularities of the surface is desired. The interaction of the magnet and the winding may be used to translate between reciprocating kinetic energy associated with the motion of the vehicle over the surface irregularities and electrical energy associated with current through the winding. The vehicle may be a car or truck and the surface may be a road. Alternatively, the vehicle may be a boat and the surface may be the surface of a body of water.
[0012] Another exemplary kinetic energy management system includes an electromagnetic shock absorber having at least two nested magnetic components, such as toroidal magnetic components, one active component creating a magnetic field and one passive component from which the energy of the field is converted to mechanical energy, or vice versa through relative movement between the active and passive component. The passive component may be a magnetic piston and the active component may be a coiled electrical winding. For conversion of kinetic energy into electrical energy, external forces, originating from surface irregularities as a vehicle travels in a forward direction, cause relative movement between the magnetic components resulting in current flowing through the active component.
[0013] In another electromechanical shock absorber, a winding or coil defines a longitudinal axis. Two fixed magnets, one disposed at each end of the longitudinal axis, act on a magnetic piston movably disposed relative to the winding and displaceable along the longitudinal axis, The relative motion between the piston and the winding may be horizontal or vertical or at any angle therebetween.
[0014] In still another exemplary system, the electromechanical shock absorber has an elongated channel defined by a radial magnetic source, a winding disposed coaxial with the radial magnetic source, two oppositely disposed axial magnets in fixed locations at opposing ends of the elongated channel and a piston disposed therebetween. The radial axial magnets may be rare earth magnets such as neodymium magnets.
[0015] The energy management system may be used to passively absorb a portion of the transverse vibration by surface irregularities as well as to provide electrical energy for later use by passively converting the kinetic energy to electricity. Alternatively, the energy management system may be used to actively manage the amplitude or the frequency of the transverse vibrations experienced by the load-bearing portion of the vehicle by selective application of a current to the windings. The energy management system may therefore include an electronic control system to control the application of current to the winding as well as to regulate the use of current generated in the winding by the movement of the magnet
[0016] The first and second main bodies of the electromagnetic shock absorber may create an enclosure or housing for the magnet, the winding, electronic controls, shock-absorbing components, and a spring. The main body may be constructed to have a similar shape and mounting function as a conventional mechanical shock absorber or may have alternate shapes and features for special applications.
[0017] The magnet may be a disc shaped compound complex radial magnetic piston manufactured or selected to effectively present axial poles of opposing polarity on its respective faces as well as to effectively present a radial pole of a single polarity.
[0018] In still another exemplary device, the piston may be a complex magnet having an axial magnetic component responsive to the oppositely disposed axial magnets, and a radial magnetic component responsive to the radial magnetic source to generally maintain the piston in a floating position within an elongated channel defined by the winding or coil. The opposing magnetic fields of the oppositely disposed axial magnets confine the floating piston within the channel and increase the number and speed of the oscillations. A cylinder may be provided defining the channel and may be wrapped tightly with a toroidal copper winding defining the winding. As the piston passes through the winding, its movement creates a moving magnetic field that is converted into electrical current flowing through the winding.
[0019] Additional magnets may be configured around the cylinder allowing the piston to float freely, reducing friction between the piston and the walls of the cylinder.
[0020] The energy management system may be used in parallel or in series with a mechanical energy managing system such as a mechanical shock absorber or a mechanical spring. Alternatively, a mechanical energy managing system may be integrated into a shock-absorbing device of the type disclosed herein.
[0021] In one exemplary energy management system disclosed, the vehicle using an electromagnetic shock absorber is a car or truck and the surface is a road. The electromagnetic shock absorber is installed in parallel with a conventional mechanical shock absorber or spring. Alternatively, the electromechanical shock absorber incorporates mechanical shock absorbing components and is substituted for a conventional mechanical shock absorber. Alternatively, the electromechanical shock absorber incorporates a spring and is substituted for a conventional mechanical spring.
[0022] In another exemplary embodiment, the vehicle is a boat and the surface is the surface of a body of water. An electromechanical shock absorber may be installed between the hull of the boat and a pontoon floating on the surface of the water adjacent the hull. A plurality of electromechanical shock absorbers may be provided adjacent each side of the boat coupled to one or more pontoons on each side of the boat. The action of waves will displace the magnet relative to the windings of the electromechanical shock absorbers to induce current in the windings to generate electrical power or to provide a damping effect on the motion of the boat in response to the waves. The windings of the electromechanical shock absorbers may also be selectively powered to raise the pontoons above the water surface when desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Some configurations of the energy management system will now be described, by way of example only and without disclaimer of other configurations, with reference to the accompanying drawings in which:
[0024] FIG. 1A is a schematic representation of an energy conversion device;
[0025] FIG. 1B is a schematic representation of an alternative energy conversion device;
[0026] FIG. 2 is a side elevational view of a first example of an energy conversion device, with internal magnetic components shown in phantom line;
[0027] FIG. 3 is a sectional view of the energy conversion device of FIG. 2 taken along line 3 - 3 thereof;
[0028] FIG. 4 is a sectional view of the energy conversion device of FIGS. 2 and 3 taken along line 4 - 4 of FIG. 3 ;
[0029] FIG. 5 is a side elevational view of a second example of an energy conversion device, with internal magnetic components shown in phantom line;
[0030] FIG. 6 is a sectional view of the energy conversion device of FIG. 5 taken along line 6 - 6 thereof;
[0031] FIG. 7 is 1 sectional view of the energy conversion device of FIGS. 5 and 6 taken along line 7 - 7 of FIG. 6 ;
[0032] FIG. 8 is a top view of an alternative complex piston for the energy conversion devices of FIGS. 1 through 6 ;
[0033] FIG. 9 is a schematic view of a prior art automotive shock absorbing system including conventional mechanical shock absorbers;
[0034] FIG. 10 is a schematic view of a conventional mechanical shock absorber illustrating the operation thereof with its internal components in an extended operational configuration;
[0035] FIG. 11 is a schematic view of the shock absorber of FIG. 10 with its internal components in a compressed operational configuration;
[0036] FIG. 12 is a schematic perspective view of a conventional shock absorber mounted in parallel with an exemplary electromagnetic shock absorber;
[0037] FIG. 13 is a schematic perspective view' of a conventional shock absorber mounted in parallel with an alternative exemplary electromagnetic shock absorber;
[0038] FIG. 14 is a schematic perspective view of another alternative exemplary electromechanical shock absorber which may be substituted for a conventional mechanical shock absorber;
[0039] FIG. 15 is a sectional view of the electromagnetic shock absorber of FIG. 12 taken along line thereof;
[0040] FIG. 16 is a partial sectional view of the electromagnetic shock absorber of FIGS. 12 and 15 taken along line 16 - 16 of FIG. 15 ;
[0041] FIG. 17 is an exploded schematic view of certain internal components of the electromagnetic shock absorber of FIGS. 12 , 15 and 16 ;
[0042] FIG. 18 is an exploded schematic view similar to FIG. 17 , but illustrating an alternative exemplary electromagnetic shock absorber;
[0043] FIG. 19 is a sectional view similar to FIG. 15 , but illustrating another alternative exemplary electromagnetic shock absorber with control components incorporated into its housing;
[0044] FIG. 20 is a sectional view similar to FIG. 15 , but illustrating still another alternative exemplary electromagnetic shock absorber with damping components incorporated into its housing;
[0045] FIG. 21 is a sectional view similar to FIG. 15 , but illustrating yet another alternative exemplary electromagnetic shock absorber with damping components and a spring incorporated into its housing;
[0046] FIG. 22 is a perspective view of an exemplary linear kinetic energy management system including an electromechanical shock absorber for use in association with a boat;
[0047] FIG. 23 is a perspective view of an alternate exemplar kinetic energy management system including a plurality of electromechanical shock absorbers for use in association with a boat;
[0048] FIG. 24 is a side elevational view of the kinetic energy management system of FIG. 23 ;
[0049] FIG. 25 is a top plan view of the kinetic energy management system of FIGS. 23 and 24 ;
[0050] FIG. 26 is a front elevational view of the kinetic energy management system of FIGS. 23-25 , illustrating the kinetic energy management system mounted to a side of a boat; and
[0051] FIG. 27 is a sectional view through yet another kinetic energy management system having an electromagnetic shock absorber into a float.
DETAILED DESCRIPTION
[0052] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. Referring now to the drawings; exemplary energy management systems are shown in detail. Although the drawings represent alternative configurations of energy management systems, the drawings are not necessarily to scale and certain features may be exaggerated to provide a better illustration and explanation of a configuration. The configurations set forth herein are not intended to be exhaustive or to otherwise limit the device to the precise forms disclosed in the following detailed description.
[0053] Referring to FIG. 1A , schematically illustrating a generalized energy conversion device 10 , the arrangement of the magnetic and electromagnetic components of energy conversion device 10 will be described. In particular, energy conversion device 10 includes a radial magnetic source 12 disposed coaxially with a winding such as a toroidal winding 14 . In the exemplary structure illustrated, radial magnetic source 12 surrounds toroidal winding 14 . Together, radial magnetic source 12 and a toroidal winding 14 define a longitudinal axis 16 as well as an elongated channel 18 for a piston 20 to reciprocate along longitudinal axis 16 . Radial magnetic source 12 has an outer circumferential surface 22 having a first polarity and an inner circumferential surface 24 having an opposite polarity to outer circumferential surface 22 . As described below, radial magnetic source 12 may, for example, be a single elongated toroidally shaped magnet or may be a plurality of bar-shaped magnets disposed radially about toroidal winding 14 . In some applications, the energy conversion device may be used without a radial magnetic source 12 .
[0054] Piston 20 comprises a disk-shaped axial magnet 28 having a first surface 30 of a first polarity and a second surface 32 of an opposite polarity to that first surface 30 . Piston 20 further comprises a toroidally-shaped radial magnet 34 surrounding axial magnet 28 and having an outer circumferential surface 36 of a first polarity and an inner circumferential surface 38 of a second polarity opposite the polarity of surface 38 . Inner circumferential surface 38 engages an outer circumferential surface 40 of axial magnet 28 . Radial magnet 34 interacts with radial magnetic source 12 to maintain piston 20 axially centered in channel 18 . This will occur whether the inner circumferential surface 24 of radial magnetic source 12 has the same polarity or the opposite polarity as the outer circumferential surface 36 of radial magnet 34 , since the forces will be approximately equal in all directions, but piston 20 will be less likely to tilt relative to longitudinal axis 16 due to any imbalance of forces if these surfaces have opposite polarity.
[0055] It should be noted that all of the magnets used in the energy conversion device may be rare earth magnets, such as neodymium magnets, to provide the desired strength combined with a low-weight. Alternative choices for the neodymium material are described later herein.
[0056] A disk-shaped axial magnet 44 is disposed at one longitudinal end of channel 18 . Axial magnet 44 has a first surface 46 facing towards first surface 30 of axial magnet 28 of piston 20 and having the same polarity as first surface 30 so as to repel piston 20 . Axial magnet 44 has a second surface 48 disposed opposite to first surface 46 and having the opposite polarity as first surface 46 . A disk shaped axial magnet 50 is disposed at the other longitudinal end of channel 18 . Axial magnet 50 has a surface 52 facing towards second surface 32 of axial magnet 28 of piston 20 and having the same polarity as second surface 32 so as to repel piston 20 . Axial magnet 50 has a second surface 54 disposed opposite to first surface 52 and having the opposite polarity as first surface 52 .
[0057] Therefore, as depicted in FIG. 1A , axial magnets 44 and 50 cooperate with axial magnet 28 of piston 20 and radial magnetic source 12 cooperates with radial magnet 34 of piston 20 to maintain piston 20 floating in a fixed position within channel 18 unless disturbed by an external force. Furthermore, if any event causes a repositioning of piston 20 relative to any of the magnet components 12 , 44 or 50 , the net magnetic forces upon piston 20 , taking also into account the force of gravity piston 20 , will cause piston 20 to oscillate within channel 18 along longitudinal axis 16 until it is restored to a balanced stationary position. As piston 20 oscillates, toroidal winding 14 generates electrical energy from the moving magnetic field. Since piston 20 is free floating within channel 18 , no energy is lost to friction between solid bearing surfaces.
[0058] Energy conversion device 10 further includes another toroidal winding 60 disposed adjacent axial magnet 50 . Toroidal winding 60 may be selectively energized to temporarily upset the balance of forces acting on piston 20 so as to initiate or assist the oscillation of piston 20 . It will be appreciated that oscillation of piston 20 may additionally or alternatively be initiated or assisted by mechanical action causing piston 20 to move relative to the other magnetic components 12 , 44 and 50 , or alternatively causing any of the magnetic components 12 , 44 and 50 to move relative to piston 20 . It will further be appreciated that relative motion between piston 20 and toroidal winding 14 will establish a current in toroidal winding 14 which may be used as a source of electrical power.
[0059] FIG. 1B schematically illustrates an alternative generalized energy conversion device 10 a in which the arrangement of the magnetic and electromagnetic components are similar to those described above except that piston 20 a and axial magnets 44 a and 50 a are ring-shaped. In this arrangement, piston 20 a is disposed outside of the radial magnetic source 12 and the toroidal winding 14 and axial magnet 50 a is disposed outside of toroidal winding 60 . Piston 20 a is composed of an inner ring-shaped radial magnet 34 a and an outer ring-shaped axial magnet 28 a . Axial magnets 44 a and 50 a interact with axial magnet 28 a and radial magnetic source 12 interacts with radial magnet 34 a according to the same principles as the similarly numbered components of the generalized energy conversion device 10 of FIG. 1A described above.
[0060] It should be noted that a plurality of toroidal windings are provided. One or more passive toroidal windings are provided to create an output current as a function of the motion of the piston. One or more active toroidal windings are provided to create a magnetic field opposing the magnetic field of the piston. The passive toroidal winding is significantly larger than the active toroidal winding. The energy created by the piston interacting with the passive toroidal winding may be transferred to and stored in an electrical device such as a battery or capacitor. The active toroidal winding may use the electrical energy previously created by the moving piston magnets interacting with the passive toroidal winding.
[0061] Referring now to FIGS. 2-4 , a first exemplary energy conversion device 101 will be described.
[0062] As shown in FIGS. 3 and 4 , toroidal winding 14 is wound about and supported by a tube 64 formed of a suitable non-conductive material such as plastic. As shown only in FIG. 4 , toroidal winding 60 may also be wound about and supported by tube 64 . An inner surface 66 of plastic tube 64 defines channel 18 for piston 20 .
[0063] As best shown in FIG. 4 , energy conversion device 10 ′ is provided with an outer housing 70 having a cylindrical wall 72 closed at one end by a flat wall 74 and attachable at another end with a cover 76 to form an enclosure for the magnetic components of energy conversion device 10 . Axial magnet 44 is affixed to cover 76 . Axial magnet 50 is affixed to base 74 inside of outer housing 70 . Piston 20 is shown spaced away from toroidal winding 14 so as to avoid loss of energy to friction between components. However, piston 20 may be proportioned with a sufficiently large diameter relative to the inner diameter of toroidal winding 14 to restrict airflow between the portions of channel 18 on either side of piston 20 . To prevent air pressure buildup on either side of piston 20 from inhibiting the motion of piston 20 , housing 70 may be provided with openings, not shown, permitting airflow to on either end of channel 18 .
[0064] Wires 78 (see FIGS. 2 and 4 ) for powering toroidal winding 60 extend through apertures 80 in cylindrical wall 72 to an external power source 82 , as shown in FIG. 4 . Power source 82 may be selectively connected to toroidal winding 60 through a switch 84 , which may be a manual switch or may be a switch activated automatically, such as by a microprocessor, when it is desired to introduce a temporary magnetic imbalance to piston 20 to initiate or assist in the oscillation of piston 20 . Wires 86 (see FIGS. 2 and 4 ) connected to toroidal winding 14 similarly extend through apertures 88 in cylindrical wall 72 to an electrical load 90 , as shown in FIG. 4 . Alternatively, wires 86 may be replaced by a wireless power transmission system.
[0065] Energy conversion device 10 ′ may be configured to provide either alternating current or direct current output. Electrical load 90 may be one or more electrical devices capable of consuming the power, one or more storage devices used to store power for later use, or a power distribution system. Exemplary storage devices for electrical load 90 include batteries, flywheels, capacitors, and other devices of capable of storing energy using electrical, chemical, thermal or mechanical storage systems. Exemplary electrical devices for electrical load 90 include electric motors, fuel cells, hydrolysis conversion devices, battery charging devices, lights, and heating elements. Exemplary power distribution systems electrical load 90 includes residential circuit breaker panel, or an electrical power grid. Electrical load 90 may also include intermediate electrical power conversion device capable of converting the power to a form useable by electrical load 90 such as an inverter.
[0066] While power source 82 and electrical load 90 are schematically illustrated as independent of energy conversion device 10 ′, either or both may be integrated with energy conversion device 10 ′ or connected with energy conversion device 10 ′ in some manner. In particular, one or both may alternatively be affixed to outer housing 70 or cover 76 or mounted within a compartment formed on outer housing 70 or cover 76 . Still another alternative would be for the power source 82 or electrical load 90 to incorporate cover 76 . Furthermore, while power source 82 and electrical load 90 are schematically illustrated as being tangentially located relative to longitudinal axis 16 , either or both may be advantageously located along longitudinal axis 16 for some implementations. Thus, for example, but not illustrated, cylindrical wall 72 of outer housing 70 may extend beyond wall 74 to provide a compartment for the storage of a power source 82 or electrical load 90 , such as cylindrical batteries, radio, or a light. Additionally or alternatively, cover 76 may be provided with a compartment or attachment feature for a power source or an electrical load.
[0067] Energy conversion device 10 ′ may use six equally spaced bar magnets 12 a through 12 f disposed about the periphery of toroidal winding 14 as a radial magnetic source. An inner wall 92 of outer housing 70 holds the array of bar magnets in their desired spaced apart relationship.
[0068] Energy conversion device 10 ′ may therefore be assembled, as shown in FIG. 4 by inserting piston 20 into outer housing 70 , sliding tube 64 carrying toroidal windings 14 and 60 and piston 20 into outer housing 70 , and then attaching cover 76 to close outer housing 70 .
[0069] Housing 70 may be provided with appropriate legs or mounting points, not shown, if desired, for selectively supporting energy conversion device 10 ′ in a horizontal position, a vertical position, or both. If the intent is to operate energy conversion device 10 ′ with longitudinal axis 16 vertically disposed, then it may be desirable to select an axial magnet 50 that is stronger than axial magnetic component of piston 20 and to select an axial magnet 44 that is weaker than axial magnetic component of the piston 20 to adjust for the gravitational force on piston 20 .
[0070] Referring now to FIGS. 5-7 , a second exemplary energy conversion device 10 ″ will be described. Energy conversion device 10 ″ is similar to energy conversion device 10 ′ except as described below.
[0071] As shown in FIGS. 6 and 7 , toroidal winding 14 is wound about and supported by a cylindrical wall 94 of an inner housing 96 . Inner housing 96 is formed of a suitable non-conductive material Inner housing 96 has a flat wall 98 (see FIGS. 5 and 6 ) closing one end of cylindrical wall 94 and an annular flange 100 extending from cylindrical wall 94 . Cylindrical wall 94 of inner housing 96 defines channel 18 for piston 20 . Axial magnet 44 is affixed to flat wall 98 within inner housing 96 .
[0072] An outer housing 70 ″ having a cylindrical wall 72 ′ (see FIG. 7 ) joined to a flat base 74 ′ provides a partial enclosure for the magnetic components of energy conversion device 10 ″ in a manner similar to outer housing 70 (see FIGS. 2 , and 4 ) of energy conversion device 10 ′, except that instead of a cover 76 , the open end of outer housing 70 ″ (see FIGS. 5 and 7 ) is closed by annular flange 100 of inner housing 96 .
[0073] Energy conversion device 10 ″ further differs from energy conversion device 10 ′ in that, instead of using six bar magnets, energy conversion device 10 ″ uses an elongated toroidal magnet 104 fitted into outer housing 70 ″ as a radial magnetic source. Energy conversion device 10 ″ further differs from energy conversion device 10 ′ by having a support 106 (see FIG. 6 ) extending from the cylindrical wall 72 ″ to selectively support energy conversion device 10 ″ on a horizontal surface. It will be appreciated that, unlike energy conversion device 10 ′ which is designed to advantageously use the force of gravity on piston 20 , energy conversion device 10 ″ may be positioned at any orientation from zero to ninety degrees relative to a horizontal plane and, if desired, support 106 may be omitted. As shown, toroidal winding 60 may be wound about axial magnet 50 . Alternatively, not shown, toroidal winding 60 may be wound about cylindrical wall 94 of inner housing 96 or around a spool.
[0074] Energy conversion device 10 ″ may therefore be assembled, as shown in FIG. 7 , by sliding toroidal magnet 104 and piston 20 into outer housing 70 ″, inserting inner housing 96 into outer housing 70 ″, and then attaching annular flange 100 to outer housing 70 ″.
[0075] Energy conversion devices 10 , 10 a , 10 ′ and 10″ may be used as a generator, a motor, a pump, a compressor, an engine, or an electrical power transformer. When used as a transformer, electrical power may be input to toroidal winding 60 and electrical power may be output from toroidal winding 14 . When used as a generator, mechanical power may be input by reciprocally moving the outer housing 70 or 70 ″ along axis 16 and electrical power may be output from toroidal winding 14 . The mechanical motion may be provided, for example, by any source that is capable of oscillating the housing along longitudinal axis 16 , such as ocean waves, wind, reciprocating fuel burning engines or manual activity. Alternatively, mechanical motion may be imparted to the piston 20 or 20 a . For example the two ends of housing 70 or 70 ″ may have openings, not shown to allow the movement of air into the channel 18 on one side of the piston and out of the channel 18 on the other side of the piston such as to impart movement to the piston as a result of pressure differential across the piston. The output of the energy conversion device can be configured to be direct or alternating current.
[0076] When used as a motor, electrical power, for example from power lines, solar, wind, or stored energy may be input to toroidal winding 60 or through toroidal winding 14 to cause vibration or reciprocal motion of piston 20 or 20 a and a reactionary motion of outer housing 70 or 70 ″. Mechanical power may be harnessed through a coupling to piston 20 or 20 a or alternatively through using or harnessing the reciprocal motion or' vibration of the outer housing 70 or 70 ″, which may occur in reaction to the motion of piston 20 or 20 a . When used as a pump or compressor, suitable valve passageways, not shown, may be provided to permit piston 20 or 20 a to pump air or another fluid or to compress a fluid.
[0077] An energy conversion device may be configured as a single stage having a single set of axial magnet 50 , a single set of toroidal windings 14 and 60 , a single radial magnetic source 12 , and a single piston 20 or 20 a , as described above. Alternatively, a compound energy conversion device, not illustrated, may have multiple stages, each with at least its own piston, which may operate in series, in parallel, or independently. When constructed with multiple stages, the individual stages may share components, such as outer or inner housings. The multiple stages may be axially aligned with each other such as, for example, by having multiple stages similar to energy conversion device 10 , 10 a , 10 ′ or 10 ″ extending sequentially along longitudinal axis 16 or by having one or more ring-type energy conversion devices 10 a disposed concentrically about a central energy conversion device 10 , 10 a , 10 ′ or 10 ″. Alternatively, multiple energy conversion devices may be connected electrically or mechanically in parallel or in series.
[0078] Refer now to FIG. 8 illustrating an alternative complex magnet 120 formed of a plurality of magnetic segments 122 a - 122 f enclosed in a ring 124 . Complex magnet 120 may be a radial neodymium ring magnet of the type sold by Engineered Concepts, 1836 Canyon Road, Vestavia Hills, Ala. 35216, owned by George Mizzell in Birmingham, Ala., and offered for sale under the name SuperMagnetMan, for example, as parts number RROU60N, RR0090N, or, RR0100S. Complex piston 120 may be used in any of the energy conversion devices 10 , 10 a , 10 ′ or 10 ″.
[0079] Applicants have determined experimentally that such magnets have the property of having an axial magnetic component such as to effective presenting a north pole on one face 126 and a south pole on an opposite face not shown while also having a radial component presenting a first pole, such as a north pole on first arcuate face 128 , and an opposite pole such as a south pole, on a second arcuate face surface 130 .
[0080] In particular, complex magnet 120 may be manufactured using multiple magnet sections 122 a - f which are created individually and then assembled into ring 124 . Ring 124 may be comprised of aluminum and have an outer cylindrical wall 132 and at least one annular wall 134 for engaging the magnetic sections Annular wall 134 may have a centrally located aperture 136 for use in mounting complex magnet to other components, such as a shaft, when required for some applications. When used with energy conversion device 10 a , shown in FIG. 1B , aperture 136 will be large enough to clear coil or winding 14 as well as radial magnetic source 12 , if a radial magnetic source is used.
[0081] For example, an acceptable complex piston has been manufactured using ten separate N42 diametric magnet segments. For some applications, a weaker complex piston may be suitable made from N40 or N32 segments, since it is easier to assemble using weaker magnet segments. It has been suggested experimentally that such variables as the gauss strength, strength and length of the piston 120 magnetic field, as well as the speed (oscillations) of the radial magnet be maximized. The addition of a second radial magnet also appears experimentally to be helpful. However, from experiments to date, it appears that the most important variables to maximize are the gauss strength and radial magnetic strength and therefore a piston made from N52 may be desirable,
[0082] It will be appreciated that the energy storage device described above may be acting in concert with and providing an input either primary or secondary, to an individually circuited system such as a residential home fuse panel fed by a commercial power grid or to a hydro, nuclear, wind, solar, wave, or any other type of electrical power generation grid such as used for private and/or public power consumption. The device may be a singular entity or multiple entities combined as units in series, parallel or independently to provide increased output. The device may be capable of acting in concert with an electrical device capable of calculating and regulating the input energy to the active toroid 60 such that the piston motion is maintained. The device may, acting in concert with an electrical device (e.g., an electronic control module capable of being programmed) be capable of calculating and regulating the input energy to the active toroid ( 60 ), reading input signals and generating output signals based on the input signals such that the piston motion is decelerated, stopped and reversed with minimum input energy to the active toroid.
[0083] A control algorithm may be provided capable of deriving piston deceleration and acceleration and calculating the required toroidal energy needed to accelerate the piston to its required velocity and generating a current and voltage input signal for the active toroid. The algorithm would minimally require input signals consisting of piston travel at three different positions, e.g., using Hall affect sensors, each sensed position being past the piston mid-travel point along the longitudinal axis toward a horizontal magnet, calculating the time between the three pulses to derive velocity and deceleration for two time periods, calculating the deceleration rate as a function of piston position, calculating the point at which the piston will stop, determining the force necessary to accelerate the piston to the desired initial velocity, calculating the required toroid force required generating a current command signal (for a fixed voltage) and measuring the acceleration as the piston travels in the opposite direction along its longitudinal axis and adjusting the toroidal power level to maintain the required piston target velocity by measuring the time required to travel between the three points.
[0084] The energy conversion device may be adapted, in concert with control algorithms, to minimize the input energy into the active toroid. The control algorithm may maintain the following relationship: F tin >F p −F Mh where F tin is the active toroid force in a direction opposite that of the piston force 20 proportional to input voltage and current, F p is the piston force, and F Mh is the force of the horizontal magnet opposing the piston force F p such that a piston traveling along its longitudinal axis is decelerated as it approaches a horizontal magnet (such as magnet 50 ), stops instantaneously and then is accelerated by the active toroid 60 , (see FIG. 1A ) at a predetermined, empirically developed rate by the applied force F tin , acting in concert with the repelling force of the horizontal magnet 50 , towards the upper horizontal magnet 44 .
[0085] Acting in concert with a stationary magnet or magnets 44 and 50 (as shown in FIG. 7 ) the longitudinal axis of this device, including these magnets, can be oriented from 0-90 degrees relative to a horizontal plane, displaced a finite distance from the vertical mid-point whose primary force fields are oriented 90 degrees from the radial magnets, said magnets located such that their fields interact with the radial magnets along the vertical axis of the radial magnets as shown in the exemplary device of FIGS. 1-7 . This magnet or magnets can be positioned either internal to the stationary radial magnets (as illustrated) or external to the stationary radial magnets, i.e., the magnet has a larger ID than the stationary radial magnet OD using a ring type magnet configuration.
[0086] It is to be understood that the above description is intended to be illustrative and not restrictive. Many configurations and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. For example, it will be appreciated that relative motion between the piston and the winding may be caused by any mechanical action such as wind, hydro (wave, current or vertical drop energy), or mechanical input from moving or bouncing objects. Alternatively, the energy conversion device may transmit power to a device or devices capable of utilizing the electrical output of the toroid without using intermediate storage. These devices include, but, are not limited to, electric motors, fuel cells, hydrolysis conversion devices, battery charging devices, lights, and heating elements. Alternatively, the piston may be directly displaced by a fluid acting directly on a face of the piston, such as moving air or water, a combustible fuel expanding against one face of the piston, or a fluid expanding or contracting in response to a temperature change.
[0087] Still another variation is providing the energy conversion device within a portable electronic device to directly provide power to the device or to charge a battery within the device. Such energy conversion devices may generate power from intentional or incidental movement of the device by a person carrying the portable electronic device or a vehicle in which the portable electronic device is carried, such as by shaking the device along the longitudinal axis of the energy conversion device. For such applications, the energy conversion device may be proportioned as a standard cylindrical battery, such as standard A, B or C batteries, and may further be provided with output and input features comparable to such batteries so that they may be substituted for such batteries or placed in series with such batteries in the portable electronic device. Alternatively, the energy storage device may be proportioned to substitute for two or more such batteries. Alternatively, a combination system of a rechargeable battery and an energy conversion may be incorporated into a self-recharging battery pack for installation in a portable electronic device. The self-recharging battery pack may be proportioned and fitted with appropriate electrical connectors to substitute for one or more conventional batteries. Such self-recharging battery packs may be provided with an indicator to indicate when the battery is charged or a control system to allow power to be drawn from the battery only when the battery is charged above a predetermined threshold.
[0088] Referring now to FIG. 9 , which schematically illustrates an example of a prior art automotive energy management system 212 using conventional mechanical shock absorbers 210 to isolate the load bearing portion of a vehicle, such as a passenger compartment, from the vibrations of the wheel and axle system experienced as the vehicle moves in a forward direction over an uneven road surface. As shown in FIG. 9 , prior art energy management systems 212 may include a spring 214 , such as a coil spring or a leaf spring, to further manage the vibration between suspension components 216 and 218 .
[0089] FIGS. 10 and 11 schematically illustrate a conventional mechanical shock absorber 210 with its internal components in an extended and compressed configuration, respectively. As illustrated, conventional mechanical shock absorber 210 typically has a rod 211 having a piston 213 on its extreme end reciprocally mounted in a cylinder 215 such that piston 213 sealingly engages an inner wall of cylinder 215 . A seal 217 is also provided between the free end of rod 211 and an end 225 of cylinder 215 receiving rod 211 . A floating piston 219 divides cylinder 215 into an oil reservoir 221 , in which piston 213 is free to oscillate along the longitudinal axis of cylinder 215 , and an air chamber 223 disposed remote from piston 213 . As seen by comparing FIG. 10 and FIG. 11 , the oil in reservoir 221 resists the motion of piston 215 in response to vibration input to shock absorber 210 , thereby absorbing some of the kinetic energy in the vibration. Floating piston 219 is free to move in response to the compression of oil in oil reservoir 221 as piston 213 is moved by rod 211 .
[0090] Referring to FIG. 12 , an electromagnetic shock absorber 250 may be placed in mechanical parallel with conventional mechanical shock absorber 210 to convert a portion of the kinetic energy of vibrations experienced by the shock absorbers 210 and 250 into electrical energy. As shown in FIG. 12 , electromagnetic shock absorber 250 may be configured to be of the same length and diameter as conventional mechanical shock absorber 210 and may be extended between the same components as conventional mechanical shock absorber 210 in adjacent mounting locations. Alternatively, as shown in FIG. 13 , electromagnetic shock absorber 250 may be configured differently than conventional mechanical shock absorber 210 and may be extended between different components of a suspension system or at mounting points experiencing a different amount of displacement than conventional technical shock absorber 210 . For some applications in particular, it may be desirable to intentionally use a leveraging system so that electromagnetic shock absorber 250 ′ and conventional mechanical shock absorber 210 experience different force levels in response to vibration to optimize their load absorbing or electrical energy generating characteristics.
[0091] Alternatively, as shown in FIG. 14 an electromagnetic shock absorber 250 ″ may be manufactured to the same dimensions as a conventional mechanical shock absorber and have shock absorbing components incorporated therein, as described in detail later herein. Electromechanical shock absorber 250 ″ may therefore be substituted for a conventional mechanical shock absorber in a suspension system since it offers the functionality of both types of shock absorbers.
[0092] Referring now generally to FIGS. 15-21 various exemplary electromagnetic shock absorbers 250 , 250 ′, 250 ″ and 250 a are illustrated and the general arrangement of the mechanical, magnetic and electromagnetic components of energy management system 300 will be described.
[0093] Referring generally to FIGS. 15-17 , schematically illustrating a generalized electromechanical shock absorber 250 , and more particularly to FIG. 15 , illustrating a section through shock absorber 250 , the arrangement of the magnetic and electromagnetic components will be described. In particular, electromechanical shock absorber 250 includes a cylinder 252 having an upper end wall 254 and a lower end wall 256 . A first rod 258 is fixed to the upper end 254 connectable to a first suitable mounting point on a suspension system. A second rod 260 , connectable to second suitable mounting point of a suspension system, is inserted through an aperture in the lower end wall 256 and is reciprocal relative to cylinder 252 .
[0094] A magnetic piston 264 is mounted to rod 260 within cylinder 252 and is constrained to oscillate within cylinder 252 in response to relative movement between the first and second mounting points of the suspension system. Magnetic piston 264 may be press fitted to rod 260 or secured thereto by other means, such as clips. Magnetic piston 264 may be a complex magnet having an axial magnetic component and a radial magnetic component, as illustrated and described in related U.S. patent application Ser. No. 61/171,641 and PCT patent application Serial No. PCT/US10/32,037 described above and incorporated by reference herein.
[0095] An optional pair of axial magnets 266 and 268 may be disposed within cylinder 252 adjacent walls 254 and 256 . Magnets 266 and 268 and magnetic piston 264 are oriented to present faces to each other of opposite polarity. Magnets 268 and 266 may be used to assist in the orientation of magnet piston 264 and to manage the oscillatory motion of magnet piston 264 .
[0096] A winding, such as a toroidal winding 270 , is provided within cylinder 252 , which may be protected from magnetic piston 264 by a cylindrical wall 272 . Magnetic piston 264 extends nearly to wall 272 . For some applications, it may be desirable for magnetic piston 264 to form a sliding seal with wall 272 . It will be appreciated that oscillatory motion of magnetic piston 264 within cylinder 252 will cause a current to flow in toroidal winding 270 , thus permitting the winding to convert the kinetic energy of vibrations in the suspension system to electrical energy which may be used by the vehicle. Conversely driving a current through toroidal winding 270 will impart a force on a magnetic piston 264 , causing relative motion between rods 258 and 260 , which may in turn deliver a force to the components of the suspension system to manage the oscillatory motion there between.
[0097] Electromechanical shock absorber 250 optionally includes another toroidal winding 274 disposed adjacent axial magnet 266 . Toroidal winding 274 may also be selectively energized to temporally exert a force on magnetic piston 264 to initiate or assist the oscillation of magnetic piston 264 . Wires 280 and 282 connected respectively to toroidal winding 270 and 274 extend from cylinder 252 to an external load 284 for the use of the current generated in winding 270 and connect toroidal windings 272 and 274 to an external source of power 286 and controller 288 for selectively powering the windings.
[0098] Cylinder 252 may be provided with apertures 285 for admission of air to cool the internal components and to regulate the buildup of air pressure on opposing sides of magnetic piston 264 .
[0099] Electromechanical shock absorber 250 may be configured to provide either alternating current or direct current output. Electrical load 284 may be one or more electrical devices capable of consuming the power, one or more storage devices used to store power for later use, or a power distribution system. Exemplary storage devices for electrical load 284 may include the vehicle main battery or a local battery for use by controller 288 and may therefore be the same component as power source 286 .
[0100] While power source 286 controller 288 , and electrical load 284 are schematically illustrated as independent of electromechanical shock absorber 250 , either or both may be integrated with an electromechanical shock absorber 250 a of FIGS. 14 and 19 as best shown in FIG. 20 and described below. In particular, one or both may alternatively be affixed to a cover 290 mounted over one end of cylinder 252 .
[0101] FIG. 18 schematically illustrates an alternative electromechanical shock absorber 250 b , in which the arrangement of the magnetic and electromagnetic components is similar to those described above, except that piston 264 a and axial magnets 266 a and 268 a are ring-shaped. In this arrangement, piston 264 a is disposed outside of the toroidal winding 270 a . Magnetic piston 264 a interacts with axial magnets 268 a and 266 a and toroidal winding 270 a according to the same principles as the similarly numbered components of the electromechanical shock absorber 250 of FIGS. 15 and 16 described above.
[0102] Still other configurations are possible. For example, FIG. 20 schematically illustrates an alternative electromechanical shock absorber 250 ′ in which a mechanical vibration absorbing system has been included. In particular, a fluid compartment 290 surrounded by wall 272 ′ resiliently flexes and absorbs some vibration in response to the pressure caused by the movement of piston 264 ′. FIG. 21 schematically illustrates another alternative electromechanical shock absorber 250 ″, in which a mechanical vibration absorbing system and a spring 294 has been included. In particular, a floating piston 292 engages wall 272 ″ and is displaceable in response to the pressure caused by the movement of piston 264 ″ to absorb some vibration between rods 258 and 260 ″. A spring 294 wound around the outside of cylinder 252 ″ and connected to rods 25811 and 260 ″ is provided in mechanical parallel arrangement with shock absorber 250 ″.
[0103] It should be noted that a plurality of toroidal windings may be provided. One or more passive toroidal windings may be provided to create an output current as a function of the motion of piston 264 , 264 ′ or 264 a . One or more active toroidal windings may also be provided to create a magnetic field opposing the magnetic field of piston 264 , 264 ′ or 264 ″ for selectively driving the piston when active oscillation management is desired. The passive toroidal winding may be significantly larger than the active toroidal winding. As described above, the energy created by piston 264 , 264 ′ or 264 a interacting with a passive toroidal winding may be transferred to and stored in an electrical storage device 284 , such as a battery or capacitor. An active toroidal winding may use the electrical energy previously created by the moving piston magnets interacting with the passive toroidal winding and subsequently stored in electrical storage device 284 . The toroidal windings may be wound about and supported by wall 272 or by a tube formed of a suitable non-conductive material such as plastic.
[0104] It will be appreciated that electromechanical shock absorbers 250 , 250 ′ and 250 ″ may be used in other applications such as non-vehicular applications, as a generator, a motor, a pump, a compressor, an engine, or an electrical power transformer. When used as a transformer, electrical power may be input to passive toroidal windings and electrical power may be output from active toroidal windings, when used as a generator, mechanical power may be input by reciprocally moving the rods relative to each other and electrical power may be output from a passive toroidal winding. The output of the energy conversion device can be configured to be direct or alternating current. The mechanical motion may be provided, for example, by any source that is capable of oscillating the shock absorber along its longitudinal axis. Alternatively, mechanical motion may be imparted to the magnetic piston by application of a current to an active winding. The mechanical motion may be used to drive a compressor or a pump. Alternatively, a compressor or pump may be incorporated into the shock absorber. For example, the magnetic piston may sealingly engage the sides of the cylindrical wall and the two ends of the housing may have openings, to allow the movement of air or a fluid pumped by the movement of the piston.
[0105] An electromechanical shock absorber may be configured as a single stage having a single set of axial magnets, a single set of toroidal windings, and a single piston as described above. Alternatively, a device may have multiple stages, each with at least its own piston, which may operate in series, in parallel, or independently. When constructed with multiple stages, the individual stages may share components, such as outer or inner housings. Alternatively, multiple energy conversion devices may be connected electrically or mechanically in parallel or in series.
[0106] For active implementation, a control algorithm may be provided capable of analyzing the vibration characteristics of the surface and applying a current to the winding to provide piston deceleration and acceleration to tune the response of the shock absorber 250 to the terrain. The system may be designed to self-adjust to changing road conditions.
[0107] Referring now generally to FIGS. 22-27 various exemplary marine versions of a kinetic energy management system similar one of the kinetic energy management systems described above are illustrated and the general arrangement of the mechanical, magnetic and electromagnetic components of kinetic energy management system 300 will be described.
[0108] Referring to FIG. 22 an exemplary kinetic energy management system 300 using a single electromagnetic shock absorber 250 is illustrated for attachment to a boat shock absorber 250 may be any of the exemplary shock absorbers described above. Kinetic energy management system 300 includes a frame structure including a shaft 302 having two or more wheels 304 for rolling engagement with the side of a boat, not shown in FIG. 22 . A frame member 306 is secured parallel to shaft 302 by two or more cross members 308 extending between shaft 302 and frame member 306 . Frame member 306 is attached to a top of a float such as a pontoon 310 . An electromagnetic shock absorber 250 is connected at one end to frame member 306 and extends upwardly there from for interconnection with the side of a boat, not shown in FIG. 22 .
[0109] Referring to FIGS. 23-26 , an exemplary kinetic energy management system 300 a using a multiple electromagnetic shock absorbers 250 is illustrated for attachment to a boat 312 (see FIGS. 25 and 26 ). Kinetic energy management systems 300 may be attached to a boat 312 in a manner similar to that described for kinetic energy management systems 300 a . The components of kinetic energy management system 300 a include shaft 302 , wheels 304 , frame member 306 , cross members 308 and pontoon 310 , similar in form and function to those described above for kinetic energy management system 300 , except that a plurality of electromagnetic shock absorbers 250 are each connected at one end to frame member 306 and extends upwardly there from for interconnection with the side of boat 312 .
[0110] The upper end of each shock absorber 250 may be connected to the side of boat 310 by a spherical rod joint 316 , as shown in FIG. 26 , or an equivalent structure. Shaft 302 may be similarly attached to the side of boat 312 by a spherical rod joint or an equivalent structure. An elastomeric travel limiter or jounce stop 314 may be provided at the upper end of each shock absorber 250 , as shown in FIG. 26 , and designed to maintain torques within limits to avoid bending of components. Cross members 308 may be pivotally attached to frame member 306 so that shaft 302 and cross members 308 form a pivoting control arm for controlling the placement of pontoon 310 relative to side of boat 312 . If desired, a third frame portion disposed at an angle above the pivoting control arm may be provided for additional securement to boat 312 . Cross members 308 may be adjustable in length to accommodate differently shaped boats. Exemplary kinetic energy management system 300 a may be installed so that shock absorbers 250 are generally perpendicular to the water, with the spherical rod joint assisting in fore-aft compliance.
[0111] Boat 312 may be provided with one or more kinetic energy management systems 300 or 300 a on each side of the boat. It will be appreciated that the kinetic, energy management systems 300 or 300 a on each side of the boat may generate electricity from wave action whether boat 312 is in motion or is resting at anchor or at a dock. Kinetic energy management systems 300 and 300 a also limit fore-aft motion of boat 312 (pitch) and side-to-side motion (roll) to provide stability to boat 312 due to the shape of pontoon 310 . In particular, long properly designed pontoons function as outriggers while minimizing drag. One or more windings in shock absorbers 250 may be selectively powered to contract the shock absorbers and thereby raise the pontoon 310 from the water when desired.
[0112] FIG. 27 illustrates yet another configuration for a kinetic energy management system wherein a cylinder 252 b of a shock absorber 250 b is fitted into a cavity 318 in a float 310 and affixed therein.
[0113] The above disclosure therefore provides a kinetic energy management system, the kinetic energy management system having a magnetic piston displaceable along a first longitudinal axis and a winding disposed about the first longitudinal axis to cyclically interact with the magnetic piston to induce an electrical current and voltage in the winding, thereby creating electrical energy. The system may have a plurality of said windings and plurality of magnetic pistons, each of said magnetic pistons cyclically imparting a magnetic field across one of said windings to contribute to the generation of electrical energy. The kinetic energy management system may have one of said magnet or said winding interconnected with a floatation component adapted for floating on the surface of a body of water and the other of and said magnet or winding interconnected with a boat whereby said kinetic energy management system may be used to manage the transverse vibration of the boat as it moves across the surface of the body of water. The flotation component may be a pontoon. Multiple shock absorbers may be mounted between the side of a boat and a pontoon. One or more kinetic management systems including a pontoon and a plurality of shock absorbers may be mounted on each side of a boat. The pontoons may be selectively raised from the water depending on conditions.
[0114] Features shown or described in association with one configuration may be added to or used alternatively in another configuration; including configurations described or illustrated in the provisional patent applications and the patent cooperation treaty patent application referred to in the above cross-reference to related applications. The scope of the device should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims; along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future configurations. In sum, it should be understood that the device is capable of modification and variation and is limited only by the following claims.
[0115] All terms are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a” and “the” should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.
[0116] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | A vehicle kinetic energy management system includes a first main body having a passive magnetic component movable therewith and a second main body movably attached to the first main body for reciprocal movement there between. The second main body includes an active magnetic component movable therewith and magnetically communicating with the passive magnetic component. One of the first and second main bodies being adapted for engagement with a vehicular component that experiences irregularities of a surface on which the vehicle travels, and the other main body engaging a load-bearing portion of the vehicle for which isolation from vibrations is desired. Interaction of the active and passive magnetic components in response to relative movement of the first and second main bodies translates between reciprocating kinetic energy associated with the vehicle motion over the surface irregularities and electrical energy associated with the active magnetic component. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates to vessels such as swimming pools and more particularly to support systems having buttresses for walls of above-ground swimming pools.
BACKGROUND OF THE INVENTION
[0002] The popularity of swimming pools, particularly in residential areas, continues to increase. This increased popularity is based at least in part on the availability of aesthetically appealing above-ground pools, whose durability permits cost-effective purchasing by consumers. Above-ground pools additionally are particularly useful in areas where substantial excavation is either impermissible or undesirable. In densely-populated regions, for example, residential lawns may not be sufficiently large to accommodate the space required for in-ground pools. Moreover, in some cases they may be inadequate to accommodate the equipment necessary to excavate in-ground pools, even if space for such pools exists. Alternatively, above-ground pools may be preferable because of the decreased time typically needed for installation (and, if necessary, removal) or the lesser maintenance requirements and costs often associated with them.
[0003] Many substantially-permanent above-ground pools are generally either circular or oval in shape, with each type comprising multiple vertical walls and a frame. Because of their strength, galvanized steel or other compositions are usually chosen as materials from which the walls are made. Nonetheless, water pressure present at and near the bottoms of filled pools often requires the walls of above-ground pools to be braced for reliable performance. This bracing requirement is particularly pertinent in connection with oval pools, whose elongated side walls are especially vulnerable to collapse from the outward pressure exerted by the water contained therein.
[0004] As a consequence of this vulnerability, existing oval above-ground pools are constructed with braces supporting the lower sections of their side walls. Each brace includes three pieces, denominated an “upright” portion, an “angled” portion, and a “connecting” portion. FIG. 1 illustrates such braces 10 of above-ground pool 14 , whose generally oval shape requires use of multiple vertical side walls 18 . As shown in FIG. 1, upright portion 22 extends upward from bottom 26 of side wall 18 , with connecting portion 28 being either at ground level or buried underground. An end of each of upright portion 22 and angled portion 30 connects to a respective end of connecting portion 28 , while the other end 34 of angled portion 30 attaches to upright portion 22 . The resulting structure resembles the outline of a right triangle, with angled portion 30 constituting the hypotenuse.
[0005] [0005]FIG. 1 details the protruding nature of braces 10 . Such braces 10 frequently extend outward several feet from side walls 18 on both sides of pool 14 , increasing the surface area of the lawn required for installing the pool. This increased surface area can cause difficulties in installing pools in areas subject to covenants or zoning regulations, as insufficient land may remain post-installation to meet setback and other legal or contractual requirements. Braces 10 may also inhibit lawn maintenance adjacent pool 14 and, to some, may detract from the aesthetic appeal of the pool itself. The three-piece structure of each brace 10 additionally increases its associated manufacturing and installing cost, while supporting less than the entire vertical height of a side wall 18 .
SUMMARY OF THE INVENTION
[0006] The present invention, by contrast, provides a support system intended to resolve these issues. Particularly suited for vessels such as elongated above-ground pools, the support system includes a set of, typically, one-piece buttresses adapted to support the entire vertical height of one or each of a series of side walls. The flared design of the buttress, furthermore, matches the support it provides the side wall to the outward water pressure present along its height for enhanced reliability, permitting use of fewer buttresses than the number of existing braces that would otherwise be necessary. The one-piece design of the buttress further eliminates some of the manufacturing and installation costs associated with existing braces, while its sleek appearance is more likely to please discerning observers.
[0007] The diminished footprint of the innovative buttress additionally reduces the surface area required for its corresponding pool. Setback and similar requirements thus pose fewer problems than with existing pools, permitting pools incorporating the present invention to be located in smaller (especially narrower) lawns. Consequently, more residential customers in densely-populated areas are able to situate these pools in the lawn space available to them, increasing the market for the pools beyond that existing today. Abolishing the open areas between the angled portions of current braces and the ground additionally avoids many of the difficulties associated with providing lawn care in those areas.
[0008] In some embodiments of the invention, each buttress is a unitary structure whose height approximates that of the side wall or walls of its associated pool. At least one surface of the buttress contacts the side wall along substantially its entire height, supporting the height of the wall continuously against the outward pressure exerted when the pool is filled with water. Because the buttress defined by these embodiments flares along its height it assumes, in side elevational view, the general form of a truncated, solid triangle. Embodiments of the buttress further comprise notched sections to retain the bottom rim of the pool—and therefore help retain the side walls—in place.
[0009] Additionally included in some support systems of the present invention may be elongated cross-members spanning the width of the pool. Often called “omegas”because of their cross-sectional appearance, the cross-members, when present, are buried so that only their upper surfaces are above the ground. Buttresses on each side of the pool may be bolted or otherwise attached to the upper surfaces to retain them in position relative to the ground. Protruding from the upper surface of a cross-member adjacent its ends are one or more tabs, which in use fit into slots in the bottom rim of the pool to maintain its position. The buttresses, side walls, bottom rim, and cross-members thus can interact to preserve the position and structure of the pool relative to the ground. Alternatively, the buttresses may extend below ground level and be bolted, interlocked, or otherwise connected or fitted to the cross-members.
[0010] It is therefore an object of the present invention to provide a system for supporting a vessel designed to be filled with water or similar fluid.
[0011] It is also an object of the present invention to provide a system including one or more buttresses for supporting the side wall or walls of an above-ground swimming pool.
[0012] It is a further object of the present invention to provide a system in which a buttress supports a wall of a pool substantially continuously along the height of the wall.
[0013] It is another object of the present invention to provide a system for supporting pool walls in which the supporting structures extend only minimally beyond the exteriors of the walls.
[0014] It is an additional object of the present invention to provide a system, including one or more buttresses, for supporting a vessel such as an above-ground pool, in which the buttresses comprise notched sections to retain the bottom rim of the pool in position.
[0015] It is yet another object of the present invention to provide a system for supporting an above-ground swimming pool in which buttresses, side walls, the bottom rim, and cross-members interact to maintain the position and structure of the pool relative to the ground.
[0016] Other objects, features, and advantages of the present invention will be apparent with reference to the drawings and remainder of the text of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a perspective view of an oval pool having an existing set of braces.
[0018] [0018]FIG. 2 is a perspective view of an oval pool utilizing a support system of the present invention.
[0019] [0019]FIG. 3 is a side elevational view of a portion of the pool and of a buttress of the support system of FIG. 2.
[0020] [0020]FIG. 4 is a top plan view of the buttress of FIG. 3.
[0021] [0021]FIG. 5 is a side elevational view of the buttress of FIG. 3 together with a surface of a cross-member of the support system of the present invention.
[0022] [0022]FIG. 6 is a perspective view of a portion of the cross-member of FIG. 5.
[0023] [0023]FIG. 7 is a (nominally) front elevational view of the buttress of FIG. 3 together with portions of the cross-member of FIG. 5 and the bottom rim of the pool of FIG. 2.
[0024] [0024]FIG. 8 is a perspective view of an alternative buttress of the present invention.
[0025] FIGS. 9 A-C are (nominally) front elevational views of yet alternative buttresses and cross-members for use as support systems of the present invention.
DETAILED DESCRIPTION
[0026] FIGS. 2 - 5 and 7 illustrate buttresses 38 of the present invention. As shown in FIG. 2, buttresses 38 may be used in connection with pool 14 ′ instead of braces 10 . Doing so can diminish significantly the surface area required for installation of pool 14 ′, permitting pool 14 ′ to be positioned in areas inadequate for placement of pool 14 . As noted earlier, setback and similar requirements additionally pose fewer problems for pool 14 ′ because of its smaller overall size.
[0027] [0027]FIGS. 2 and 3 detail typical locations of buttresses 38 in connection with pool 14 ′. Illustrated in FIG. 2 is a set of buttresses 38 spaced along side 42 of (generally) oval pool 14 ′. Although not shown in FIG. 2, a similar set of buttresses 38 may be spaced along opposite side 46 of pool 14 ′. Because pool 14 ′ is oval, sides 42 and 46 are elongated relative to ends 50 and 54 and subject to greater stresses caused by the pressure of water W within the pool 14 ′.
[0028] This pressure within pool 14 ′ additionally is greatest at bottom 26 of side wall 18 (adjacent ground G) and decreases toward the corresponding top 58 of the wall 18 . To support the entirety of height H of side wall 18 , the above-ground height of buttresses 38 may be substantially similar or identical to height H and, as shown in FIG. 3, most or all of their surfaces 62 A and 62 B (see FIGS. 4 and 7) may contact the side wall 18 . To match more closely the support provided side wall 18 to the pressure of water W as a function of height H, buttresses 38 additionally may be flared in depth as illustrated in FIGS. 2 and 3. Such flaring results in buttress 38 having its minimum depth D 1 at its top 66 and its maximum depth D 2 at its bottom 70 (also adjacent ground G), with the depth increasing substantially continuously between top 66 and bottom 70 . Buttress 38 thus resembles, in the side elevational view shown in FIG. 3, a right triangle.
[0029] Unlike brace 10 , however, buttress 38 of FIG. 3 has solid sides 74 A and 74 B, a solid face 78 , and is truncated at top 66 . Surfaces 62 A and 62 B, moreover, function as flanges of buttress 38 . The result is a unitary structure for buttress 38 that both provides greater and more uniform and continuous support for side wall 18 and has a sleeker profile than braces 10 . Furthermore, for some embodiments of buttress 38 , maximum depth D 2 does not exceed ten inches, an amount significantly less than the distance (typically thirty-six inches) from pool 14 that braces 10 protrude. Other dimensions of an exemplary buttress 38 include height between approximately forty-two and sixty inches, width of approximately four inches, and a minimum depth D 1 of approximately two to four inches. Buttress 38 is usually made of metal such as galvanized steel but may be manufactured of other materials when necessary or appropriate. The face 78 , sides 74 A and 74 B, and surfaces 62 A and 62 B of buttress 38 additionally need not be integrally formed, although so forming them may avoid reducing the strength of the overall structure. Surfaces 62 A and 62 B also need not necessarily be formed at substantially right angles to respective sides 74 A and 74 B as shown in FIG. 4.
[0030] [0030]FIG. 5 illustrates notched section 82 of buttress 38 . In use, buttress 38 may be connected (by bolts or other suitable means) to a cross-member 86 spanning the width of pool 14 ′. Such a cross-member 86 is shown in FIG. 6 and is buried in ground G so that only upper surface 90 is visible, and it is to this surface 90 that buttress 38 connects. Attaching buttress 38 to cross-member 86 in this manner thus retains the buttress 38 in position relative to ground G. Once buttress 38 is positioned, rim 94 (see FIG. 7) may be fitted into section 82 to assist in fixing its placement relative to the ground G. Slots of rim 94 additionally may receive tabs 98 protruding from upper surface 90 of cross-member 86 to complete its positioning. Side wall 18 may then be fitted into rim 94 in conventional fashion to retain it in place. Those skilled in the art will thus recognize that buttresses 38 , side wall 18 , rim 94 , and cross-members 86 of the present invention may be designed if desired to interact appropriately to preserve the position and structure of pool 14 ′ relative to the ground G.
[0031] Shown in FIG. 8 is an alternative buttress 38 ′. Unlike corresponding components of buttress 38 , face 78 ′ of buttress 38 ′ is curved, and surfaces 62 A′ and 62 B′ are formed at acute angles to respective sides 74 A′ and 74 B′. Buttress 38 ′ additionally extends beyond notched section 82 ′ to terminate at lower edge 102 , which in use is buried underground.
[0032] FIGS. 9 A-C detail alternate cross-members 106 A-C. Like upper surface 90 of cross-member 86 , upper surfaces 110 of cross-members 106 A-C are at or near the level of ground G. Similar to buttress 38 ′, furthermore, buttresses 114 A-C extend so that lower edges 118 A-C are buried underground. In the buttress 114 A of FIG. 9A, lower edges 118 A are bent to form flanges 122 , which include apertures in which bolts 126 or other fasteners may be placed. Horizontal sections 130 additionally include apertures for receiving bolts 126 , thereby permitting buttress 114 A to be fastened to cross-member 106 A. By connecting buttress 114 A to horizontal sections 130 rather than vertical sections 134 of cross-member 106 A, bolts 126 are subjected to reduced shear stresses optionally excavating ground G to pour a concrete or other base C beneath horizontal section 130 may enhance the ability of buttress 114 A to support a pool.
[0033] Cross-members 106 B and 106 C instead may include slots 138 or recessed segments 142 for receiving pins or tabs 146 of buttresses 114 B or 114 C. Such slots 138 or recesses formed by segments 142 effectively retain buttresses 114 B or 114 C in position relative to respective cross-members 106 B or 106 C by engaging, or interlocking with, tabs 146 below ground G. Although lower edge 118 B is flanged and lower edge 118 C is not, such edges 118 B-C may be interchanged as necessary or desired. In any case, the result is a relatively secure positioning of a buttress 38 ′, 114 A, 114 B, or 114 C vis-a-vis a cross-member 106 A, 106 B, or 106 C by connecting them underground.
[0034] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. | Support systems for vessels such as above-ground swimming pools are disclosed. Each system may include one or more buttresses adapted to support substantially the entire vertical height of the side wall or each of a series of side walls of the pool. The buttresses, which flare along their lengths, closely match the support they provide each side wall to the outward water pressure present-along its height for enhanced reliability. The diminished space required for installation of the disclosed buttresses reduces the surface area required for their associated pool. | 4 |
FIELD OF INVENTION
[0001] The present invention relates to the discovery of particular heterocyclic compounds, and further to particular salts of these heterocycles, possessing increased activity as mGluR5 antagonists. In addition, the present invention relates to therapeutic methods of use of these compounds for the treatment and prevention of various diseases and conditions.
BACKGROUND OF THE INVENTION
[0002] Unsaturated heterocylic compounds find a wide variety of uses. For example, compounds of this class find uses as modulators of physiological processes that are mediated by ligand-activated receptors. Receptors that are activated by ligands are located throughout the nervous, cardiac, renal, digestive and bronchial systems, among others. In the nervous system, for example, heterocyclic compounds are capable of functioning as agonists or antagonists of receptors for neurotransmitters, neurohormones and neuromodulators. Ligand-activated receptors have been identified in a wide variety of species, including humans, other mammals and vertebrates as well as in invertebrate species. Therefore, compounds of this class are also able to modulate receptor-mediated processes throughout phylogeny and find uses in a wide variety of applications, e.g., as pharmaceuticals, insecticides, fungicides and other uses.
[0003] Receptors activated by excitatory amino acids, such as the amino acid L-glutamic acid (glutamate), are a major excitatory neurotransmitter receptor class in the mammalian central nervous system. Anatomical, biochemical and electrophysiological analyses suggest that glutamatergic systems are involved in a broad array of neuronal processes, including fast excitatory synaptic transmission, regulation of neurotransmitter release, long-term potentiation, long-term depression, learning and memory, developmental synaptic plasticity, hypoxic-ischemic damage and neuronal cell death, epileptiform seizures, visual processing, as well as the pathogenesis of several neurodegenerative disorders. See generally, Nakanishi et al., Brain Research Reviews 26:230-235 (1998); Monaghan et al., Ann. Rev. Pharmacol. Toxicol. 29:365-402 (1980). This extensive repertoire of functions, especially those related to learning, neurotoxicity, and neuropathology, has stimulated recent attempts to describe and define the mechanisms through which glutamate exerts its effects.
[0004] Glutamate has been observed to mediate its effects through receptors that have been categorized into two main groups: ionotropic and metabotropic. Ionotropic glutamate receptors are generally divided into two classes: the N-methyl-D-aspartate (NMDA) and non-NMDA receptors. Both classes of receptors are linked to integral cation channels and share some amino acid sequence homology. GluR1-4 are termed AMPA (a-amino-3-hydroxy-5 methylisoxazole-4-propionic acid) receptors because AMPA preferentially activates receptors composed of these subunits, while GluRS-7 and KA1-2 are termed kainate receptors as these are preferentially sensitive to kainic acid. Thus, an “AMPA receptor” is a non-NMDA receptor that can be activated by AMPA. AMPA receptors include the GluR1-4 family, which form homo-oligomeric and hetero-oligomeric complexes which display different current-voltage relations and calcium permeability. Polypeptides encoded by GluR1-4 nucleic acid sequences can form functional ligand gated ion channels. An AMPA receptor includes a receptor having a GluR1, GluR2, GluR3 and/or GluR4 subunit. A NMDA receptor includes a receptor having NMDARI, NMDAR2a, NMDAR2b, NMDAR2c, NMDAR2d and/or NMDAR3 subunits.
[0005] Metabotropic glutamate receptors are divided into three groups based on amino acid sequence homology, transduction mechanism and pharmacological properties, namely Group I, Group II and Group III. Each Group of receptors contains one or more types of receptors. For example, Group I includes metabotropic glutamate receptors 1 and 5 (mGluR1 and mGluR5), Group II includes metabotropic glutamate receptors 2 and 3 (mGluR2 and mGluR3) and Group m includes metabotropic glutamate receptors 4, 6, 7 and 8 (mGluR4, mGluR6, mGluR7 and mGluR8). Several subtypes of a particular mGluR type may exist. For example, subtypes of mGluR1 include mGluR1a, mGluR1b, mGluR1c and mGluR1d.
[0006] Anatomical studies demonstrate a broad and selective distribution of metabotropic glutamate receptors in the mammalian nervous system. For example, mGluR1 is expressed in the cerebellum, olfactory bulb, hippocampus, lateral septum, thalamus, globus pallidus, entopeduncular nucleus, ventral pallidum and substantia nigra (Petralia et al., (1997) J. Chem. Neuroanat., 13:77-93; Shigemoto et al., (1992) J. Comp. Neurol., 322:121-135). In contrast, mGluR5 is weakly expressed in the cerebellum, while higher levels of expression are found in the striatum and cortex (Romano et al., (1995) J. Comp. Neurol., 355:455-469). In the hippocampus, mGluR5 appears widely distributed and is diffusely expressed.
[0007] Metabotropic glutamate receptors are typically characterized by seven putative transmembrane domains, preceded by a large putative extracellular amino-terminal domain and followed by a large putative intracelluar carboxy-terminal domain. The receptors couple to G-proteins and activate certain second messengers depending on the receptor group. Thus, for example, Group I mGluR's activate phospholipase C. Activation of the receptors results in the hydrolysis of membrane phosphatidylinositol (4,5)-bisphosphate to diacylglycerol, which activates protein kinase C, and inositol trisphosphate, which in turn activates the inositol trisphosphate receptor to promote the release of 20 intracellular calcium.
[0008] A wide variety of heterocyclic compounds having activity as mGluR5 antagonists have been described in our International Publication No. WO 01/16121 and related national phase applications such as 09/387,073 (abandoned) and 10/217,800, issued as U.S. Pat. No. 6,774,138, for modulating the activity of the mGluR5 receptor and for use in the treatment of mGluR5 mediated conditions. Because of the physiological and pathological significance of excitatory amino acid receptors generally, and metabotropic glutamate receptors in particular, there is a need to identify ever more effective methods of modulating excitatory amino acid receptor-mediated processes, as well as more effective therapeutic methods of treatment and methods for prevention of diseases. There is thus a continuing need in the art to identify new and increasingly potent members of a compound class that can modulate excitatory amino acid receptors.
SUMMARY OF THE INVENTION
[0009] The identification of a series of compounds which falls within the scope of the group of compounds described and claimed in WO 01/16121 and in U.S. Pat. No. 6,744,138 but which is not specifically disclosed therein, which series of compounds possesses special advantages in terms of drug-like properties. That is, the compounds described herein show increased potential for use as drugs due to their possessing uniquely advantageous properties in terms of potency and/or selectivity and/or pharmacokinetic properties and/or in vivo receptor occupancy properties. Specifically, it has been discovered that the selection of a 1,3-thiazol-2-yl ring moiety linked by an ethynylene to the 3 position of a pyridyl ring or the 5 position of a pyrimidinyl ring, wherein the ring is substituted with selected substituents, results in a compound with superior drug-like properties. The invention also discloses pharmaceutically acceptable salt forms of these heterocyclic compounds, in particular chloride salts and trifluoroacetate salts.
[0010] The inventive compounds are useful for a wide variety of applications. For example these compounds can act to modulate physiological processes by functioning as antagonists of glutamate receptors in the nervous system. The inventive compounds may also act as insecticides and as fungicides. Pharmaceutical compositions containing invention compounds also have wide utility.
[0011] In accordance with the present invention, there are also provided methods of modulating the activity of excitatory amino acid receptors using a specifically defined class of heterocyclic compounds. In one embodiment, there are provided methods of modulating metabotropic glutamate receptors. The present invention also provides methods of treating disease using heterocyclic compounds. Diseases contemplated include cerebral ischemia, chronic neurodegeneration, psychiatric disorders, schizophrenia, mood disorders, emotion disorders, disorders of extrapyramidal motor function, obesity, disorders of respiration, motor control and function, attention deficit disorders, concentration disorders, pain disorders, neurodegenerative disorders, epilepsy, convulsive disorders, eating disorders, sleep disorders, sexual disorders, circadian disorders, drug withdrawal, drug addiction, compulsive disorders, anxiety, panic disorders, depressive disorders, skin disorders, retinal ischemia, retinal degeneration, glaucoma, disorders associated with organ transplantation, asthma, ischemia and astrocytomas. The invention further discloses methods of preventing disease conditions related to diseases of the pulmonary system, diseases of the nervous system, diseases of the cardiovascular system, mental retardation (including mental retardation related to Fragile X syndrome), diseases of the gastrointestinal system such as gastroesophageal reflux disease and irritable bowel syndrome, diseases of the endocrine system, diseases of the exocrine system, diseases of the skin, cancer and diseases of the ophthalmic system.
DETAILED DESCRIPTION OF THE INVENTION
[0012] In accordance with the present invention, there are provided compounds of the formula:
[0000]
[0000] wherein X is H and Y is selected from:
[0000]
[0000] or wherein Y is H and X is selected from:
[0000]
[0000] where said compound does not comprise radioisotopes, and pharmaceutically acceptable salts thereof.
[0013] Also in accordance with the present invention, there are provided compounds of the formula:
[0000]
[0000] wherein Y is selected from:
[0000]
[0000] where said compound does not comprise radioisotopes, and pharmaceutically acceptable salts thereof.
[0014] As employed herein, “alkyl” refers to straight or branched chain alkyl radicals having in the range of about 1 up to 12 carbon atoms; “substituted alkyl” refers to alkyl radicals further bearing one or more substituents such as hydroxy, alkoxy, mercapto, aryl, heterocycle, halogen, trifluoromethyl, pentafluoroethyl, cyano, cyanomethyl, nitro, amino, amide, amidine, amido, carboxyl, carboxamide, carbamate, ester, sulfonyl, sulfonamide, and the like.
[0015] As employed herein, “halogen” refers to fluoride, chloride, bromide or iodide radicals.
[0016] Those of skill in the art recognize that invention compounds may contain one or more chiral centers, and thus can exist as racemic mixtures. For many applications, it is preferred to carry out stereoselective syntheses and/or to subject the reaction product to appropriate purification steps so as to produce substantially optically pure materials. Suitable stereoselective synthetic procedures for producing optically pure materials are well known in the art, as are procedures for purifying racemic mixtures into optically pure fractions. Those of skill in the art will further recognize that invention compounds may exist in polymorphic forms wherein a compound is capable of crystallizing in different forms. Suitable methods for identifying and separating polymorphisms are known in the art.
[0017] In accordance with another embodiment of the present invention, there are provided pharmaceutical compositions comprising heterocyclic compounds as described above, in combination with pharmaceutically acceptable carriers. Optionally, invention compounds can be converted into non-toxic acid addition salts, depending on the substituents thereon. Thus, the above-described compounds (optionally in combination with pharmaceutically acceptable carriers) can be used in the manufacture of medicaments useful for the treatment of a variety of indications.
[0018] Pharmaceutically acceptable carriers contemplated for use in the practice of the present invention include carriers suitable for oral, sublingual intravenous, subcutaneous, transcutaneous, intramuscular, intracutaneous, intrathecal, epidural, intraoccular, intracranial, inhalation, rectal, vaginal, and the like administration. Administration in the form of creams, lotions, tablets, capsules, pellets, dispersible powders, granules, suppositories, syrups, elixirs, lozenges, injectable solutions, sterile aqueous or non aqueous solutions, suspensions or emulsions, patches, and the like, is contemplated. Pharmaceutically acceptable carriers include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, dextrans, and the like.
[0019] Invention compounds can optionally be converted into non-toxic acid addition salts. Such salts are generally prepared by reacting the compounds of this invention with a suitable organic or inorganic acid Representative salts include hydrochloride, hydrobromide, sulfate, bisulfate, methanesulfonate, acetate, oxalate, adipate, alginate, aspartate, valerate, oleate, laurate, borate, benzoate, lactate, phosphate, toluenesulfonate (tosylate), citrate, inalate, maleate, fumarate, succinate, tartrate, napsylate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, benzenesulfonate, butyrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, glucoheptanoate, glycerophosphate, heptanoate, hexanoate, undecanoate, 2-hydroxyethanesulfonate, ethanesulfonate, and the like. Salts can also be formed with inorganic acids such as sulfate, bisulfate, hemisulfate, hydrochloride, chlorate, perchlorate, hydrobromide, hydroiodide, and the like. Examples of a base salt include ammonium salts; alkali metal salts such as sodium salts, potassium salts, and the like; alkaline earth metal salts such as calcium salts, magnesium salts, and the like; salts with organic bases such as dicyclohexylamine salts, N-methyl-D-glucamine, phenylethylamine, and the like; and salts with amino acids such as arginine, lysine, and the like. Such salts can readily be prepared employing methods well known in the art.
[0020] In accordance with another embodiment of the present invention, there are provided methods of modulating the activity of excitatory amino acid receptors, said method comprising contacting said receptors with at least one compound as described above. Thus, compounds contemplated for use in accordance with invention modulations methods include those having the structure A-L 1 -B-L 2 -Z (as described above and herein) or enantiomers, diastereomeric isomers or mixtures of any two or more thereof, or pharmaceutically acceptable salts thereof, in an amount sufficient to modulate the activity of said excitatory amino acid receptor.
[0021] As employed herein, “excitatory amino acid receptors” refers to a class of cell-surface receptors which are the major class of excitatory neurotransmitter receptors in the central nervous system. In addition, receptors of this class also mediate inhibitory responses. Excitatory amino acid receptors are membrane spanning proteins that mediate the stimulatory actions of the amino acid glutamate and possibly other endogenous acidic amino acids. Excitatory amino acids are crucial for fast and slow neurotransmission and they have been implicated in a variety of diseases including Alzheimer's disease, stroke, schizophrenia, head trauma, epilepsy, and the like. In addition, excitatory amino acids are integral to the processes of long-term potentiation and depression which are synaptic mechanisms underlying learning and memory. There are three main subtypes of excitatory amino acid receptors: (1) the metabotropic receptors; (2) the ionotropic NMDA receptors; and (3) the non-NMDA receptors, which include the AMPA receptors and kainate receptors.
[0022] As employed herein, the phrase “modulating the activity of refers to altered levels of activity so that the activity is different with the use of the invention method when compared to the activity without the use of the invention method. Modulating the activity of excitatory amino acid receptors includes the suppression or augmentation of the activity of receptors. Suppression of receptor activity may be accomplished by a variety of means, including blocking of a ligand binding site, biochemical and/or physico-chemical modification of a ligand binding site, binding of agonist recognition domains, preventing ligand-activated conformational changes in the receptor, preventing the activated receptor from stimulating second messengers such as G-proteins, and the like. Augmentation of receptor activity may be accomplished by a variety of means including, stabilization of a ligand binding site, biochemical and/or physico-chemical modification of a ligand binding site, binding of agonist recognition domains, promoting ligand-activated conformational changes in the receptor, and the like.
[0023] Excitatory amino acid receptor activity can be involved in numerous disease states. Therefore modulating the activity of receptors also refers to a variety of therapeutic applications, such as the treatment of cerebral ischemia, chronic neurodegeneration, psychiatric disorders, schizophrenia, mood disorders, emotion disorders, disorders of extrapyramidal motor function, obesity, disorders of respiration, motor control and function, attention deficit disorders, concentration disorders, pain disorders, neurodegenerative disorders, epilepsy, convulsive disorders, eating disorders, sleep disorders, sexual disorders, circadian disorders, drug withdrawal, drug addiction, compulsive disorders, anxiety, panic disorders, depressive disorders, skin disorders, retinal ischemia, retinal degeneration, glaucoma, disorders associated with organ transplantation, asthma, ischemia or astroytomas, and the like.
[0024] The compounds contemplated for use in accordance with of invention modulatory methods are especially useful for the treatment of mood disorders such as anxiety, depression, psychosis, drug withdrawal, tobacco withdrawal, memory loss, cognitive impairment, dementia, Alzheimer's disease, and the like; disorders of extrapyramidal motor function such as Parkinson's disease, progressive supramuscular palsy, Huntington's disease, Gilles de la Tourette syndrome, tardive dyskinesia, and the like.
[0025] Compounds contemplated for use in accordance with the invention are also especially useful for the treatment of pain disorders such as neuropathic pain, chronic pain, acute pain, painful diabetic neuropathy, post-herpetic neuralgia, cancer-associated pain, pain associated with chemotherapy, pain associated with spinal cord injury, pain associated with multiple sclerosis, causalgia and reflex sympathetic dystrophy, phantom pain, post-stroke (central) pain, pain associated with HIV or AIDS, trigeminal neuralgia, lower back pain, myofacial disorders, migraine, osteoarthritic pain, postoperative pain, dental pain, post-burn pain, pain associated with systemic lupus, entrapment neuropathies, painful polyneuropathies, ocular pain, pain associated with inflammation, pain due to tissue injury, and the like.
[0026] Moreover, compounds contemplated for use in accordance with the invention are especially useful for the treatment of cerebral ischemia, chronic neurodegeneration, psychiatric disorders, schizophrenia, mood disorders, emotion disorders, disorders of extrapyramidal motor function, obesity, disorders of respiration, motor control and function, attention deficit disorders, concentration disorders, pain disorders, neurodegenerative disorders, epilepsy, convulsive disorders, eating disorders, sleep disorders, sexual disorders, circadian disorders, drug withdrawal, drug addiction, compulsive disorders, anxiety, panic disorders, depressive disorders, skin disorders, retinal ischemia, retinal degeneration, glaucoma, disorders associated with organ transplantation, asthma, ischemia and astrocytomas. The invention further discloses methods of preventing disease conditions related to diseases of the pulmonary system, diseases of the nervous system, diseases of the cardiovascular system, mental retardation (including mental retardation related to Fragile X syndrome), diseases of the gastrointestinal system such as gastroesophageal reflux disease and irritable bowel syndrome, diseases of the endocrine system, diseases of the exocrine system, diseases of the skin, cancer and diseases of the ophthalmic system.
[0027] “Contacting” may include contacting in solution or in solid phase.
[0028] “Pharmaceutically acceptable salt” refers to a salt of the compound used for treatment which possesses the desired pharmacological activity and which is physiologically suitable. The salt can be formed with organic acids such as acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, heptanoate, hexanoate, 2-hydroxyethanesulfonate, lactate, malate, maleate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, oxalate, tartrate, toluenesulfonate, undecanoate, and the like. The salt can also be firmed with inorganic acids such as sulfate, bisulfate, chlorate, perchlorate, hemisulfate, hydrochloride, hydrobromide, hydroiodide, and the like. In addition, the salt can be formed with a base salt, including 22 ammonium salts, alkali metal salts such as sodium salts, potassium salts, and the like; alkaline earth metal salts such as calcium salts, magnesium salts, and the like; salts with organic bases such as dicyclohexylamine salts, N-methyl-D-glucamine, phenylethylamine, and the like; and salts with amino acids such as arginine, lysine, and the like.
[0029] Salt forms of compounds herein find several advantages. Certain pharmaceutically acceptable salt forms of heterocyclic compounds described herein, achieve higher solubility as compared with nonsalt forms. In addition, certain salt forms are more compatible with pharmaceutical uses. For example, the hydrochloric acid salt of 2-(phenylethynl)-1,3-thiazole is an oil while the toluene sulfonic acid salt form of 2-(phenylethynl)-1,3-thiazole is a solid that is soluble in aqueous medium. Characteristics of salt forms of compounds depend on the characteristics of the compound so treated, and on the particular salt employed.
[0030] In accordance with another embodiment of the invention, there are provided methods of modulating the activity of metabotropic glutamate receptors, said method comprising contacting metabotropic glutamate receptors with a concentration of a heterocylic compound as described above in accordance with invention methods for modulating the activity of excitatory amino acid receptors, sufficient to modulate the activity of said metabotropic glutamate receptors.
[0031] As used herein, the phrase “metabotropic glutamate receptor” refers to a class of cell-surface receptors which participates in the G-protein-coupled response of cells to glutamatergic ligands. Three groups of metabotropic glutamate receptors, identified on the basis of amino acid sequence homology, transduction mechanism and binding selectivity are presently known and each group contains one or more types of receptors. For example, Group I includes metabotropic glutamate receptors 1 and 5 (mIGluR1 and mGluRS), Group II includes metabotropic glutamate receptors 2 and 3 (mGluR2 and mGluR3) and Group III includes metabotropic glutamate receptors 4, 6, 7 and 8 (mGluR4, mGluR6, mGluR7 and mGluR8). Several subtypes of each mGluR type may be found; for example, subtypes of mGluR1 include mGluR1a, mGluR1b and mGluR1c.
[0032] In accordance with another embodiment of the invention, there are provided methods of treating a wide variety of disease conditions, said method comprising administering to a patient having a disease condition a therapeutically effective amount of at least one of the heterocyclic compounds described above in accordance with invention methods for modulating the activity of excitatorγ amino acid receptors.
[0033] As used herein, “treating” refers to inhibiting or arresting the development of a disease, disorder or condition and/or causing the reduction, remission, or regression of a disease, disorder or condition. Those of skill in the art will understand that various methodologies and assays may be used to assess the development of a disease, disorder or condition, and similarly, various methodologies and assays may be used to assess the reduction, remission or regression of a disease, disorder or condition.
[0034] Disease conditions contemplated for treatment in accordance with the invention include cerebral ischemia, chronic neurodegeneration, psychiatric disorders, schizophrenia, mood disorders, emotion disorders, disorders of extrapyramidal motor function, obesity, disorders of respiration, motor control and function, attention deficit disorders, concentration disorders, pain disorders, neurodegenerative disorders, epilepsy, convulsive disorders, eating disorders, sleep disorders, sexual disorders, circadian disorders, drug withdrawal, drug addiction, compulsive disorders, anxiety, panic disorders, depressive disorders, skin disorders, retinal ischemia, retinal degeneration, glaucoma, disorders associated with organ transplantation, asthma, ischemia, astrocytomas, and the like.
[0035] Disease conditions contemplated for treatment in accordance with the present invention further include diseases of the pulmonary system, diseases of the nervous system, diseases of the cardiovascular system, diseases of the gastrointestinal system, diseases of the endocrine system, diseases of the exocrine system, diseases of the skin, cancer, diseases of the ophthalmic system, and the like.
[0036] As used herein, “administering” refers to means for providing heterocyclic compounds and/or salts thereof, as described herein, to a patient; using oral, sublingual intravenous, subcutaneous, transcutaneotis, intramuscular, intracutaneous, intrathecal, epidural, intraoccular, intracranial, inhalation, rectal, vaginal, and the like administration. Administration in the form of creams, lotions, tablets, capsules, pellets, dispersible powders, granules, suppositories, syrups, elixirs, lozenges, injectable solutions, sterile aqueous or non-aqueous solutions, suspensions or emulsions, patches, and the like, is also contemplated. The active ingredients may be compounded with non-toxic, pharmaceutically acceptable carriers including, glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, dextrans, and the like.
[0037] For purposes of oral administration, tablets, capsules, troches, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups, elixirs and lozenges containing various excipients such as calcium carbonate, lactose, calcium phosphate, sodium phosphate, and the like may be employed along with various granulating and disintegrating agents such as corn starch, potato starch, alginic acid, and the like, together with binding agents such as gum tragacanth, corn starch, gelatin, acacia, and the like. Lubricating agents such as magnesium stearate, stearic acid, talc, and the like may also be added. Preparations intended for oral use may be prepared according to any methods known to the art for the manufacture of pharmaceutical preparations and such preparations may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, saccharin, and the lake, flavoring agents such as peppermint, oil of wintergreen, and the like, coloring agents and preserving agents in order to provide pharmaceutically palatable preparations.
[0038] Preparations for oral use may also contain suitable carriers include emulsions, solutions, suspensions, syrups, and the like, optionally containing additives such as wetting agents, emulsifying and suspending 24 agents, sweetening, flavoring and perfuming agents, and the like. Tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period of time.
[0039] For the preparation of fluids for parenteral administration, suitable carriers include sterile aqueous or non-aqueous solutions, suspensions, or emulsions. For parenteral administration, solutions for the practice of the invention may comprise sterile aqueous saline solutions, or the corresponding water soluble pharmaceutically acceptable metal salts, as previously described. For parenteral administration, solutions of the compounds used in the practice of the invention may also comprise non-aqueous solutions, suspensions, emulsions, and the like. Examples of non-aqueous solvents or vehicles are propylene glycol, polyethylene glycol, vegetable oils, such as olive oil and corn oil, gelatin, and injectable organic esters such as ethyl oleate. Such dosage forms may also contain adjuvants such as preserving, wetting, emulsifying, and dispersing agents. They may be sterilized, for example, by filtration through a bacteria-retaining filter, by incorporating sterilizing agents into the compositions, by irradiating the compositions, or by heating the compositions. They can also be manufactured in the form of sterile water, or some other sterile injectable medium immediately before use.
[0040] Aqueous solutions may also be suitable for intravenous, intramuscular, intrathecal, subcutaneous, and intraperitoneal injection. The sterile aqueous media employed are all readily obtainable by standard techniques well known to those skilled in the art. They may be sterilized, for example, by filtration through a bacteria-retaining filter, by incorporating sterilizing agents into the compositions, by irradiating the compositions, by heating the compositions, and the like. They can also be manufactured in the form of sterile water, or some other sterile medium capable of injection immediately before use.
[0041] Compounds contemplated for use in accordance with the present invention may also be administered in the form of suppositories for rectal or vaginal administration. These compositions may be prepared by mixing the drug with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, and the like, such materials being solid at ambient temperatures but liquefy and/or dissolve in internal cavities to release the drug.
[0042] The preferred therapeutic compositions for inocula and dosage will vary with the clinical indication. Some variation in dosage will necessarily occur depending upon the condition of the patient being treated, and the physician will, in any event, determine the appropriate dose for the individual patient. The effective amount of compound per unit dose depends, among other things, on the body weight, physiology, and chosen inoculation regimen. A unit dose of compound refers to the weight of compound without the weight of carrier (when carrier is used).
[0043] The route of delivery of compounds and compositions used for the practice of the invention is determined by the disease and the site where treatment is required. Since the pharmacokinetics and pharmacodynamics of compounds and compositions described herein will vary somewhat, the most preferred method for achieving a therapeutic concentration in a tissue is to gradually escalate the dosage and monitor the clinical effects. The initial dose, for such an escalating dosage regimen of therapy, will depend upon the route of administration.
[0044] In accordance with invention methods, the medicinal preparation can be introduced parenterally, by dermal application, and the like, in any medicinal form or composition. It is used as a solitary agent of medication or in combination with other medicinal preparations. Single and multiple therapeutic dosage regimens may prove useful in therapeutic protocols.
[0045] As employed herein, the phrase “a therapeutically effective amount”, when used in reference to invention methods employing heterocyclic compounds and pharmaceutically acceptable salts thereof, refers to a dose of compound sufficient to provide circulating concentrations high enough to impart a beneficial effect on the recipient thereof. The specific therapeutically effective dose level for any particular patient will depend upon a variety of factors including the disorder being treated, the severity of the disorder, the activity of the specific compound used, the route of administration, the rate of clearance of the specific compound, the duration of treatment, the drugs used in combination or coincident with the specific compound, —the age, body weight, sex, diet and general health of the patient, and like factors well known in the medical arts and sciences. Dosage levels typically fall in the range of about 0.001 up to 100 mg/kg/day; with levels in the range of about 0.05 up to 10 mg/kg/day being preferred.
[0046] In still another embodiment of the invention, there are provided methods for preventing disease conditions in a subject at risk thereof, said method comprising administering to said subject a therapeutically effective amount of at least one of the heterocyclic compounds described above in accordance with invention methods for modulating the activity of excitatory amino acid receptors.
[0047] As used herein, the phrase “preventing disease conditions” refers to preventing a disease, disorder or condition from occurring in a subject who may be at risk for the disease, but has not yet been diagnosed as having the disease. Those of skill in the art will understand that a variety of methods may be used to determine a subject at risk for a disease, and that whether a subject is at risk for a disease will depend on a variety of factors known to those of skill in the art, including genetic make-up of the subject, age, body weight, sex, diet, general health, occupation, exposure to environmental conditions, marital status, and the like, of the subject.
[0048] Those of skill in the art can readily identify a variety of assays that can be used to assess the activity of excitatory amino acid receptors. For receptor species that activate a second messenger pathway, assays that measure receptor-activated changes in intracellular second messengers can be employed to monitor receptor activity. For example, inhibition of G-protein-coupled metabotropic glutamate receptors using a radioligand binding assay. (See Example 109.)
[0049] Similarly, activation of excitatory amino acid receptors that leads to the release of intracellular calcium or changes in intracellular calcium concentration can also be used to assess excitatory amino acid receptor activity. Methods of detection of transient increases in intracellular calcium concentration are well known in the art. (See e.g., Ito et al., J. Neurochem. 56:531-540 (1991) and Example 108). G-protein coupled receptors are also coupled to other second messenger systems such as phosphatidylinositol hydrolysis (see, e.g., Berridge et al, (1982) Biochem. J. 206: 587-5950; and Nakajima et al., J. Biol. Chem. 267:2437-2442 (1992) and Example 110).
[0050] The following examples are intended to illustrate but not to limit the invention in any manner, shape, or form, either explicitly or implicitly. While they are typical of those that might be used, other procedures, methodologies, or techniques known to those skill in the art may alternatively be used.
Intermediate 1
2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0051]
[0052] 2-Chloro-5-iodopyridine (40 mmol, 10.0 g), 2-methyl-4-[(trimethylsilyl)ethynyl]-1,3-thiazole (40 mmol, 7.8 g), dichlorobis(triphenylphosphine)palladium(II) (2 mmol, 1.4 g), copper(I) iodide (4 mmol, 760 mg) and triethylamine (200 mmol, 28 mL) were added to deoxygenated DMF (200 mL) at room temperature. The reaction was then warmed to 60° C. and tetrabutylammonium fluoride (40 mmol, 40 mL of 1.0 M solution in THF) was added dropwise via syringe. Stirring continued for 2.5 hrs and the reaction contents were then poured in to a separatory funnel and partitioned with 1:1 hexanes:EtOAc (1000 mL) and water (500 mL). The organic layer was then washed with 5 portions of 5% NaCl (250 mL each). The combined aqueous layers were back-extracted with 1:1 hexanes:EtOAc (500 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with 1:1 EtOAc:hexanes to afford 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine as a tan solid. 1 H-NMR (CDCl 3 , 300 MHz) δ 8.57 (s, 1H), 7.77 (d, 1H), 7.45 (s, 1H), 7.32 (d, 1H), 2.75 (s, 3H). MS (ESI) 235.2 (M+H + ).
Intermediate 2
2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0053]
[0054] 2-Chloro-5-bromopyrimidine (5.0 g, 26 mmol), 2-methyl-4-ethynyl-1,3-thiazole (3.2 g, 26 mmol), tetrakis(triphenylphosphine)palladium(0) (0.6 g, 0.5 mmol), copper(I) iodide (0.1 g, 0.5 mmol) and triethylamine (13 g, 130 mmol) were added to deoxygenated toluene (50 mL) at room temperature. The reaction was then warmed to 60° C. Stirring continued for 2.5 hrs and the reaction contents were then poured in to a separatory funnel and partitioned with EtOAc (100 mL) and water (100 mL). The organic layer was then washed with water twice (250 mL each). The organic layer were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with 1:1 EtOAc:hexanes to afford 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine as a tan solid. 1 H-NMR (CDCl 3 , 300 MHz) δ 8.78 (s, 2H), 7.52 (s, 1H), 2.78 (s, 3H).
Example 1
3-fluoro-5-{5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridin-2-yl}benzonitrile
[0055]
Step 1: 3-fluoro-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)benzonitrile
[0056]
[0057] 3-Bromo-5-fluorobenzonitrile (30.0 mmol, 9.23 g), bis(pinacolato)diboron (30.0 mmol, 7.62 g), PdCl 2 (dppf) 2 (1:1 complex with dichloromethane, 1.2 mmol, 980 mg), and potassium acetate (105 mmol, 10.3 g) were combined in deoxygenated dioxane (150 mL) and heated at 80° C. for 4 hrs, at which time the reaction was determined to be complete by GC/MS analysis. The reaction was cooled to room temperature, and poured in to a separatory funnel containing EtOAc (300 mL) and water (200 mL). The aqueous layer was back extracted with EtOAc (75 mL), and the combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was carried on to the next step with out further purification or characterization.
Step 2: 3-fluoro-5-{5-[(2-methyl-3-thiazol-4-yl)ethynyl]pyridin-2-yl}benzonitrile
[0058]
[0059] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (30 mmol, 7.02 g) and 3-fluoro-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)benzonitrile (30 mmol, crude material, above procedure), dichlorobis(triphenylphosphine)palladium(II) (1.5 mmol, 1.05 g), and potassium carbonate (120 mmol, 16.6 g) were added to deoxygenated DME:water (1:1, 300 mL) at room temperature. The reaction was warmed to 80° C. and stirred overnight under nitrogen, then partitioned in a separatoly funnel with EtOAc (500 mL) and water (300 mL). The organic layer was washed with one additional portion of water (100 mL) and the combined aqueous layers back extracted with EtOAc (100 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with 30% EtOAc in hexanes, to afford the title compound as a tan solid. 1 H-NMR (CDCl 3 , 500 MHz) δ 8.89 (m, 1H), 8.17 (dd, 1H), 8.04 (m, 1H), 7.98 (dd, 1H), 7.75 (d, 1H), 7.50 (s, 1H), 7.42 (m, 1H), 2.79 (s, 3H). MS (ESI) 320.0 (M+H + ).
[0060] 3-fluoro-5-{5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridin-2-yl}benzonitrile was dissolved in methylene chloride and an equal molar amount of HCl in ether was added dropwise. The solvent was evaporated in vaccuo to yield an off white solid. MS (ESI) 320.0 (M+H + ).
Example 2
2-(2-fluorophenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0061]
[0062] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (0.43 mmol, 100 mg), 2-fluorophenylboronic acid (0.47 mmol, 66 mg), dichlorobis(triphenylphosphine)palladium(II) (0.03 mmol, 18 mg), and potassium carbonate (1.72 mmol, 238 mg) were added to deoxygenated DME:water (1:1, 3 mL) at room temperature. The reaction was heated for 5 min at 150° C. via microwave irradiation, then partitioned in a separatory funnel with EtOAc (100 mL) and water (30 mL). The organic layer was washed with one additional portion of water (20 mL) and the combined aqueous layers back extracted with EtOAc (50 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with a 10 to 40% EtOAc gradient in hexanes, to afford the title compound as a tan solid, which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. 1 H-NMR (CD 3 OD, 500 MHz) δ 9.13 (s, 1H), 8.69 (d, 1H), 8.30 (d, 1H), 7.98 (s, 1H), 7.84 (dd, 1H), 7.70 (m, 1H), 7.42-7.53 (m, 2H), 2.83 (s, 3H). MS (ESI) 295.13 (M+H + ).
Example 3
2-(3-fluorophenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0063]
[0064] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (0.43 mmol, 100 mg), 3-fluorophenylboronic acid (0.47 mmol, 66 mg), dichlorobis(triphenylphosphine)palladium(II) (0.03 mmol, 18 mg), and potassium carbonate (1.72 mmol, 238 mg) were added to deoxygenated DME:water (1:1, 3 mL) at room temperature. The reaction was heated for 5 min at 150° C. via microwave irradiation, then partitioned in a separatory funnel with EtOAc (100 mL) and water (30 mL). The organic layer was washed with one additional portion of water (20 mL) and the combined aqueous layers back extracted with EtOAc (50 μL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with a 10 to 40% EtOAc gradient in hexanes, to afford the title compound as a tan solid, which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. 1 H-NMR (CD 3 OD, 500 MHz) δ 8.99 (s, 1H), 8.58 (d, 1H), 8.28 (d, 1H), 7.95 (s, 1H), 7.74 (m, 2H), 7.60 (m, 1H), 7.38 (m, 1H), 2.73 (s, 3H). MS (ESI) 295.13 (M+H + ).
Example 4
2-{5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridin-2-yl}benzonitrile
[0065]
[0066] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (1.0 mmol, 234 mg), 2-cyanophenylboronic acid (1.2 mmol, 176 mg), dichlorobis(triphenylphosphine)palladium(II) (0.05 mmol, 35 mg), and potassium carbonate (3.5 mmol, 500 mg) were added to deoxygenated DME:water (1:1, 5 mL) at room temperature. The reaction was heated for 5 min at 150° C. via microwave irradiation, then partitioned in a separatory funnel with EtOAc (100 mL) and water (30 mL). The organic layer was washed with one additional portion of water (20 mL) and the combined aqueous layers back extracted with EtOAc (50 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with a 0% to 60% EtOAc gradient in hexanes, to afford the title compound as a white solid, which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. MS (ESI) 301.4 (M+H + ).
Example 5
2-(2-methylphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0067]
[0068] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (1.0 mmol, 234 mg), 2-methylphenylboronic acid (2.0 mmol, 272 mg), dichlorobis(triphenylphosphine)palladium(II) (0.05 mmol, 35 mg), and potassium carbonate (3.5 mmol, 500 ing) were added to deoxygenated DME:water (1:1, 5 mL) at room temperature. The reaction was heated for 18 h at 80° C., then partitioned in a separatory funnel with EtOAc (100 mL) and water (30 mL). The organic layer was washed with one additional portion of water (20 mL) and the combined aqueous layers back extracted with EtOAc (50 μL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with a 0% to 60% EtOAc gradient in hexanes, to afford the title compound as a tan solid, which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. 1 H-NMR (CD 3 OD, 500 MHz) δ 9.14 (s, 1H), 8.76 (d, 1H), 8.18 (d, 1H), 8.03 (s, 1H), 7.44-7.61 (m, 4H), 2.76 (s, 3H), 2.26 (s, 3H). MS (ESI) 291.2 (M+H + ).
Example 6
2-(5-fluoro-2-methoxyphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0069]
[0070] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (1.0 mmol, 234 mg), 2-methoxy-5-fluorophenylboronic acid (2.0 mmol, 340 mg), dichlorobis(triphenylphosphine)palladium(II) (0.05 mmol, 35 mg), and potassium carbonate (3.5 mmol, 500 mg) were added to deoxygenated DME:water (1:1, 5 mL) at room temperature. The reaction was heated for 18 h at 80° C., then partitioned in a separatory funnel with EtOAc (100 mL) and water (30 mL). The organic layer was washed with one additional portion of water (20 mL) and the combined aqueous layers back extracted with EtOAc (50 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with a 0% to 60% EtOAc gradient in hexanes, to afford the title compound as a tan solid, which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. 1 H—N-NMR (CD 3 OD, 500 MHz) δ 9.08 (s, 1H), 8.73 (d, 1H), 8.34 (d, 1H), 8.03 (s, 1H), 7.58 (dd, 1H), 7.45 (m, 1H), 7.33 (m, 1H), 3.97 (s, 3H), 2.77 (s, 3H). MS (ESI) 325.4 (M+Hf).
Example 7
2-(2-chlorophenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0071]
[0072] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (1.0 mmol, 234 mg), 2-methoxy-5-fluorophenylboronic acid (2.0 mmol, 312 mg), dichlorobis(triphenylphosphine)palladium(II) (0.05 mmol, 35 mg), and potassium carbonate (3.5 mmol, 500 mg) were added to deoxygenated DME:water (1:1, 5 mL) at room temperature. The reaction was heated for 18 h at 80° C., then partitioned in a separatory funnel with EtOAc (100 mL) and water (30 mL). The organic layer was washed with one additional portion of water (20 mL) and the combined aqueous layers back extracted with EtOAc (50 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with a 0% to 60% EtOAc gradient in hexanes, to afford the title compound as a tan solid, which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. 1 H-NMR (CD 3 OD, 500 MHz) δ 9.15 (s, 1H), 8.73 (d, 1H), 8.20 (d, 1H), 7.97 (s, 1H), 7.57-7.69 (m, 3H), 7.59 (m, 1H), 2.77 (s, 3H). MS (ESI) 310.9 (M+H + ).
Example 8
2-(2-methoxyphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0073]
[0074] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (1.0 mmol, 234 mg), 2-methoxyphenylboronic acid (2.0 mmol, 304 mg), dichlorobis(triphenylphosphine)palladium(II) (0.05 mmol, 35 mg), and potassium carbonate (3.5 mmol, 500 mg) were added to deoxygenated DME:water (1:1, 5 mL) at room temperature. The reaction was heated for 18 h at 80° C., then partitioned in a separatory funnel with EtOAc (100 mL) and water (30 mL). The organic layer was washed with one additional portion of water (20 μL) and the combined aqueous layers back extracted with EtOAc (50 mL). The combined organic layers were dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with a 0% to 60% EtOAc gradient in hexanes, to afford the title compound as a pale yellow solid, which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. 1 H-NMR (CD 3 OD, 500 MHz) δ 9.02 (s, 1H), 8.73 (d, 1H), 8.34 (d, 1H), 7.97 (s, 1H), 7.68-7.77 (m, 2H), 7.32 (d, 1H), 7.24 (dd, 1H), 3.99 (s, 3H), 2.77 (s, 3H). MS (ESI) 307.2 (M+H + ).
[0075] The following compounds were prepared using a similar method as described in Example 8 for 2-(2-methoxyphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine:
Example 9
2-(4-fluoro-2-methylphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridinium trifluoroacetate
[0076]
[0077] MS (ESI) 310 (M+H + ).
Example 10
2-(3,5-difluoro-2-methoxyphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridinium Trifluoroacetate
[0078]
[0079] 1 H-NMR (CDCl 3 , 500 MHz). 8.71 (m, 1H), 8.02 (m, 1H), 7.98 (m, 1H), 7.78 (m, 1H), 7.39 (m, 1H), 7.12 (m, 1H), 3.85 (s, 3H), 2.80 (s, 3H). MS (ESI) 343 (M+H + ).
Example 11
2-(4-fluoro-2-methoxyphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridinium Trifluoroacetate
[0080]
[0081] MS (ESI) 326 (M+ H + ).
Example 12
2-(5-fluoro-2-methylphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridinium Trifluoroacetate
[0082]
[0083] MS (ESI) 309 (M+H + ).
Example 13
2-(2-methylphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0084]
[0085] 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine (200 mg, 0.85 mmol), 2-methylphenylboronic acid (250 mg, 1.7 mmol), Pd 2 dba 3 (20 mg, 0.021 mmol), [2′-(dicyclohexylphosphino)biphenyl-2-yl]dimethylamine (15 mg, 0.038 mmol) and sodium fluoride (1.72 mmol, 238 mg) were added to deoxygenated dioxane (3 mL). The reaction was heated for 4 hours at 100° C. The crude reaction was chromatographed on an HPLC (C18 column). 1 H-NMR (CDCl 3 , 500 MHz) δ 8.96 (s, 2H), 8.15 (d, 1H), 7.49 (s, 1H), 7.3-7.4 (m, 3H), 2.78 (s, 3H), 2.62 (s, 3H). MS (ESI) 292.02 (M+H + ).
[0086] The following compounds were prepared using a similar method as described in Example 13 for 2-(2-methylphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine:
Example 14
5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]-2-[2-(methylthio)phenyl]pyrimidine
[0087]
[0088] 1 H-NMR (CDCl 3 , 500 MHz) δ 9.0 (s, 2H), 7.89 (d, 1H), 7.49 (s, 1H), 7.1-7.3 (m, 3H), 2.78 (s, 3H), 2.49 (s, 3H). MS (ESI) 323.90 (M+H + ).
Example 15
2-(2-chlorophenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0089]
[0090] 1 H-NMR (CDCl 3 , 500 MHz) δ 9.0 (s, 2H), 7.81 (d, 1H), 7.3-7.5 (m, 4H), 2.78 (s, 3H). MS (ESI) 311.88 (M+H + ).
Example 16
2-(2,3-dimethylphenyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0091]
[0092] 1 H-NMR (CDCl 3 , 500 MHz) δ 9.0 (s, 21H), 7.81 (d, 1H), 7.1-7.5 (m, 4H), 2.78 (s, 3H), 2.4 (s, 6H). MS (ESI) 305.95 (M+H + ).
Example 17
1-{5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridin-2-yl}-1H-pyrrolo[2,3-b]pyridine
[0093]
[0094] To a stirred solution of 1H-pyrrolo[2,3-b]pyridine (2.0 mmol, 236 mg) in DMF (20 mL) at 60° C. was added sodium hydride (2.5 mmol, 100 mg of 60% wt dispersion in mineral oil). After 30 min, 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (0.5 mmol, 117 mg) was added and the reaction was wanned to 75° C. and stirred overnight under nitrogen. The reaction was then partitioned with EtOAc:hexanes (1:1, 100 mL) and water (50 mL). The organic layer was washed with 5% NaCl (4×50 mL), then dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was chromatographed on SiO 2 , eluting with 3% MeOH in DCM, to afford the title compound as a white solid that was dissolved in ether and precipitated as the hydrochloride salt with 1N HCl in ether. 1 H-NMR (CD 3 OD, 500 MHz) δ 8.88 (m, 2H), 8.65 (d, 1H), 8.54 (d, 1H), 8.30 (dd, 1H), 8.05 (d, 1H), 7.94 (s, 1H), 7.83 (dd, 1H), 7.24 (d, 1H), 2.82 (s, 3H). MS (ESI) 317.4 (M+H + ).
Example 18
1-{5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridin-2-yl}-1H-pyrrolo[2,3-c]pyridine
[0095]
[0096] 6-azaindole hydrobromide (198 mg, 1.0 mmol), 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (1.0 mmol, 234 mg), and cesium carbonate (3.2 mmol, 1.04 g) were combined in DMF (15 mL) and heated at 120° C. for 18 hrs. The reaction was cooled to room temperature and partitioned in a separatory funnel with 1:1 hexanes:EtOAc (100 mL) and water (50 mL). The organic layer was washed with 5% NaCl (4×25 mL), then dried over MgSO 4 , filtered, and concentrated in vacuo. The crude residue was purified on SiO 2 , elution with a 0% to 6% iPrOH gradient in DCM to afford the title compound as a white solid which was dissolved in ether and precipitated as the hydrochloride salt with 1M HCl in ether. 1 H-NMR (CD 3 OD, 500 MHz) δ 10.1 (s, 1H), 8.83 (m, 2H), 8.43 (d, 1H), 8.27 (d, 1H), 8.22 (d, 1H), 7.99 (d, 1H), 7.92 (s, 1H), 7.26 (d, 1H), 2.79 (s, 3H). MS (ESI) 317.2 (M+H + ).
Example 19
5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]-2-piperidin-1-ylpyridine
[0097]
[0098] 200 mg (0.85 mmol, 1 eq) 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine, 0.25 mL (2.5 mmol, 3 eq) piperidine and 2 mL DMF were combined. The reaction mixture was heated at 90° C. for 16 h, quenched with pH 10 PBS, extracted with DCM. Silica gel chromatography (gradient 10% to 50% EtOAc/Hexanes) gave 5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]-2-piperidin-1-ylpyridine (L-001106455). The mono HCl salt was made by dissolving the free base into diethyl ether, adding 1 eq of HCl, and isolated by filtration. LC-MS calculated for C 16 H 17 N 3 S 283, observed m/e 284.3 (M+H) + . 1 H-NMR (500 MHz, DMSO-d 6 ) δ 8.20 (s, 1H), 7.92-7.93 (m, 2H), 7.30 (d, 1H), 3.73 (m, 4H), 2.68 (s, 3H), 1.61-1.66 (m, 6H).
Example 20
2-(2-methylpyrrolidin-1-yl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0099]
[0100] 200 mg (0.85 mmol, 1 eq) 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine, 0.30 mL (2.5 mmol, 3 eq) 2-methylpyrrolidine and 2 mL NMP were combined. The reaction mixture was heated in the microwave at 180° C. for 30 min, quenched with pH 10 PBS; extracted with DCM. Silica gel chromatography (gradient 10% to 50% EtOAc/Hexanes) gave 2-(2-methylpyrrolidin-1-yl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (L-001120970). The mono HCl salt was made by dissolving the free base into diethyl ether, adding 1 eq of HCl, and isolated by filtration. LC-MS calculated for C 16 H 17 N 3 S 283, observed m/e 284.0 (M+H) + .
Example 21
2-(2-methylpyrrolidin-1-yl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0101]
[0102] 117 mg (0.50 mmol, 1 eq) 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine, 0.50 mL (5 mmol, 10 eq) 2-methylpyrrolidine and 1 mL NMP were combined. The reaction mixture was heated at 200° C. for 15 min, quenched with pH 10 PBS, extracted with DCM. Silica gel chromatography (gradient 10% to 40% EtOAc/Hexanes) gave 2-(2-methylpyrrolidin-1-yl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine (L-001152863). LC-MS calculated for C 15 H 16 N 4 S 284, observed m/e 285.3 (M+H) + .
Example 22
N-(tert-butyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidin-2-amine
[0103]
[0104] 117 mg (0.50 mmol, 1 eq) 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine, 0.50 mL (5 mmol, 10 eq) t-butyl amine and 1 mL NMP were combined. The reaction mixture was heated at 180° C. for 10 min. The reaction mixture was purified without workup. Preparative reverse phase HPLC (gradient 30% to 100% MeCN/water) gave N-(tert-butyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidin-2-amine as the TFA salt. LC-MS calculated for C 14 H 16 N 4 S 272, observed m/e 273.2 (4+H) + .
[0105] The following compounds were prepared using a similar method as described in Example 22 for N-(tert-butyl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidin-2-amine.
Example 23
2-(3-methylpiperidin-1-yl)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0106]
[0107] 1 H-NMR (CDCl 3 , 300 MHz) δ 8.46 (s, 2H), 7.35 (s, 1H), 4.63 (m, 2H), 2.94 (t, 1H), 2.75 (s, 3H), 2.60 (m, 1H), 1.88 (bs), 1.78 (m, 1H), 1.65 (m, 1H), 1.55 (m, 1H), 1.22 (m, 1H), 0.98 (d, 3H). MS (ESI) 299.16 (M+H + ).
Example 24
5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]-2-piperidin-1-ylpyrimidine
[0108]
[0109] 1 H-NMR (CDCl 3 , 300 MHz) δ 8.46 (s, 2H), 7.35 (s, 1H), 3.85 (m, 4H), 2.75 (s, 3H), 2.60 (m, 1H), 1.69 (m, 2H), 1.63 (m, 4H). MS (ESI) 285.14 (M+H + ).
Example 25
2-isopropoxy-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0110]
[0111] 50 mg 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine, 200 mg potassium carbonate and 5 mL isopropanol were combined. The reaction mixture was heated at 80° C. for 1 h. RPHPLC gave 5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]-2-isopropoxy-1-ylpyrimidine. 1 H-NMR (500 MHz, CDCl 3 ) δ 8.20 (s, 1H), 8.70 (s, 2H), 7.45 (s, 1H), 5.36 (m, 1H), 2.81 (s, 3H), 1.44 (d, 6H). MS (ESI) 259.88 (M+H) +
[0112] The following compounds were prepared using a similar method as described in Example 25 for 2-isopropoxy-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine:
Example 26
2-isopropoxy-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridinium Trifluoroacetate
[0113]
[0114] MS (ESI) 259 (M+H) +
Example 27
2-tert-butoxy-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0115]
[0116] 1 H NMR (CDCl 3 500 MHz) δ 8.315-8.310 (d, 1H), 7.644-7.622 (dd, 1H), 7.34 (s, 1H), 6.61-6.60 (d, 1H), 2.73 (s, 1H), 1.59 (s, 9H). MS (ESI) 273.06 (M + +H).
Example 28
2-(tert-butylthio)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0117]
[0118] 1 H NMR (CDCl 3 500 MHz) d 8.580-8.576 (d, 1H), 7.56-7.54 (dd, 1H), 7.34 (s, 1H), 7.18-7.17 (d, 1H), 2.69 (s, 3H), 1.49 (s, 9H). MS 289.14 (M+H).
Example 29
2-(tert-butylthio)-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine as White Solid
[0119]
[0120] 1 H NMR (MeOD 4 500 MHz) 8.73 (s, 2H), 7.98 (s, 1H), 2.86 (s, 3H), 1.63 (s, 9H). MS (ESI) 290.03 (M + +H).
Example 30
2-cyclohexyl-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0121]
[0122] 200 mg (0.85 mmol, 1 eq). 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine, 50 mg (0.043 mmol, 0.05 eq) tetrakis(triphenylphosphine)palladium(0), and 2 mL of 0.5 M cyclohexylzinc bromide in THF (1 mmol, 1.1 eq) were combined. The reaction mixture was heated at 150° C. in the microwave for 5 min, quenched with pH 7 PBS, extracted with DCM. Silica gel chromatography (gradient 0% to 40% EtOAc/Hexanes) gave 2-cyclohexyl-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (L-001106449). The mono HCl salt was made by dissolving the free base into diethyl ether, adding 1 eq of HCl, and isolated by filtration. LC-MS calculated for C 17 H 18 N 2 S 282, observed m/e 283.3 (M+H) + . 1 H-NMR (500 MHz, DMSO-d 6 ) δ 8.87 (s, 1H), 8.30 (d, 1H), 8.03 (s, 1H), 7.71 (d, 1H), 2.94 (s, 1H), 2.69 (s, 3H), 1.35-1.91 (m, 10H).
Example 31
2-tert-butyl-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine
[0123]
[0124] 200 mg (0.85 mmol, 1 eq) 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine, 50 mg (0.043 mmol, 0.05 eq) tetrakis(triphenylphosphine)palladium(0), and 2 mL of 0.5 M t-butylzinc bromide in THF (1 mmol, 11.1 eq) were combined. The reaction mixture was heated at 150° C. in the microwave for 5 min, quenched with pH 10 PBS, extracted with DCM. Silica gel chromatography (gradient 5% to 50% EtOAc/Hexanes) gave 2-tert-butyl-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (L-001109555). LC-MS calculated for C 15 H 16 N 2 S 256, observed m/e 257.0 (M+H) + . 1 H-NMR (500 MHz, CDCl 3 ) δ 8.74 (s, 1H), 7.76 (d, 1H), 7.45 (s, 1H), 7.12 (d, 1H), 2.77 (s, 3H), 2.12 (m, 1H), 0.97 (d, 9H).
Example 32
2-cyclohexyl-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine
[0125]
[0126] 200 mg (0.85 mmol, 1 eq) 2-chloro-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine, 50 mg (0.043 mmol, 0.05 eq) tetrakis(triphenylphosphine)palladium(0), and 2 mL of 0.5 M cyclohexylzinc bromide in THF (1 mmol, 1.1 eq) were combined. The reaction mixture was heated at 150° C. in the microwave for 5 min, quenched with pH 10 PBS, extracted with DCM. Silica gel chromatography (gradient 10% to 40% EtOAc/Hexanes) gave 2-cyclohexyl-5-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyrimidine (L-001152744). LC-MS calculated for C 16 H 17 N 3 S 283, observed m/e 284.1 (M+H) + .
Examples 33-107
[0127] Using synthetic techniques similar to those described above and well known to those skilled in the art, the following compounds were prepared:
[0000]
[0000] (Examples are to be read left to right across the rows of the table.)
Example 108
Calcium Flux Assay
[0128] The activity of compounds was examined against the hmGluR5a receptor stably expressed in mouse fibroblast Ltk-cells (the hmGluR5a/L38-20 cell line). See generally Daggett et al., Neuropharmacology 34:871-886 (1995). Receptor activity was detected by changes in intracellular calcium ([Ca 2+ ] i ) measured using the fluorescent calcium-sensitive dye, fura-2. hmGluR5a/L38-20 cells were plated onto 96-well plates, and loaded with 3 □M fura-2 for 1 h. Unincorporated dye was washed from the cells, and the cell plate was transferred to a custom-built 96-channel fluorimeter (SIBIA-SAIC, La Jolla, Calif.) which is integrated into a fully automated plate handling and liquid delivery system. Cells were excited at 350 and 385 nm with a xenon source combined with optical filters. Emitted light was collected from the sample through a dichroic mirror and a 510 nm interference filter and directed into a cooled CCD camera (Princeton Instruments). Image pairs were captured approximately every 1 s, and ratio images were generated after background subtraction. After a basal reading of 20 s, an EC 80 concentration of glutamate (10 □M) was added to the well, and the response evaluated for another 60 s. The glutamate-evoked increase in [Ca 2+ ] i in the presence of the screening compound was compared to the response of glutamate alone (the positive control).
Example 109
[ 3 H]-mGluR5Antagonist Binding to Rodent Brain Membranes
[0129] In accordance with Anderson J J, Rao S P, Rowe B, Giracello D R, Holtz G, Chapman D F, Tehrani L, Bradbury M J, Cosford N D, Varney M A, [ 3 H]Methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine binding to inetabotropic glutamate receptor subtype 5 in rodent brain: in vitro and in vivo characterization. J Pharmacol Exp Ther. 2002 December; 303(3): 1044-51, membranes were prepared (as described in Ransom R W and Stec N L (1988) Cooperative modulation of [ 3 H]MK-801 binding to the N-methyl-D-aspartate receptor-ion channel complex by L-glutamate, glycine, and polyamines. J Neurochem 51:830-836) using whole rat brain, or in Glu5 +/+ or mGlu5 −/− whole mouse brain. Binding assays were performed as described in Schaffhauser H, Richards J G, Cartmell J, Chaboz S, Kemp J A, Klingelschmidt A, Messer J, Stadler H, Woltering T and Mutel V (1998) In vitro binding characteristics of a new selective group HI metabotropic glutamate receptor radioligand, [ 3 H]LY354740, in rat brain. Mol Pharmacol 53:228-233.) at room temperature with slight modifications. Briefly, membranes were thawed and washed once with assay buffer (50 mM HEPES, 2 mM MgCl 2 , pH 7.4), followed by centrifugation at 40,000×g for 20 min. The pellet was resuspended in assay buffer and briefly homogenized with a Polytron.
[0130] For protein linearity experiments, increasing concentrations of membrane protein were added to 96-well plates in triplicate and binding was initiated by addition of 20 nM [ 3 H]methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine. The assay was incubated for 2 h and non-specific binding was determined using 10 μM MPEP. The binding was terminated by rapid filtration through glass-fiber filters (Unifilter-96 GF/B plate, Packard) using a 96-well plate Brandel cell harvester. Following addition of scintillant, the radioactivity was determined by liquid scintillation spectrometry. Protein measurements were performed by BioRad-DC Protein assay using bovine serum albumin as the standard.
[0131] Saturation binding experiments were performed in triplicate with increasing concentrations of [ 3 H]methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine (1 pM to 100 nM). The time course of association was measured by the addition of 10 nM [ 3 H]methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine to the membranes at different time points (0-240 min), followed by filtration. Dissociation was measured by the addition of 100 μM unlabeled methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine at different time points to membranes previously incubated for 3 h with 10 nM [ 3 H]methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine. For competition experiments, 100 μg membrane protein and 10 nM [ 3 H]methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine was added to wells containing increasing concentration of the test compound in duplicate (methoxymethyl-3-[(2-methyl-1,3-thiazol-4-yl)ethynyl]pyridine or MPEP). [3H]-3-Methoxy-5-(pyridin-2-ylethynyl)pyridine may also be used as the radioligand in the procedure described above. (See, Cosford, N. D. P.; Roppe, J.; Telrani, L.; Seiders, T. J.; Schweiger, E. J. et al. [3H]-Methoxymethyl-MTEP and [3H]-methoxy-PEPy): Potent and selective radioligands for the Metabotropic Glutamate Subtype 5 (mGlu5) Receptor. Bioorg. Med. Chem. Lett. 2003, 13, 351-354.)
Example 110
Phosphatidylinositol Hydrolysis (IP) Assay
[0132] Inositol phosphate assays were performed as described by Berridge et al. (1982) (Berridge et al, (1982) Biochem. J. 206: 587-5950; and Nakajima et al., J. Biol. Chem. 267:2437-2442 (1992)) with slight modifications. Mouse fibroblast Ltk cells expressing hmGluR5 (hmGluR5/L38-20 cells) were seeded in 24-well plates at a density of 8×105 cells/well. One □Ci of [ 3 H]-inositol (Amersham PT6-271; Arlington Heights, Ill.; specific activity=17.7 Ci/mmol) was added to each well and incubated for 16 h at 37° C. Cells were washed twice and incubated for 45 min in 0.5 ml of standard Hepes buffered saline buffer (HBS; 125 mM NaCl, 5 mM KCl, 0.620M MgSO 4 , 1.8 mM CaCl 2 , 20 mM HEPES, 6 mM glucose, pH to 7.4). The cells were washed with HBS containing 10 mM LiCl, and 400 ill buffer added to each well. Cells were incubated at 37° C. for 20 min. For testing, 50 □L, of 10× compounds used in the practice of the invention [made in HBS/LiCl (100 mM)] was added and incubated for 10 minutes. Cells were activated by the addition of 10 pM glutamate, and the plates left for 1 hour at 37° C.
[0133] The incubations were terminated by the addition of 1 mL ice-cold methanol to each well. In order to isolate inositol phosphates (IPs), the cells were scraped from wells, and placed in numbered glass test tubes. Chloroform (1 mL) was added to each tube, the tubes were mixed, and the phases separated by centrifugation. IPs were separated on Dowex anion exchange columns (AG 1-XS100-200 mesh formate form). The upper aqueous layer (750 □L) was added to the Dowex columns, and the PCT/US00/23923 109 columns eluted with distilled water (3 mL). The eluents were discarded, and the columns were washed with 60 mM ammonium formate/5 mM Borax (10 mL), which was also discarded as waste. Finally the columns were eluted with 800 mM ammonium formate/0.1 M formic acid (4 mL), and the samples collected in scintillation vials. Scintillant was added to each vial, and the vials shaken, and counted in a scintillation counter after 2 hours. Phosphatidylinositol hydrolysis in cells treated with certain exemplary compounds was compared to phosphatidylinositol hydrolysis in cells treated with control. Using this procedure an IC 50 value of 33 nM was obtained for Example 1 and an IC 50 value of 2 nM for Example 18.
Example 111
Activity of Representative Compounds
[0134] The activity of certain of the compounds disclosed in the previous examples is presented below (N.D.=not determined):
[0000] Example Calcium Flux Assay (nM) Ki (nM) 1 3 20 2 1.0 2.0 3 0.9 2.7 4 2.2 2.6 5 6.3 1.0 6 4.4 1.2 7 1.1 0.7 8 1.0 0.9 9 1.1 N.D. 10 0.7 N.D. 11 1.3 N.D. 12 0.6 1.1 13 0.6 0.6 14 0.8 7.5 15 1.0 2.6 16 0.4 8.6 17 0.4 3.8 18 4.9 19.3 19 1.8 2.8 20 1.0 1.4 21 1.5 1.5 22 1.2 0.9 23 1.6 1.6 24 0.3 2.6 25 1.4 9.0 26 0.1 2.0 27 1.4 1.0 28 1.7 0.9 29 0.5 10 30 2.2 2.3 31 2.9 12.2 32 1.0 4.8 33 19 7 34 18 15 35 17 5 36 14 3 37 14 10 38 13 8 39 13 4 40 12 9 41 11 5 42 11 17 43 11 0.65 44 11 2 45 11 7 46 11 2 47 11 19 48 9 12.5 49 9 5.5 50 9 12 51 8 9 52 8 2 53 8 8 54 8 1.5 55 7 4 56 7 13 57 7 7.5 58 7 1.5 59 6 4 60 6 1.5 61 6 12 62 6 11 63 6 4 64 6 0.8 65 6 8 66 5 9 67 5 7 68 5 7 69 5 14 70 5 5 71 5 4.5 72 5 7 73 4 2 74 4 7.5 75 4 4 76 3.5 3 77 3 13 78 3 1.4 79 3 16 80 3 3 81 3 6 82 3 2 83 2 12 84 2 7 85 2 1 86 2 7 87 2 N.D. 88 2 4 89 1.6 2 90 1.5 4 91 1 1 92 12 7 93 11 3 94 9 6 95 8 9 96 5 5 97 5 13 98 4 8 99 2.8 33 100 2.3 23 101 2 24 102 2 26 103 1.6 1.6 104 1.5 6 105 1 1 106 N.D. 6 107 16 9 Nd = not determined
Note that the relatively high values in the calcium flux and binding assays, for Example 18, are counterbalanced by assay results in the IP assay (as reported in Example 110).
[0135] While the invention has been described in detail with reference to certain preferred embodiments thereof, it will be understood that modifications and variations are within the spirit and scope of that which is described and claimed. | The identification of a unique series of compounds which possesses special advantages in terms of drug-like properties due to their possessing advantageous properties in terms of potency and/or pharmacokinetic and/or selectivity and/or in vivo receptor occupancy properties. Specifically, the selection of a 1,3-thiazol-2-yl ring member linked by an ethynylene to the 3 position of a pyridyl ring or the 5 position of a pyrimidinyl ring, wherein the ring is substituted with selected substituents, results in a compound having superior drug-like properties. The invention includes pharmaceutically acceptable salt forms of these heterocyclic compounds, in particular chloride salts and trifluoroacetate salts. | 2 |
RELATED APPLICATIONS
This application is a division of application Ser. No. 462,629, filed Jan. 31,1983, now U.S. Pat. No. 4,470,877, which is a continuation-in-part of copending applications U.S. Ser. No. 441,711 filed Nov. 15, 1982, which is a continuation-in-part of U.S. Ser. No. 263,371 filed May 13, 1981, now U.S. Pat. No. 4,372,814 by the present inventors.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to paper-making, and more particularly refers to the production of a calcium sulfate-filled and neutral sized paper particularly well adapted for use as cover sheets in the production of gypsum wallboard.
2. Description of the Prior Art
Paper for gypsum board is conventionally made by pulping up waste paper constituents of old corrugated paper, or kraft cuttings and waste news. In cleaning, screening and refining the suspended materials in water suspension, the process paper stock is diluted still further with water and then formed by draining the plies of paper on several continuously moving wire cylinders, where the separate plies are joined together by a carrying felt. The weak paper web is then dewatered in a press section where water is pressed out of the web. The pressed paper is dried in a multi-cylinder drying section with steam added to each cylinder. The dried paper is subjected to a squeezing or calendaring operation for uniformity in thickness and is then finally wound into rolls. The paper is subsequently utilized as paper cover sheets to form gypsum wallboard by depositing a calcined gypsum slurry between two sheets, and permitting the gypsum to set and dry.
Conventional paper used in gypsum wallboard has definite limitations with regard to the utilization of heat energy. First, it has definite drainage limitations in forming and pressing, and additional limitations in the drying rate. The drainage rate limitations impose a large paper drying energy load on the mill. It would be highly desirable to have a more porous paper for utilization as paper cover sheets in the formation of gypsum wallboard to permit the achievement of a substantial reduction in drying energy load, while still having a paper which has the requisite physical properties with regard to physical strength even though less pulp is utilized.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide paper for use as paper cover sheets in the production of gypsum wallboard.
It is another object of the invention to provide paper for use in making gypsum wallboard which is highly porous and requires less energy for drying than conventional paper previously utilized for this purpose.
It is still another object to provide a paper of the type described which has sufficiently high tensile strength for use in gypsum wallboard.
It is still a further object to provide a porous paper for making gypsum wallboard which is so treated that excellent adhesion is obtained between the paper cover sheet and the gypsum core even though the paper has a greater porosity than that found in conventional paper.
Other objects and advantages of the invention will become apparent upon reference to the description below.
According to the invention, a paper eminently suitable for use in fabricating gypsum wallboard is produced using substantially conventional paper processes, and having the following composition (dry weight basis):
(A) cellulosic fibers in an amount of from about 65% to about 90% and preferably having a fiber freeness of from about 300 ml to about 550 ml Canadian Standard Freeness,
(B) calcium sulfate as a filler in an amount of from about 10% to about 35%,
(C) a binder in an amount from about 1% to about 31/2,
(D) a flocculant in an amount of from about 0.1% to about 0.2%
(E) a buffering agent in an amount from about 0.25% to about 10%,
(F) a neutral sizing agent in an effective amount to prevent water penetration,
(G) an anionic polymer in an amount suitable for retaining said filler in said paper, and
(H) a cationic starch when a succinic anhydride is used as the neutral sizing agent.
In a preferred embodiment, after the paper is treated with a neutral internal sizing agent during its formation, it is subsequently treated with a surface sizing agent after formation of the paper, in order to provide certain properties including better adhesion to the gypsum core when used to make gypsum wallboard.
During the paper-making process, rapid drying is obtained with less than the normal amount of heat energy required. The finished paper has excellent porosity, tensile strength and fire resistant properties. Further, when the paper is utilized as paper cover sheets in the manufacture of gypsum wallboard, the porosity of the paper facilitates the drying and setting of finished wallboard.
The paper may be utilized as paper cover sheets for the production of gypsum wallboard. In the setting and drying of the wallboard, because of the excellent porosity of the paper, less energy need be utilized and more rapid drying is obtained, to produce a wallboard wherein the paper has excellent tensile strength and fire resistant properties. In a preferred embodiment the paper is treated with an internal sizing agent during its formation, and subsequently treated with a surface sizing agent after formation, in order to provide better adhesion to the gypsum core.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the examples which follow the paper was prepared by the method of Procedure A which follows:
PROCEDURE A
An aqueous slurry was prepared comprising 20 oven dry grams of fiber and 3500 ml of water. The slurry was subjected to stirring with a three bladed propeller at 200 RPM. During the agitation, the designated amount of CaSO 4 land-plaster filler in amounts of from 10-30% were added dry to the slurry. After there minutes of agitation, 4 lb/ton of the designated flocculant were added in a solution containing 0.1% solids. After agitation was carried out for an additional three minutes, the designated amount of binder in amounts from about 0.5% to 3% were added at a total solids content from about 3% to 50%. Stirring or agitation was continued at 1250 RPM for an additional three minutes after which time the slurry was diluted to a consistency of 0.3% total solids content. A sufficient amount of the slurry was then added to a standard 61/4" (159mm) diameter sheet mold. Size emulsion in designated amounts was added to the sheet mold contents which were subsequently agitated. After agitation, the anionic polymer retention aid was added to the sheet mold in designated amounts followed by agitation. A 1.50 gram handsheet was subsequently formed in the sheet mold. The drainage time was recorded and the wet sheet was couched off the 150 mesh sheet mold screen.
Handsheets were stacked while still wet on blotters and then covered with a mirror polished disc. The handsheets were then pressed at 50 pounds/square inch for five and one half minutes. At this point the wet blotters were removed and the handsheets were inverted so that the metal plate was on the bottom. Dry blotters were utilized to replace the wet ones and the stack was pressed at the same pressure for two and one-half minutes. The partially dry handsheets were peeled off the metal plates and dried on a rotating drum dryer for one pass which took approximately 40 seconds. At the end of this period the handsheets were dry.
The dried handsheets were then coated with 0.35 lb/ton of a silicone surface sizing agent and then redried for 20 seconds in the handsheet dryer. Afterwards the handsheets were oven-cured at 140° F. for 24 Hrs. and then allowed to come to equilibrium at room conditions for 1 hour before testing.
Additionally, in the examples which follow, where gypsum board was prepared from the papers which were fabricated and described in the tables, the gypsum wallboard was prepared from the papers utilizing the method of Procedure B which follows:
PROCEDURE B
Production of Gypsum Wallboard
Gypsum wallboard was produced by discharging a stucco slurry from a mixer onto prepared paper with the topliner face downward while the paper was moving continuously. A top sheet, which is newslined, was brought into contact with the upper surface of the slurry, and subsequently the combination of facing papers and slurry was passed under a forming roll to distribute the slurry uniformly and to form the board into a uniform cross-section. The edges of the paper were folded up and over the edges of the top paper, and the edges of the board were formed in the same operation.
The wet gypsum board was carried through the forming section of the board machine on a continuously moving belt until the board core was fully hydrated to calcium sulfate dihydrate. Subsequently, the board was conveyed onto continuously moving strip belt conveyors to the knife section where the board was cut into conventionally desired lengths.
The board was then inverted with the manila face up and fed into a drying kiln on continuously turning rollers, where it was dried to a uniform 5-6% moisture content. The board was inspected and then stacked into packages.
Testing of Gypsum Wallboard
Before gypsum wallboard is marketed it is first subjected to specific quality control tests to ascertain that the board meets quality standards. Among the various tests which are generally conducted are ASTM nail pull and transverse strengths. Also tested are humidified bond for both face and backsides of the board, face Cobbs and total immersion absorption water resistance tests on board to be used for high humidity application and/or sheathing board, and face absorption water absorptiveness tests on board for plaster application.
The nail pull test consists of applying an ever-increasing amount of weight on a specially designed nail until the head is pulled through the board sample. Weight at failure is recorded.
Transverse strength tests are carried out by applying a force downwardly in the center of the specimen which is supported at two opposing outer edges. The face which is positioned downwardly is the face which is tested. Force applied at failure is the measurement of transverse strength.
The humidified bond test consists of humidifying the board for three hours at 90% relative humidity and 90° F. temperature, and then applying a force on the board sufficient to break the bond between the paper and the board core. The applied force or weight at failure is the measure of bond strength.
Face Cobb and absorption tests are carried out by conventional methods.
The total immersion water absorption tests are conducted by immersing a 12 inch by 12 inch sample of board for two hours in 70° F. temperature water. The weight of water absorbed is determined by difference and converted to percent absorption based on dry weight.
In copending application application U.S. Ser. No. 263,371, filed May 13, 1981 referred to above, results were given of tests made utilizing calcium sulfate as a mineral filler for paper to be used in making gypsum wallboard. The results of those experiments were not entirely satisfactory since insufficient calcium sulfate was retained in the paper when used with the retention aids disclosed therein. It has been subsequently found that excellent retention of calcium sulfate as a mineral filler may be accomplished by the use of an anionic polyacrylamide retention aid when added to the dilute furnish used when making the paper. When this anionic polyacrylamide polymer was added, the filler retention was vastly improved and the handsheets strengths were also improved.
In Examples 1-17 below are results for various handsheets containing various proportions of calcium sulfate landplaster (CaSO 4 . 2H 2 O) as a filler together with varying amounts of an anionic polymer utilized as the retention aid. The handsheets were all prepared according to Procedure A. The compositions and the results of conventional paper tests are shown in Table I below. Since the experiments were designed primarily to test the effect of the anionic polymer as a retention aid, conventional ingredients normally used in making paper suitable for use in making gypsum wallboard were not incorporated.
Further, the white water from a given handsheet was recirculated to make the subsequently formed handsheets.
TABLE I__________________________________________________________________________CALCIUM SULFATE - LANDPLASTER AS A GYPSUM BOARD PAPER FILLER,NO INTERNAL NOR SURFACE SIZES APPLIED (2) (3) No. of (1) Cationic AnionicEx- Hand- % % Floccu- Polymer Ca.sup.++am- sheets CaSO.sub.4 Latex lant Ret. Aid ion Basis Poro-ple and Added Added Addition Addition Zeta % Ash As Concen- Weight sity Break- TearNum- Recircu- to to Rate, Rate, Potential, CaSO.sub.4.2H.sub. 2 O tration, lb/ Sec- ing Fac- Burstber lations Sheet Sheet lb/ton lb/ton MV (Dihydrate) ppm 1000 ft.sup.2 onds Meters tor Factor__________________________________________________________________________1 5 27 3 4 0 -12.4 18.6 70 14.7 52.1 5208 20.3 8632 10 27 3 4 0 -13.0 16.0 80 14.6 67.4 5208 20.0 7693 15 27 3 4 0 -12.7 14.4 99 14.5 23.9 5033 20.5 8694 20 27 3 4 0.75 -14.4 22.5 94 15.4 32.1 5224 20.3 8815 25 27 3 4 1.50 -13.0 27.6 94 16.1 21.7 4934 20.8 8196 30 27 3 4 (4) 0.75 -12.4 23.3 89 15.2 24.0 4822 21.9 8777 35 27 3 4 (4) 1.50 -12.7 20.4 84 16.4 24.4 4489 22.1 8908 5 20 2 4 0 -5.2 15.0 41 15.2 11.2 4338 22.5 6979 10 20 2 4 0 -6.2 16.9 45 17.4 16.2 3967 23.3 67210 15 20 2 4 0 -5.5 12.0 42 17.1 34.0 4271 15.1 75111 20 20 2 4 0.75 -5.5 18.2 44 14.4 6.2 3686 12.5 57212 25 20 2 4 1.50 -6.6 19.2 50 17.2 28.0 3931 15.9 58813 5 10 1 4 0 -4.9 6.8 44 19.5 38.6 4330 19.9 82814 10 10 1 4 0 -5.8 6.9 46 18.4 30.8 5050 22.9 84215 15 10 1 4 0 -5.4 6.4 48 17.5 36.6 3949 18.2 82316 20 10 1 4 0.75 -4.7 9.4 46 17.6 45.4 4215 15.5 79917 25 10 1 4 1.50 -4.8 7.4 49 17.2 32.0 4190 18.6 674__________________________________________________________________________ (1) Carboxylated Styrene Butadiene Latex with S/B ratio of 50/50, Dow XD 30374.02 Anionic Latex. (2) Low Molecular Weight, Moderate Charge Density Cationic Polyacrylamide (Quarternary Amine), Dow XD 30440.01 Cationic Flocculant. (3) High Molecular Weight, High Charge Density Anionic Polyacrylamide (Hydrated), Dow XD 30057.03 Anionic Polymer. (4) Effect of H.M.W., M.C.D. Cationic Retention Aid on System. Cationic Polyacrylamide (Quaternary Amine) Dow XDR 185526-P967.
From the results shown above, it is evident that as the number of recirculations increases Ca ++ ion concentration builds up, retention of the landplaster deteriorates without the admixture of the anionic polymer retention aid. This is true for every level of landplaster evaluated. This constituted 27% in examples 1-7, 20% in examples 8-12, and 10% in examples 13-17. The results of examples 6 and 7, where a cationic polymer instead of an anionic polymer was used clearly illustrate the deterioration in both filler retention by percent and breaking length with the admixture of the cationic polymer. These results clearly show the need for the use of an anionic polymer for proper landplaster retention in a system that is highly anionic as indicated by the negative Zeta potential.
In examples 18-27 below paper handsheets utilizing calcium sulfate dihydrate as a filler, an anionic polymer as a retention aid and a ketene dimer as an internal sizing agent were prepared according to the method of Procedure A above. The compositions utilized in examples 18-27 and the conventional tests results are shown below below in Table II:
TABLE II__________________________________________________________________________KETENE DIMER AS (1) INTERNAL SIZING AGENT FOR CaSO.sub.4(5) FILLED GYPSUM BOARD PAPER Paper Tests Board Tests % CaSO.sub.4 Cobb Saturation (Humidified Bond Test Results) Basis as Water Water Bond Bond Example Weight Land- Resistance, Resistance, Failure, Strength,Example Description Number lb/1000 ft.sup.2 plaster Grams Minutes Percent Lb (Force)__________________________________________________________________________No Retention AidWith Silicone (4) 18 54.05 14.9 0.60 120+ 0.0 14.3Without Silicone 19 67.70 13.4 0.61 120+ 0.0 7.5Anionic Retention Aid (2)0.75 lb/ton Retention AidWith Silicone (4) 20 51.87 15.1 0.55 120+ 7.8 13.8Without Silicone 21 46.14 14.5 0.63 120+ 78.5 9.01.50 lb/ton Retention AidWith Silicone (4) 22 50.97 20.9 0.54 120+ 13.2 14.2Without Silicone 23 50.02 20.1 0.62 120+ 18.1 11.0Cationic Retention Aid (3)0.75 lb/ton Retention AidWith Silicone (4) 24 53.0 22.2 0.47 120+ 2.3 14.8Without Silicone 25 46.2 18.9 0.54 120+ 18.5 12.01.50 lb/ton Retention AidWith Silicone (4) 26 45.9 16.7 0.51 120+ 32.2 14.4Without Silicone 27 47.7 19.3 0.57 120+ 34.5 14.3__________________________________________________________________________ (1) 5 lb/ton of size as Hercon 32 (2) Solid form of Dow XD 30057.03 HMW, HCD Anionic Polyacrylamide (3) Dow EO retention aid (4) 0.35 lb/ton of Goldschmidt 5342 Silicone (5) 30% CaSO.sub.4 as Landplaster, 3% Latex, S/B, C; 4 lb/ton Cationic Flocculant
The results of the experiments of Examples 18-27 above and shown in Table II indicate the suitability of a ketene dimer as an internal size for calcium sulfate dihydrate (landplaster) filled gypsum board paper. The results shown in the table are based on tests conducted on handsheets prepared by the method of Procedure A except that saturated calcium sulfate water was used in making up the furnish and in diluting the furnish in a large 12"×12" sheet mold where heavier basis weight handsheets were produced than those produced by the basic method of Procedure A. The data shown above in Table II indicate that where a proprietary ketene dimer size such as HERCON 32 marketed by the Hercules Company, is used either with an anionic or a cationic polymer retention aid, it provides improved landplaster retention in the presence of calcium ions. The paper sizing tests indicate that the HERCON 32 ketene dimer size provided excellent sizing results regardless of the charge of the retention aid and with or without silicone surface size application. The board test data also shown in Table II demonstrate that with few exceptions the ketene dimer internally sized paper, when additionally surface sized with a silicone polymer, provides good bond to gypsum board. The desirability of the use of the silicone surface size is indicated by the generally lower bond failures and higher bond strength which were obtained when the silicone size was applied, compared to the handsheets where it was not applied.
The ketene dimer has the following structural formula: ##STR1## wherein the two radicals, R, each may have 8-18 carbon atoms, and the indicated ring is a lactone ring.
Conventionally, the ketene dimers are formed from a 50/50 mixture of palmitic and stearic fatty acids, although they may be formed from any fatty acids with 10 to 20 carbon atoms. The ketene dimers are usually emulsified in a cationic starch solution in the ratio of 3 or 4 parts of dimer to 1 part of cationic starch. Proprietary ketene dimers usually contain a cationic polymer which acts as a size retention aid in the paper machine furnish.
Succinic Acid Anhydride as an Internal Sizing Agent for CaSO 4 -Filled Gypsum Board Paper
In Examples 28-30 succinic acid anhydride internal size was utilized in preparing a calcium sulfate-filled gypsum board paper, utilizing an anionic polymer as a retention aid. Additionally a silicone polymer size acidified with 1% alum solids was applied as a surface size to the dried paper. The formulations of Examples 28-30 and tests results of the prepared paper, as well as gypsum board samples prepared from the papers as shown below in Table III. Additionally tests results of the paper and of the prepared gypsum board are shown.
TABLE III__________________________________________________________________________SUCCINIC ACID ANHYDRIDE AS INTERNAL SIZING AGENT FOR CaSO.sub.4FILLED GYPSUM BOARD PAPER* Paper Test Board Tests **Anionic Cobb Saturation Humidified Bond Test Results Polymer Water Water (Conditioned for 3 hrs at 90° F./90% RH) Example Rate, Resistance, Resistance, Bond Failure, Bond Strength,Example Description Number lb/ton Grams Minutes Percent lb (Force)__________________________________________________________________________55 lb/1000 ft.sup.2 Basis Weight 28 0.0 0.63 120+ 38.9 9.0Handsheets Sized Internallywith 5 lb/ton of ACCOSIZE 18and 10 lb/ton of STA-LOK 500.Anionic Polymer added to 29 0.75 0.58 120+ 19.4 17.0Furnish after Size at RatesIndicated.0.35 lb/ton of Acidified 30 1.50 0.55 120+ 0.0 16.0RE-30 Silicone Applied toSurface of Paper After Drying.__________________________________________________________________________ *Paper Composition: 30% CaSO.sub.4 as Landplaster, 3% Dow Styrene/Butadiene Carboxylated Latex, 4 lb/ton of Dow Cationic Flocculant **Anionic Polymer is Dow XD 30057.03, High Molecular Weight, Medium Charg Density Anionic Polyacrylamide Produced from Acrylic Acid Hydrated Polyacrylamide.
The data obtained from testing the samples of Examples 28-30 show that at all levels of anionic polymer application, paper sizing by the combination of internal size and silicone resin surface sizes produced excellent paper. The tests made on the finished gypsum wallboard show that the anionic polymer is particularly useful in providing a sheet which demonstrates superior bond to the gypsum board to which it is applied. This is shown by the decreasing bond failure and the increasing bond strength with increasing anionic polymer addition. The handsheets prepared and illustrated in Table III were prepared in a method similar to that of Procedure A but with a large 12"×12" sheet mold to produce 12"×12" 55 lb/1000 ft 2 basis weight handsheets.
The internal size utilized was ACCOSIZE 18, a trademarked product marketed by American Cyanamid which contains 1% anionic surfactant as an emulsifying agent, and which was emulsified in a turbine emulsifier with 3% cationic potato starch as the emulsifying medium. Two pounds of starch were used with each pound of sizing material.
In Examples 31 and 32 a ketene dimer was compared to succinic acid anhydride as an internal size for calcium carbonate-filled gypsum board paper. The handsheets of these examples were prepared in a manner similar to that of Procedure A, except that the large 12"×12" sheet mold was used to make 12"×12" handsheets of 55 lb/1000 ft 2 basis weight and a cationic in place of an anionic retention aid was used. The formulations and results are shown below Table IV.
TABLE IV__________________________________________________________________________ALTERNATE SIZE, BINDER AND RETENTION AID FOR CaCO.sub.3FILLED PAPER FOR GYPSUM BOARD__________________________________________________________________________Ketene Dimer as Internal Size for CaCO.sub.3 - Filled Gypsum BoardPaper,(1) 0.5 lb/ton of Cationic Retention Aid Added to Furnish, No SurfaceSize Applied to Dry Paper SurfaceExample Description:55 lb/1000 ft.sup.2 basis weight handsheets, made with 80% kraft, 20%news fiber furnish, 27% CaCO.sub.3, 3% DowCarboxylated styrene-butadiene latex, and 4 lb/ton of Dow CationicFlocculant XD - 30440.01. Board Tests Paper Tests (Conditioned for 3 Hrs at 90° F./90% RH) Cobb Saturation Bond Failure, Bond Strength Water Water Percent Lb (Force) Example Resistance, Resistance, High Low High Low Number Grams Minutes Avg. Value Value Avg. Value Value__________________________________________________________________________CONTROL10 lb/ton Fibran 68 (2) 31 0.66 20 21.4 50.0 0 9.0 13 7Internal Size with15 lb/ton ofSTA-LOK 500KETENE DIMER5 lb/ton of Hercon 40 32 0.56 120+ 18.4 21.5 16.7 9.0 11 8No additional cationicstarch.__________________________________________________________________________ (1) High Molecular Weight, Medium Charge Density Cationic Polyacrylamide. (2) Succinic Acid Anhydride Sizing Agent Made by National Starch and Chemical Company and Combined with 1 Part of Nonionic Surfactant Emulsifying Agent to 17 parts of Size.STA-LOK 500 Cationic Potato Starch as Binder and(1) Anionic Polymer as Retention Aid in CaCO.sub.3 - Filled Gypsum BoardPaper (2)Example Description:80% old corrugated and 20% waste news refined to 350 ml. CSF. Anionic Filler Binder CaCO.sub.3 (3) Polymer Addition Addition Basis Retention 1st. Pass Sheet SheetExample Rate, Rate, Rate, Weight in Sheet, Retention Porosity TensileNumber lb/ton Percent Percent lb/1000 ft.sup.2 Percent Percent Seconds Strength__________________________________________________________________________33 0 5.0 0.5 66.1 91.6 93.1 71.0 78.834 1.0 5.0 0.5 64.5 93.7 93.1 49.4 74.135 0 10.0 1.0 63.0 86.1 92.4 59.6 76.136 1.0 10.0 1.0 67.4 91.2 93.1 79.0 85.237 0 15.0 1.5 61.1 83.8 94.6 74.8 85.138 1.0 15.0 1.5 65.4 86.2 96.9 58.6 75.1__________________________________________________________________________ (1) Dow High Molecular Weight, High Charge Density Anionic Polyacrylamide XD 30057.03. (2) Paper Contains No Cationic Flocculant nor Latex. (3) lb/in at 55 lb B.W./1000 ft.sup.2.
As indicated in the above table the ketene dimer provides excellent sizing and paper bond performance, compared to the succinic acid anhydride.
Examples 33-38, the data for which are shown in Table IV above, demonstrate the advantages to be obtained by the use of STA-LOK 500 cationic potato starch as a binder when used together with an anionic polymer as a retention aid. The handsheets prepared in examples 33-38 used in this study were prepared in a manner similar to that of Procedure A, except that saturated calcium carbonate (CaCO 3 ) water was used to make the handsheets within the sheet mold as dilution. The results show that cationic starch binder provides excellent retention of the filler and that improvement in filler retention and porosity is provided by the anionic polymer.
The examples above resulted in the preparation of handsheets by laboratory methods. Consequently a buffer such as calcium carbonate was not added. However, in a full scale paper-making operation, a buffer such as calcium carbonate must be added to the calcium sulfate-filled furnish because the calcium sulfate tends to buffer the system to a lower pH. This is not a problem in the laboratory where there is no build up in acidity from the lab furnish, and consequently no buffers were used in the laboratory experiments. However, on a paper-making machine which engages in a large amount of recirculation of water which is drained from the furnish in making the sheet, continual input of acidic paper stock causes a build up of acidity in the system which must be buffered to maintain neutral to slightly alkaline conditions in order to insure that the strength of the sheet will be optimum.
EXAMPLE 39
A commercial run is carried out in the plant to produce a calcium sulfate dihydrate paper for conversion to marketable gypsum board. The paper line is first set up to make conventional paper utilizing 100% conventional paper stock. After the line is running, the process is converted to making calcium sulfate paper by adding a cationic flocculant, finely ground calcium sulfate dihydrate filler and calcium carbonate buffer to the filler refiner dump chest. Latex binder is added to the filler machine chest followed by addition of anionic polyacrylamide retention aid to the dilute machine furnish after the fan pumps.
The initial paper is comprised of succinic acid anhydride internally sized regular furnish manila paper which is the cover sheet which faces outward when the gypsum board is attached to the wall frame. The change over to calcium sulfate furnish is accomplished by adding calcium sulfate landplaster and latex to the filler portion of the sheet at twice the steady state rate and the cationic flocculant, and anionic retention aid at the steady state rate. Water is added to the topliner and dilute aqueous silicone emulsion is added to the bondliner in the wet calender stack after the dryers. The silicone emulsion contains 1% alum solids. Internal sizing levels are adjusted to provide sufficient moisture pickup, 2.5%, in the calender stack. Internal sizing levels applied to the various plies are 3, 8, 5, and 9 lb/ply ton of succinic acid anhydride cationized with 2.0 lb cationic starch/lb of size utilized respectively in the two bondliner plies, the filler ply beneath the topliner and the two topliner plies. The bondliner of the filler portion of the sheet is the part in contact with the gypsum core of the board. The topliner is the portion of the sheet facing outwardly. The bondliner internal and surface sizing levels are set to provide uniform resistance to excessive wetting of the sheet in board manufacture. The topliner internal sizing is set to obtain adequate decorating properties of the dried board.
Steady state proportions in the filler stock portion of the sheet are achieved as given below following conversion to calcium sulfate dihydrate filled paper:
______________________________________Fiber Kraft Cuttings 56% Waste News 14%Fillers Calcium Sulfate 22-25% (Dihydrate) Calcium Carbonate 2-5% (Buffer)Chemicals Styrene-Butadiene 3% Latex Cationic Polyacrylamide 2-4 lb/ton Flocculant Anionic Polyacrylamide 0.5-1.50 lb/ton Retention Aid Silicone Surface Size 0.35-0.50 lb/ton Solids______________________________________
The manila topliner comprising 25% of the total manila sheet consists of flyleaf or magazine trimmings.
Following manufacture of filled manila, newslined, the covering paper which faces toward the house frame is made using above filled-paper stock proportions throughout all of the sheet. Sizing levels of succinic acid anhydride employed are 4, 8, 8 and 9 lb/ply ton in the bondliner plies and the two top plies respectively, where the bondliner is the portion of the sheet against the gypsum core.
The papers so formed as above are more porous and give up moisture by drainage and drying more readily than conventional gypsum board cover sheets. These properties provide substantial drying steam energy savings of 27%. The papers formed above are then used to produce gypsum wallboard in the conventional manner, as described in Procedure B above. The more open porosity of the filled-paper compared to conventional paper provides a 5% board drying energy savings due to easier drying. The converted board demonstrates excellent paper-to-core bond, transverse strengths and decorating characteristics.
The following are the desired ranges for the various constituents utilized:
Fiber Freeness:
Range: 300-550 ml. CSF
Optimum: 350 ml. CSF
Filler, as Calcium Sulfate or Calcium Carbonate:
Range: 10-35 dry weight %
Binder, as Latex or Cationic Starch:
Range: 1-3%
Ratio: 1% Binder/10% Filler
Cationic Flocculant, with Latex Only: Range: 2-4 lb/ton or 0.1-0.2%
Buffer for Calcium Sulfate-Filled Furnish:
As either CaCO 3 or Na 2 CO 3 3
Range: 0.25-10%
Sizing Agent:
As either Ketene Dimer or Succinic Acid Anhydride Compound
Range: 3-7 lb/ton or 0.15-0.35%
Retention Aids:
Cationic Starch: 10-14 lb/ton or 0.5-0.7%
Anionic or Cationic Polymers: 0.5-1.5 lb/ton or 0.025-0.075%
The composite paper of the present invention utilizing calcium sulfate as a filler has several advantages when utilized as paper cover sheets for making gypsum wallboard over other papers conventionally used which do not have a mineral filler. First, it is more porous than conventional papers. Consequently, in the fabrication of the paper, the water utilized drains off more rapidly so that the amount of heat energy required for drying the paper is about 27% less than that required for drying conventional paper. Furthermore, the porous structure of the sheet provides faster drying, higher machine speeds and greater production with existing papermill equipment. Further, when the paper is utilized in the fabrication of gypsum wallboard, because it is porous, about 5% less heat energy is required in drying and setting the wallboard than is required for use with conventional paper cover sheets. Additionally, because of the selected ratios of filler to paper fibers, and because of the binders and binder ratios utilized, the paper has excellent physical properties. Further, in the improved embodiment, utilizing an additional surface size on the side of the paper which engages the gypsum core results in considerably improved bond between the paper and the gypsum core even when subjected to elevated temperature and humidity. Additionally, from an economic standpoint, the use of plentiful and inexpensive gypsum as a filler leads to substantial material economies. Further, the presence of gypsum in the paper leads to excellent adhesion between the paper and the gypsum core of the final gypsum board.
Additional advantages accrue from the use of an internal neutral or slightly alkaline size which results in a paper sheet which is stronger than that made with an acid size such as rosin and alum. Consequently, a sheet of comparable strength to that of the conventional rosin-alum sized sheet may be obtained while using less cellulose fibers. This results in a thinner sheet which drains more readily and more rapidly, and requires less heat for drying, resulting in substantial fuel savings. Alternatively, weaker and less expensive fiber may be utilized, since neutral size does not weaken the fibers. When an acid size such as rosin and alum is used the fibers are materially weakened. An alum and rosin sized sheet is acid by nature due to the addition of the alum. Being acid, the fibers which make up the sheet are stiff and generally tubular and non-conformable. As a result, the bonding provided by these fibers is poorer than that which may be obtained with a more conformable fiber. In contrast, paper which is made with neutral size consists of fibers which are conformable. They assume a flatter position more readily than fibers which are subjected to acid. As a result they provide better bonding and better strength. Consequently, as stated, the improved strength properties of the sheet imparted by the neutral sized fibers can be utilized to reduce the basis weight of the sheet, that is, the amount of materials utilized, and/or to reduce the amount of hard stock used to maintain the strength of the sheet. Other advantages obtained through the use of neutral size are reduced corrosion on the paper machine and a generally cleaner system than an alum and rosin system.
Additionally through the use of a surface size, improved uniformity of internal sizing is obtained. Because of this, the amount of the internal size application may be reduced, while still obtaining good results. Moreover, when manila paper is used, a significant increase in the soft stock content may be utilized. This is made possible by the improved strength of the sheet under like conditions when neutral size is used. The same advantages are obtained when using other papers.
A further advantage has been observed. When paper machines formed of non-corrosion-resistant metal parts are used, such as those made of steel and iron, corrosion is greatly reduced. This result is obtained because the system utilizing neutral size is maintained at a pH of about 7.0-7.8. Consequently the ferrous metal parts are not attacked. On the other hand, the pH conditions of 4.5-5.0, as experienced in the use of an alum and rosin size, cause corrosion of unprotected non-corrosion-resistant metals.
The large reduction of elimination of both alum and rosin size results in a stock system which is a lot cleaner ionically and chemically. This means that fewer problems are encountered with chemical buildup which causes variations in paper quality and excessive filling of the paper machine cylinder wires. Additionally fouling of carrying felts results in a high frequency of shutdowns for cleaning. The use of neutral size also greatly reduces the conditions of high chemical buildup in the system, which may contribute to the above difficulties.
The cationic starch of the invention has several functions. First, it acts as an emulsifying medium in which the size particles are dispersed. Second, it serves to coat the individual particles of size to protect them from hydrolysis. Third, the cationic starch imparts a positive charge to the individual size particles causing them to remain separated from each other. Fourth, the cationic starch serves to attach the size particles electrostatically to individual cellulose fibers. Fifth, the cationic starch acts as a retention aid or binder for the size particles and maintains them affixed to the cellulose fibers. Sixth, the cationic starch enhances the tensile strength of the final paper by improving the fiber-to-fiber bond. Finally, the cationic starch acts as a retention aid to retain the buffer particles, such as calcium carbonate, to the paper fibers.
The buffering agent is utilized to maintain the internal neutral size at a pH of at least 7 and preferably 7 to 7.8. This prevents acid conditions from occurring which would be detrimental to fiber strength. If the acidity of the furnish in the system is not neutralized by the presence of the buffer, the system becomes acid from the acidity in the waste paper furnish and the benefits of the neutral size such as high sheet strength and reduced furnish cost can not be achieved.
The surface size utilized on the surface of the bond liner prevents migration of starch out of the gypsum core and contributes towards better bond between the paper and the core. Suitable surface size materials are silicone resins. Their efficiency may be enhanced by the addition of an acid material to the silicone resin prior to application which assists in the polymerization of the silicone resin. Suitable acidic materials are alum and boric acid.
The neutral or slightly alkaline sizing agents of the present invention may be of two kinds. The first type are the substituted cyclic dicarboxylic acid anhydrides corresponding to the following structural formula: ##STR2## wherein R represents a dimethylene or trimethylene radical and wherein R' is a hydrophobic group containing more than 5 carbon atoms which may be selected from the group consisting of alkyl, alkenyl, aralkyl or aralkenyl groups. Substituted cyclic dicarboxylic acid anhydrides falling within the structural formula above are the substituted succinic and glutaric acid anhydrides.
Specific examples of the above described sizing agents include iso-octadecenyl succinic acid anhydride, n-hexadecenyl succinic acid anhydride, dodecenyl succinic acid anhydride, dodecyl succinic acid anhydride, decenyl succinic acid anhydride, octenyl succinic acid anhydride, nonenyl succinic acid anhydride, triisobutenyl succinic acid anhydride, capryloxy succinic acid anhydride, heptyl glutaric acid anhydride, and benzyloxy succinic acid anhydride. It has been found that optimum results are obtained with acid anhydrides in which R' contains more than twelve carbon atoms. In addition to the above individual compounds, mixtures of these compounds may also be employed.
Among the preferred neutral sizing compositions are Accosize 18 and Fibran 68. Accosize 18 is a trademarked product of American Cyanamid Company and is a substituted succinic acid anhydride having a total of from 15 to 20 carbon atoms, and contains about 1% of an anionic surfactant. Fibran 68 is a trademarked product of National Starch and Chemical Corporation and is a substituted succinic acid anhydride having a total of 15-20 carbon atoms. Fibran 68 normally does not contain any emulsifying agent. However, it is advantageous to add such an agent to promote the emulsification of the product. The amount of sizing agent employed may range from about 0.15% to about 0.35% of the dry weight of the finished paper. Larger amounts may be used without adverse effects, but the excess adds little to the sizing properties.
Other useful neutral or alkaline sizing agents for use in the present invention are ketene dimers, the structural formula of which has been set out above. Among the useful materials are Hercon 32 and Hercon 40 marketed by the Hercules Company.
In those examples where it is used, the cationic retention agent is useful in promoting or aiding the retention of the sizing agents and for bringing the agents into close proximity to the pulp fibers. Although any of a large number of cationic agents may be utilized in the invention, such as alum, aluminum chloride, long chain fatty amines, sodium aluminate, thermosetting resins and polyamide polymers, the preferred cationic agents are the various cationic starch derivatives including primary, secondary, tertiary or quarternary amine starch derivatives. Such derivatives are prepared from all types of starches including corn, tapioca, potato, waxy maize, wheat and rice. The cationic starch agent may be used in an amount by weight of from about 0.5% to about 0.7% based on the dry weight of the paper. A preferred cationic starch is STA-LOK 500 manufactured by the A. E. Staley Manufacturing Company.
The buffer material may be any of a number of compounds which are salts of a cation of a strong base and an anion of a weak acid. Although a number of materials may be utilized such as sodium carbonate and sodium bicarbonate, the preferred buffering agent is calcium carbonate. This material is instrumental in maintaining the pH of the sizing agent and paper in a range of from about 7 to about 7.3. Additionally, the CaCO 3 buffer as filler improves sheet porosity and improves drainage rate, thereby facilitating the drying of the paper and reducing the amount of energy necessary to manufacture the paper and the resultant gypsum wallboard. An amount of at least 2% should be utilized. An amount greater than about 6% is no longer functional as a buffer, but larger amounts up to 10% and greater may be used where the calcium carbonate serves as both a buffer and a filler.
It has been found advantageous to provide a surface coating on the bond liner of the paper, that is, the surface of the paper which becomes affixed to the gypsum core of the wallboard. A preferred material is an epoxy resin such as a silicone emulsion RE-30 a trademarked material marketed by Union Carbide Corporation. Additionally, a silicone emulsion, Tego 5342A, a trademarked material manufactured and marketed by the Goldschmidt Chemical Corporation is suitable. Further, it has been found that even though the use of an acid material to facilitate setting or curing of a sizing agent is detrimental when used as an internal sizing agent, the use of an acid material such as alum or boric acid with the epoxy sizing agent as a surface size facilitates the cure of the epoxy resin, and, because it does not enter internally into the paper, does not adversely affect the strength of the paper fibers.
As stated, in order to achieve the required quality performance of neutral-size paper utilized to fabricate gypsum wallboard, the addition of a weak acid material such as alum to the dilute silicone emulsion in the concentration of 1% alum solids is critical for achieving optimum performance.
Prior to the use of the present novel application of alum to the external silicone size itself, it was found that neutral-sized paper which was contaminated at discreet points in the surface of the paper with dirt, shives and bark, and which was surface sized with untreated silicone emulsion had a tendency to form mini-cockles (dimples) in the gypsum wallboard. Subsequent field tests showed that the paper in the area of the dimpling was poorly sized internally and had substantial amounts of dirt in it.
When alum-treated silicone was applied to the surface of the paper in manufacture, the dimpling of the board was eliminated. It is believed that the alum-acidified silicone did not strike into the paper in the areas of poor internal sizing, whereas the untreated silicone did strike in. This strike-in defeated the purpose of the silicone which was to give uniform paper sizing to provide a cockle-free board. It is believed that where a surface size strikes into the sheet of paper it is unavailable at the paper surface to provide surface sizing.
Alum-treated silicone size is most effective when applied to the surface of a sheet having a filler of a material such as calcium carbonate which acts as a buffer. When the alum-treated silicone comes in contact with the calcium carbonate, the pH changes from 3.5-4.0 to neutrality. It is believed that this causes the silicone to cure out on the paper surface, thereby providing the desired sizing uniformity. The alum addition appears to have no appreciable adverse effect on the tensile strength of the resulting paper, nor any visible adverse effect on the stability of the silicone emulsion nor on its tendency to polymerize. Whatever curing effect takes place occurs as the silicone is applied to the surface of the unsized, neutral and 5% calcium carbonate filled paper.
It is to be understood that the invention is not to be limited to the exact details of operation or materials described, as obvious modifications and equivalence will be apparent to one skilled in the art. | A composite paper particularly adapted for use as cover sheets in the production of gypsum wallboard, the paper being sufficiently porous to permit better drainage and more rapid drying in the production of the paper, and when applied to the surfaces of a gypsum slurry for forming wallboard, permits less heat to be utilized in the wallboard conversion, thereby saving energy in the board production required for drying the board. The paper comprises in weight percent:
(A) cellulosic fibers in an amount of from about 65% to about 90% and preferably having a fiber freeness of from about 300 ml to about 550 ml Canadian Standard Freeness,
(B) calcium sulfate as a filler in an amount of from about 10% to about 35%,
(C) a binder in an amount from about 1% to about 31/2%,
(D) a flocculant in an amount of from about 0.1% to about 0.2%,
(E) a buffering agent in an amount from about 0.25% to about 10%,
(F) a neutral sizing agent in an effective amount to prevent water penetration,
(G) an anionic polymer in an amount suitable for retaining said filler in said paper, and
(H) a cationic starch when a succinic anhydride is used as the neutral sizing agent.
In a preferred embodiment, after the paper is treated with a neutral internal sizing agent during its formation, it is subsequently treated with a surface sizing agent after formation of the paper, in order to provide certain properties including better adhesion to the gypsum core when used to make gypsum wallboard. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a method of supporting a roof, particularly a roof of an underground excavation such as a mine, and to a system for carrying out the method, i.e. to apparatus for this purpose.
2. The Prior Art
In underground excavations, for example in mining galleries, tunnels and the like, it is usually necessary to support the roof of the excavation against cave-in under the pressure of the overburden. Various approaches for effecting such support are known from the prior art. For example, in coal mining it is known to use the so-called "room and pillar system" in which roof bolting is used, i.e. steel rods or bars which penetrate the rock layers and hold them together to prevent collapse. It is also known to provide various types of supporting structures of wood and/or steel in which rigid or slightly yieldable supporting elements are used to support the roof from below against collapse.
The problem with this latter type of approach, to which the present invention is also directed, is that the prior-art proposals are all relatively complicated and expensive and are difficult to erect and to move. The elements involved are relatively expensive and of considerable weight so that they are difficult to handle. There is also a decided lack of economy, both in the materials involved and in the installation work required.
SUMMARY OF THE INVENTION
It is a general object of the present invention to overcome the disadvantages of the prior art.
A more particular object of the invention is to provide an improved method of supporting an overburden, particularly a roof of an underground excavation such as a mine, which is not possessed of the prior-art disadvantages.
A concomitant object of the invention is to provide such an improved method which allows the handling and installation of the support elements in a simpler and quicker manner than heretofore possible.
Another object of the invention is to provide such a method which facilitates the erection of roof supports and reduces the costs involved therein.
A further object of the invention is to provide an improved system (e.g. arrangement) for supporting a roof, particularly a roof of an underground excavation such as a mine.
The improved system is to be simpler and less expensive to construct than those of the prior art.
An additional object of the invention is to provide such an improved system which utilizes support elements that can be readily moved and installed because they are light in weight.
A concomitant object of the invention is to provide such a system wherein the support elements are inexpensive.
Still another object is to provide a system the prop casings of which can be transported and stored in substantial quantities at a time, but require extremely little space.
Yet a further object is to provide such a system in which the diameter of the prop casings (and hence the final load-bearing capacity of the ultimately obtained column) can be varied in an extremely simple and efficient manner.
Pursuant to the above objects, and still others which will become apparent from a reading of the specification, one feature of the invention resides in a method of supporting an overburden, particularly a roof of an underground excavation such as a mine. Briefly stated, such a method may comprise the steps of providing a hollow tubular prop casing having at least one section of self-supporting sheet material and which is circumferentially incomplete and has a longitudinally extending slit, overlapping marginal portions of the sheet material bounding the slit, to an extent requisite for obtaining a desired diameter of the section, arresting the overlapped portions in their overlapped condition, erecting the prop casing so that it bears upon the roof to be supported, and filling the prop casing with a hardenable substance in flowable condition so that the substance, upon hardening thereof, forms a solid column which is by itself able to support the roof.
The system or arrangement according to the invention may, briefly stated, comprise a hollow tubular prop casing having at least one section of self-supporting sheet material and which is circumferentially incomplete and has a longitudinally extending slit bounded by marginal portions which can be overlapped to a desired degree to give the section a selectable diameter, means for arresting the marginal portions in a desired overlapped position, and means for filling the prop casing, subsequent to erection of the same so that it bears upon the roof to be supported, with a hardenable substance in flowable condition so that the substance, upon hardening thereof, forms a solid column which is by itself able to support the roof.
It is important to understand that the inventive prop casing has no supporting function per se at all, acting only as a receptacle for the hardenable substance. The supporting function is carried out by the hardenable substance when the same has hardened and forms a solid column within the prop casing. For this reason the prop casing can be made of relatively lightweight and inexpensive material, for instance sheet metal, synthetic plastic material such as polyvinylchloride or polyethylene, or even of a heavy grade of cardboard the inner surface of which is coated (e.g. with wax or with foil of such synthetic plastic material as polyvinylchloride or polyethylene) to prevent the cardboard from disintegrating under the influence of the filler substance while the same is still in flowable condition.
The filler substance itself may be a concrete slurry, i.e. a mixture of water and a quick-binding cement, preferably in form of cement powder. Aggregate may be added (it may already be accommodated in the prop casing before the slurry is admitted into the same) to further increase the strength of the column being formed. In lieu of, or in addition to the aggregate the prop casing may, after it is erected at the place where support is required, already contain at least some of the cement powder which is ultimately required to make the slurry. Other materials are also suitable for the hardenable substance, for example gypsum which again may be reinforced with aggregate, or a two-component adhesive system of synthetic plastic material which, when the two components are admixed with one another, will harden and form the requisite solid column. Here, again, aggregate may be employed in addition, to become embedded in the two-component system so as to further reinforce the same. The aggregate can be in form of gravel or the like as is known from the construction industry. If gypsum is used, some or all of the gypsum powder required to form the solid column may already be contained in the erected hollow prop casing before water is admitted into the same, and if a two-component adhesive system is used one of the two components may already be wholly or in part accommodated in the erected hollow prop casing before the other component is admitted into the same. The aggregate may be admitted from outside during admission of the other component, or of the water, but preferably will already be present in the interior of the prop casing at this time.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat diagrammatic vertical section, illustrating one embodiment of the invention;
FIG. 2 is a section on line II--II of FIG. 1;
FIG. 3 is a view similar to FIG. 1, but of a different embodiment of the invention;
FIG. 4 is a vertical section showing still another embodiment;
FIG. 5 is a partly sectioned enlarged view showing a detail of the embodiment in FIG. 4;
FIG. 6 is a vertical sectional view illustrating an additional embodiment;
FIG. 7 is a view similar to FIG. 6, but of a further embodiment;
FIG. 8 is a view analogous to the one in FIG. 7 but showing a modified embodiment;
FIG. 9 is still a further axial section, showing an additional embodiment;
FIGS. 10-13 are all cross-sections showing, diagrammatically, how the overlapped condition of the respective casings may be fixed against change; and
FIG. 14 is another cross-section, showing how a plurality of the inventive casings may be interleaved for storage and transport.
DESCRIPTION OF PREFERRED EMBODIMENTS
In all Figures herein the overburden to be supported, e.g. the roof of a mining excavation, is designated with reference character R, and the floor with character F.
With this in mind, and turning now to FIGS. 1-2, it will be seen that in the embodiment there illustrated the prop casing is composed of two tubular sections 1 and 2 which can be telescoped together or apart to change the length of the casing, as required. However, it is to be understood that a single casing may be used where telescopic adjustment is not required.
Each of the sections 1 and 2 is composed of one of the earlier-mentioned self-supporting sheet materials, i.e. of a material which is capable of retaining a tubular shape once given to it, and to confine the hardenable material for which it is to act as a casting form. The material of each of the sections is provided with a longitudinally through-going slit, as visible in FIG. 2. The slit of section 2 is bounded by marginal portions 3, 4 and the slit of section 1 by marginal portions 5, 6. These portions can be overlapped to the desired degree to thereby increase or decrease the diameter of the respective tubular section, for example in dependence upon the load to be supported by the same. How the portions are arrested in overlapped condition will later be described with reference to FIGS. 10-13.
After the portions have been overlapped and arrested in their overlapped condition, the casing is erected and the sections 1, 2 telescoped apart until they bear upon the roof R and floor F. In this position they may then be arrested against relative movement in axial direction of the casing; for example, in the manner disclosed in allowed U.S. application Ser. No. 860,096 the disclosure of which is incorporated herein in its entirety. Thereafter, the casing is filled with the hardenable material, e.g. again in the manner disclosed in the aforementioned U.S. application, and the material is allowed to harden.
When the hardening is completed the material forms within the sections 1, 2 a rigid support column 7 which by itself constitutes the support for the roof R. It will be appreciated, therefore, that the casing composed of the sections 1, 2 need only act to contain the material until it hardens to form column 7; i.e. it acts as a casting form having the particular virtues of light weight, adjustability, economy of material and economy of storage, transportation and installation.
During admission and hardening of the material which will ultimately form the column 7, use may be made of a device 8 which will be described in more detail later, in connection with FIGS. 4 and 5.
Naturally, more than two sections 1, 2 may be used together, so that the overall length (i.e. height) of the casing can be selected at will in accordance with the particular requirements of a given application.
If, as mentioned before, a single-section casing is used, then the casing 9 may--as shown in FIG. 3--be provided with a portion shaped as a bellows 10. This bellows portion 10 is axially compressible to some extent so that, after the casing 9 is put in place between roof R and floor F and the compressing force is terminated, the inherent expansion of the bellows portion 10 causes the upper and lower ends of the casing 10 to be urged against the roof and the floor with sufficient force to hold the casing in place and to prevent escape of the flowable material while it undergoes hardening. Of course, use of this measure is also possible in a bi-partite or multi-partite casing (e.g. the one in FIG. 1), if desired.
The embodiment of FIGS. 4-5 makes use of the same sections as FIGS. 1-2 and, therefore, the same reference numerals have been used for these sections as well as for the column 7.
The device 8 is shown in detail in FIGS. 4 and 5. Its purpose is to avoid loss of pressure or of volume in the hardenable substance after the same has been filled under pressure into the prop casing. If such a loss were to occur, the hardenable substance would recede downwardly out of contact with the roof R; this would prevent the firm engagement required to support the roof.
Device 8 cooperates with the filling tube 11 which is provided in its wall with at least one opening 12 that communicates with the interior of the casing when the tube 11 and device 8 are installed in registering apertures of the casing wall. Flowable material admitted into the tube 11 enters the casing through the opening 12. Device 8 is in effect a plug which may be a tubular container filled with concrete or any other suitable material (or it may simply be a concrete casting) and has at its leading (inner) end a reduced-diameter portion. Inwardly of the opening 12 the filling tube has an endwall 14 and inwardly of the same a tubular extension 15. After the tube 11 is installed in the casing from one side, the plug 8 is inserted into the casing from the other side until its portion 13 enters the tubular extension 15. The casing is now filled with the hardenable substance via tube 11 and opening 12. When filling is completed, but while the not-illustrated filling device still feeds material under pressure to the tube 11 (i.e. still maintains pressure upon the contents of the casing) the plug 8 is driven into the casing, as indicated by the arrow in FIG. 4, until the portion 13 enters the aperture through which tube 11 (which in the process is being expelled) previously extended into the casing. The portion 13 now closes this aperture and the device 8 thus prevents the loss of pressure or volume.
The embodiment in FIG. 6 is similar to the one in FIG. 4, except that here the casing is made up of a center section 16 onto the top of which two extension sections 17, 18 are telescoped, whereas two further extension sections 19, 20 are telescoped onto the bottom end of the section 16. The device 8 is used again, as before.
The use of the multiple extension sections permits length adjustment of the casing to the requisite extent. That could, however, also be achieved by using two sections 16 of e.g. identical length, whereas it will be noted that the sections 17-20 in FIG. 6 are rather short. The reason for this is that these short sections 17-20 are used only secondarily to extend the length of the overall casing. Their primary purpose is to provide a larger interface between the column 7 and the roof R, respectively the floor F. This, as will be evident from the drawing, is achieved by the fact that several (here two at each end) successively larger-dimensioned sections are used, so that the inner diameter of the final section 18 respectively 20 is substantially larger than the corresponding diameter of the section 16. Naturally, the diameter of the surface of that portion of column 7 which is located in the respective section 18 or 20 and which engages the roof or floor, will similarly be larger. This embodiment is therefore especially suitable for use in circumstances where the roof and/or floor is not very stable.
The embodiment in FIG. 7 is a variation of the one in FIG. 6. Here, a non-telescoping section 21 is used and has its lower end portion surrounded with spacing by a section 22 of small height. The section 22 is first filled with hardenable material in flowable state (may be the same as used for column 7). When this material has partially but not fully hardened, the section 21 is put in place and filled with the material for column 7 (one may wait until material 23 has hardened). The section 22 with its filling 23 thus in effect serves as a "foundation" which prevents escape of the flowable material from the bottom of section 21, furnishes a stable support for the section 21 and, of course, bridges relatively small differentials in the height of the section 21 and the distance from floor F to roof R.
The embodiment of FIG. 8 operates on the same principle as the one in FIG. 7, except that here short extension sections 24 and 25 are used adjacent the roof and the floor; these again contain hardenable material, identified with reference numeral 6. The sections 24 and 25 are of frustoconical configuration, each having its widest part adjacent the roof or floor, respectively, so as to provide a large stress-transmitting interface between the fillings 26 (and hence the column 7) and the floor F and roof R, respectively.
FIG. 9 shows an embodiment using a single, non-telescoping section 27 which it is desired to so erect that it will be pressed against the roof R with a relatively small force, but one which is adequate to maintain the section 27 in position while it is being filled and the filling hardens to form the column 7. For this purpose a wire structure 28 (e.g. an axially springily yielding ring or coil of wire) is placed between the lower end of section 27 and the floor F. To prevent the escape of flowable material from section 27 once filling of the same begins, a substance is applied around the wire structure 28 and lower end of section 27, so as to embed them and seal them to the floor F. This substance may, for example, be quick-hardening cement; once it has sufficiently hardened the introduction of flowable material into the section 27 can begin in the usual manner. The substance 29, incidentally, also increases the size of the interface via which stresses are transmitted between the column 7 and the floor F.
The same arrangement may also be provided between the roof R and the upper end of section 27, or it may be used there instead of at the lower end. Of course, the substance 29 must harden quickly enough, and have an appropriate consistency, to assure that it will not drip off the roof R when applied thereto.
Different ways of maintaining the desired degree of overlap of the marginal portions of the sheet-material sections, are shown in FIGS. 10-13. In this connection it is noted that the term "overlap" as used herein is expressly intended to refer also to the conditions shown in FIGS. 10 and 11, i.e. where the marginal portions do not actually overlie one another but instead are merely butted together.
In all FIGS. 10-13 the illustrated section is designated with reference numeral 30. In FIG. 10, however, its butted-together edges are bonded together by means of a suitable known-per se adhesive 31 and/or one or more (axially spaced) straps 32 of metal or synthetic plastic material are cinched about the section 30.
In FIG. 11 the butted-together edges of section 30 are held in place by an adhesive strip 33 of e.g. metal or synthetic plastic material which straddles them and extends longitudinally of section 30.
FIG. 12 shows that adhesive material 34 (known per se) may be placed between the overlapped edge portions to secure them to each other, whereas FIG. 13 shows that staples 35 (one shown) or the like may be driven through the overlapped edge portions of section 30 to hold them in position.
Of course, the possibilities shown in FIGS. 10-13 are not to be considered exhaustive; other possibilities, such as e.g. the placing of axially spaced retaining rings or the like about the sections, are also feasible.
Finally, FIG. 14 shows the versatility of the improvement according to the invention. For storage and/or transport a large number of sections--here designated 36-39--may simply be interleaved, i.e. coiled together. It must be remembered that each section is in effect an item of sheet-material which may or may not be precurved, but which can certainly be rolled up together with other similar items. Nor is the number of such items per roll confined to four, as shown by way of example in FIG. 14.
It can readily be seen that a large number of the sections can be stored and transported in a space not much larger than that which is taken up by a single section. This is a consideration which is particularly important in terms of the usually cramped below-ground storage and transportation facilities. Moreover, the sections are light in weight, and can therefore be erected by very small numbers of personnel and without the aid of expensive and bulky equipment. The material of the sections themselves, as well as the filling material for them, is inexpensive and this, in conjunction with the ease and small expense of their erection, promises to drastically influence tunnelling and underground mining activities, where such roof supports are needed in very large numbers.
While the invention has been illustrated and described as embodied in the supporting of mine roofs, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | Roofs of underground excavations are supported by forming sheet-material elements into tubes whose diameter can be varied by changing the overlap between the longitudinal edges of the rolled-up sheet material, standing the tubes upright to bear against the roof and the floor of the excavation, and filling them with hardenable material in flowable condition which, after hardening, will form a roof-supporting column. | 4 |
BACKGROUND OF THE INVENTION
The copending application of D. Maricle, U.S. Ser. No. 863,816 filed -- describes a regenerative cell utilizing an aqueous solution of hydrochloric acid or a chloride salt as the electrolyte in a hydrogen-chlorine fuel cell. Such a cell requires a storage space for the HCl or salt electrolyte in the discharged state, necessitating a pumped electrolyte system. Further, complete separation of gaseous hydrogen chloride from the aqueous electrolyte is difficult during discharge of the cell making it difficult to store this HCl in any form except in the aqueous electrolyte. In this form, it necessitates the use of materials for the storage tank that are resistant to the corrosive action. If this HCl is removed as a gas, and also when the chlorine is removed from the electrolyte as a gas during charging of the cell, these gases carry with them substantial wetness from the electrolyte. In this form, these gases are much more corrosive than when dry. The cell accessories thus require the use of materials resistant to these gases or the use of extensive drying techniques which are undesirable complications.
SUMMARY OF THE INVENTION
The principal feature of this invention is a hydrogenchlorine regenerative cell utilizing an anhydrous electrolyte thereby avoiding the corrosive action of the chlorine gas and also the hydrogen chloride dissolved in or carrying moisture from the water of the electrolyte. Another feature is the use of an electrolyte in which both gaseous hydrogen, chlorine and hydrogen chloride gas are readily dissolved but from which they are readily evolved or evaporated by reason of the low vapor pressure. This evolution of the HCl from the electrolyte facilitates storage of HCl since it can be stored as a compressed gas.
According to this invention, the regenerative cell utilizes hydrogen and chlorine as the reactant gases, electrodes capable of functioning as reversible gas diffusion hydrogen and chlorine electrodes and as an electrolyte, an anhydrous inorganic or organic solvent or a molten salt having a low vapor pressure with respect to both chlorine and hydrogen chloride. If it is desirable to use as an electrolyte a solvent that is non-ionic, a conductive salt may be added to make the electrolyte conductive or the dissolved HCl may itself function as the conductive material in the electrolyte.
The foregoing and other objects, features, and advantages of the present invention will become more apparent in the light of the following detailed description of preferred embodiments thereof as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a diagrammatic view of a fuel cell utilizing the invention. de
DESCRIPTION OF THE PREFERRED EMBODIMENT
The cell to which the invention is applicable is shown diagrammatically and only a single cell is shown. In the usual construction a stack of cells would be assembled to produce the desired voltage within the stack. The cell includes a matrix 2 which is porous and supports the electrolyte therein. This electrolyte is selected to be water-free. A preferred electrolyte is anhydrous phosphoric acid (H 3 PO 4 ) or H 2 SO 4 , either of which dissolves the gaseous HCl, Cl 2 and H 2 to a sufficient extent to support the electrochemical reactions within the cell, from which the hydrogen chloride is readily separated during the discharge of the cell and from which the H 2 and Cl 2 are readily evolved during charge. Other electrolytes may be molten salts such as a mixture of AlCl 3 , NaCl and KCl with a melting point of 70° F. or, less desirably, organic solvent such as propylene carbonate or inorganic solvents such as POCl 3 .
On opposite sides of the matrix 2 are the electrodes 4 and 6 each of which is a gas diffusion electrode as for example compressed graphite fibers formed into a thin plate. One example is described in U.S. Pat. No. 3,972,735. Both electrodes may be the same material or it may be desirable to make the cathode, the chloride electrode, from a titanium screen, provided the density of the screen accomplishes the necessary results of a gas diffusion electrode.
On the face of the hydrogen electrode 4, the anode, is a catalyst layer 8 preferably supported platinum so applied as not to affect the porosity and the necessary functioning of the electrode. One example of this structure is described in U.S. Pat. No. 4,028,274. On the face of the chlorine electrode, the cathode, is a catalyst layer 10 in contact with the matrix. This catalyst is preferably ruthenium oxide so applied as not to affect the necessary functioning of the cathode as a gas diffusion electrode. As an alternative to the graphite electrode, the cathode maybe a titanium screen as above stated.
Against the electrodes on the sides opposite to the matrix are chambers 12 and 14, supplied with gas under pressure, hydrogen to chamber 12 and chlorine to chamber 14. These gases may be supplied from tanks 16 and 18 through conduits 20 and 22 to the respective chambers. These conduits may have pressure control valves 24 and 26 therein so that the gases in the chambers will be at the most favorable pressure when the cell is being discharged. Parallel conduits 28 and 30 may have pumps 32 and 34 for pumping the respective gases from the chamber under pressure into the tanks during charging or recharging of the cell.
The generated hydrogen chloride gas resulting from cell discharge is collected in a tank 36 connected by a branching conduit 38 to both chambers 12 and 14. A pump 40 may pump this gas into the tank under pressure. During recharging hydrogen chloride enters chambers 12 and 14 through another branching conduit 42 to be electrochemically broken up into hydrogen and chlorine which enter the respective chambers. A pressure control 44 may be provided in conduit 42.
In operation, during discharge, H 2 and Cl 2 enter the chambers 12 and 14, respectively, at one end of the chamber and pass through the respective electrodes into contact with the electrolyte in the catalyst areas. These gases combine electrochemically in the cell producing electricity and forming gaseous HCl that is dissolved temporarily in the electrolyte. As the quantity of dissolved HCl increases in the electrolyte by the cell discharge, some of this HCl is evolved from the electrolyte, migrates through the electrodes in a direction opposite to the movement of H 2 and Cl 2 and this evolved HCl then passes through the branching conduit 38 into the tank 36. Obviously, a small amount of H 2 and Cl 2 will become mixed with the HCl but this is not detrimental to the operation of the cell. Obviously, as shown, the conduit 38 connects to the chambers 12 and 14 at the ends remote from the conduits supplying the gaseous H 2 and Cl 2 . The electricity produced is led off from the electrodes by leads 46.
During charge, electricity is supplied from a source through the leads 46 to the electrodes. HCl is now supplied through branch conduit 42 to the chambers and this gas flows through the electrodes to be dissolved in the electrolyte from which it is electrolyzed into H 2 and Cl 2 at the respective electrodes. These gases pass through the electrodes to the chambers and are collected in the respective tanks. The small amount of HCl that mixes with the H 2 and Cl 2 gases is not detrimental to the cell operation.
On charge, storage of both products is exothermic and the delivery of HCl to the cell is endothermic, so suitable heat exchangers or heat pumps may be essential to be successful operation. For optimum efficiency of the total cell, these exchangers and heat pumps will be interconnected for heat transfer between them to minimize heat loss. On discharge, the reverse is true so the heat exchangers and/or heat pumps would operate in the reverse direction to provide an appropriate heat balance.
The advantages of an anhydrous cell are many. One is that the volume of electrolyte is limited to that required to operate the fuel cell power section. Both the reactant gases and the product (gaseous HCl) can be pumped from the electrolysis cells and stored as gases or pure liquids rather than dissolved in aqueous solvents. Thus improves the gravimetric and volumetric energy density.
Another advantage is that with an anhydrous electrolyte there is no water to cause the gases to be wet and both chlorine and hydrogen chloride gases are much less corrosive when dry. Thus, there is no need to dry either of these gases when they are being stored in the tanks.
Although the gases may be stored as a gas it may be desirable to store both chlorine and HCl in liquified form rather than as gases, or the HCl may be stored by adsorption on a solid support material. Hydrogen may be stored cryogenically as a highly compressed gas or as a metal hydride such as TiFeH 1 .6.
Obviously, in discharge, the fuel cell operates in the usual way. Gaseous hydrogen and gaseous chlorine entering the cell through the respective electrodes combine to form hydrogen chloride gas and in so doing the pairing molecules of the gases produce electricity. The electricity may be led from the cell by the usual electrical connections to the electrodes.
During charge, electricity entering the cell by way of the electrodes breaks the hydrogen chloride dissolved in the electrolyte into hydrogen and chlorine at the respective electrodes and these gases enter the respective chambers from which they are pumped for storage.
To minimize polarization of the chlorine electrode while avoiding excess self-discharge by migration of dissolved chlorine to the hydrogen electrode, it may be desirable to use in the electrolyte an additional chlorine salt by which to control the solubility of the chlorine gas in the electrolyte.
Although the invention has been shown and described with respect to a preferred embodiment thereof, it should be understood by those skilled in the art that other various changes and omissions in the form and detail thereof may be made therein without departing from the spirit and the scope of the invention. | A regenerative fuel cell in which the reactive gases are hydrogen and chlorine and the electrolyte is a conductive anhydrous solvent in which the chlorine gas and the hydrogen chloride gas are soluble, this electrolyte readily releasing the gaseous hydrogen chloride for storage during discharge of the cell. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/045,928 filed Sep. 4, 2014. The disclosure of the above application is incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to an active electromechanical hydraulic fluid level control system for an automatic transmission, and more particularly to an assembly for actively controlling hydraulic fluid level between a sump and a side or front cover in an automatic transmission using an electromechanical device.
BACKGROUND
[0003] A typical automatic transmission includes a hydraulic control system that is employed to provide cooling and lubrication to components within the transmission and to actuate a plurality of torque transmitting devices such as clutches and brakes. The hydraulic control system typically includes a sump located at a bottom of the transmission that collects the hydraulic fluid from the remainder of the hydraulic control system. The sump stores the hydraulic fluid to be suctioned back into the hydraulic control system by a pump. A minimum level of hydraulic fluid is required in the sump in order to feed the hydraulic control system for all ranges of transmission operation and to account for dynamic movement of the hydraulic fluid within the sump. It is desirable to keep the amount of hydraulic stored in the sump to this minimum level since hydraulic fluid in the sump interferes with the rotating components of the transmission. The rotating components, including for example gears, clutch plates, and interconnecting members, traveling through the stored hydraulic fluid within the sump experience increased drag, thus increasing spin losses and in turn decreasing the efficiency of the transmission.
[0004] The minimum level of hydraulic fluid that must be stored in the sump varies based on various factors including the operating temperature of the hydraulic fluid. Therefore it is desirable to store excess hydraulic fluid out of the sump and in a separate area that does not interfere with rotating components. One solution is to actively control the level of hydraulic fluid between the sump and a front or side cover of the transmission using a passive thermal valve. These passive thermal valves allow hydraulic fluid to flow between the sump and the front cover based on the temperature of the hydraulic fluid. While these systems are useful for their intended purpose, there is a need in the art for an active control system that minimizes cost and mass and that allows excess hydraulic fluid to be stored out of the sump during normal operating conditions but not during certain other conditions, such as end-of-line testing or transportation of the transmission.
SUMMARY
[0005] An active electromechanical armature assembly for a transmission is provided. The active electromechanical armature assembly improves fuel economy by storing transmission fluid in areas away from rotating components during hot operation. However, during other conditions the transmission fluid is kept in the sump. The active electromechanical armature assembly is a device which converts electrical energy into mechanical movement of an armature or plunger. Movement of the plunger seals and unseals an opening that communicates between the sump and the side or front cover of the transmission. The present invention improves fuel economy by as much as 0.5% by storing excess hydraulic fluid away from rotating components.
[0006] In one example, an assembly for use in a transmission of a motor vehicle includes a first fluid reservoir, a second fluid reservoir having a hole that communicates with the first fluid reservoir; and an electromechanical assembly disposed in the second fluid reservoir. The electromechanical assembly includes a coil, an armature disposed within the coil and moveable between a first position and a second position, and a plunger head connected to an end of the armature for sealing the hole between the first and second fluid reservoirs when the armature is in the first position.
[0007] In another example, the first fluid reservoir is located in a sump of the transmission and the second fluid reservoir is located in a side cover of the transmission.
[0008] In another example, the control valve further includes a biasing member that biases the armature to the second position.
[0009] In another example, the control valve further includes a coil housing connected to an end cap, and the coil is disposed within the coil housing and the armature extends out from the end cap.
[0010] In another example, the coil is disposed around an inner sleeve and the armature is slidable within the inner sleeve.
[0011] In another example, the coil is interconnected to an electronic control module.
[0012] In another example, the armature includes a base portion slidably disposed within the inner sleeve and a neck portion connected to the plunger head, and the neck portion is extended out from a bore in the end cap.
[0013] In another example, the plunger head includes an angled front surface that complements an angled surface surrounding the hole.
[0014] In another example, the biasing member is disposed partially within the inner sleeve and partially within an enlarged section of the bore of the end cap.
[0015] In another example, the biasing member is disposed around the neck portion of the armature and is in contact with an inner surface of the end cap and with the end surface of the base portion of the armature.
[0016] In another example, the first reservoir is separated from the second reservoir by a separator wall, and the hole is disposed through the separator wall.
[0017] In another example, the control valve is connected to the separator wall.
[0018] In another example, the second reservoir is disposed in a bottom portion of a side cover of the transmission.
[0019] In another example, the second reservoir is not in direct communication with rotating components of the transmission.
[0020] Further features and advantages of the present invention will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0022] FIG. 1 is a schematic diagram of an exemplary front wheel drive transmission according to the principles of the present invention;
[0023] FIG. 2 is an enlarged cross section of a portion of the exemplary front wheel drive transmission shown in FIG. 1 ;
[0024] FIG. 3 is a front or side view of the exemplary front wheel drive transmission of FIG. 1 with a side or front cover removed;
[0025] FIG. 4 is a side view of an electromechanical armature assembly used in the exemplary front wheel drive transmission according to the principles of the present invention;
[0026] FIG. 5A is a cross-sectional view taken in the direction of arrows 5 - 5 in FIG. 4 of the electromechanical armature assembly in a first position; and
[0027] FIG. 5B is a cross-sectional view taken in the direction of arrows 5 - 5 in FIG. 4 of the electromechanical armature assembly in a second position.
DESCRIPTION
[0028] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0029] With reference to FIG. 1 , a schematic diagram of an exemplary transmission is generally indicated by reference number 10 . The transmission 10 is an automatic, front wheel drive, multiple speed transmission. However it should be appreciated that the transmission may be a manual transmission or any other type of transmission without departing from the scope of the present invention. The transmission 10 includes a typically cast, metal housing 12 which encloses and protects the various components of the transmission 10 . The housing 12 includes a variety of apertures, passageways, shoulders and flanges which position and support these components. The transmission generally 10 includes an input shaft 14 , an output shaft 16 , a starting device 18 , and a gear arrangement 20 . The input shaft 14 is connected with a prime mover (not shown) such as an engine. The prime mover may be an internal combustion gas or Diesel engine or a hybrid power plant. The input shaft 14 receives input torque or power from the prime mover. The output shaft 16 is preferably connected with a final drive unit (not shown) which may include, for example, propshafts, differential assemblies, and drive axles. The input shaft 14 is coupled to and drives the gear arrangement 20 through the starting device 18 . The starting device 18 is illustrated as a torque converter in the example provided, though various other hydrodynamic and mechanical devices may be used without departing from the scope of the present invention.
[0030] The gear arrangement 20 generally provides multiple forward and reverse speed or gear ratios between the input shaft 14 and the output shaft 16 . The gear arrangement 20 may have various forms and configurations but generally includes a plurality of gear sets or a continuously variable unit having a chain or belt and movable pulley pairs, a plurality of shafts or interconnecting members, and at least one torque transmitting mechanism. The gear sets may include intermeshing gear pairs, planetary gear sets, or any other type of gear set. The plurality of shafts may include layshafts, countershafts, sleeve or center shafts, reverse or idle shafts, or combinations thereof. The torque transmitting mechanisms may include clutches, brakes, synchronizer assemblies or dog clutches, or combinations thereof, without departing from the scope of the present invention.
[0031] Operation of the starting device 18 and gear arrangement 20 , including selection of gear ratios via clutch and brake engagement, is controlled by an electronic transmission control module (ETCM) 22 and a hydraulic control system 24 . The ETCM 22 is preferably an electronic control device having a preprogrammed digital computer or processor, control logic, memory used to store data, and at least one I/O peripheral. The control logic includes a plurality of logic routines for monitoring, manipulating, and generating data. The ETCM 22 controls the actuation of the torque transmitting mechanisms in the gear arrangement 20 via the hydraulic control system 24 . The hydraulic control system 24 generally includes electrically controlled solenoids and valves that selectively communicate hydraulic fluid throughout the transmission 10 in order to control, lubricate, and cool the various components of the transmission 10 .
[0032] The hydraulic fluid used by the hydraulic control system 24 is primarily stored in a sump or reservoir 26 . The sump 26 is preferably located at a bottom of the transmission 10 . A pump (not shown) produces a suction that draws the hydraulic fluid from the sump 26 and into the hydraulic control system 24 where the hydraulic fluid is used to engage torque transmitting mechanisms and to cool and lubricate the transmission 10 .
[0033] The transmission 10 further includes a front or side cover 28 attached to a side or front of the transmission 10 . The side cover 28 protects components of the hydraulic control system 24 within the transmission 10 and functions as a secondary transmission oil storage reservoir, as will be described in greater detail below.
[0034] Turning to FIGS. 2 and 3 , the transmission housing 12 includes a separator wall 12 a that extends vertically from a bottom of the housing 12 to a top of the housing 12 . A rim or flange 12 b extends perpendicularly out from the separator wall 12 a. The flange 12 b is disposed around the entire outer periphery of the separator wall 12 a, forming a pocket or cavity 32 . Various components of the transmission 10 are disposed within the cavity 32 , for example a transmission valve body 34 of the hydraulic control system 24 . The transmission valve body 34 contains many of the pressure regulation valves, directional valves and solenoids that control the transmission 10 .
[0035] The side cover 28 is configured to connect and seal to the flange 12 b, thus enclosing the cavity 32 . For example, the side cover 28 includes a wall or rim 28 a that extends perpendicularly out from a main portion 28 b. The rim 28 a is disposed around the entire outer periphery of the side cover 28 . The rim 28 a includes a plurality of bolt holes 36 that align with a plurality of bolt holes 38 formed on the flange 12 b. A plurality of bolts 40 or other fasteners connect the side cover 28 to the housing 12 overtop the cavity 32 . A seal (not shown) is disposed on or radially inward of the rim 28 a in order to seal the side cover 28 to the flange 12 b of the housing 12 .
[0036] A lower portion or secondary reservoir 32 a of the cavity 32 acts as a secondary hydraulic fluid reservoir to the sump 26 . The secondary reservoir 32 a is not in communication with any rotating components of the transmission 10 . Communication of the hydraulic fluid from the secondary reservoir 32 a to the sump 26 is controlled via an active electromechanical armature assembly or control valve 50 . The electromechanical armature assembly 50 is disposed within the secondary reservoir 32 a of the cavity 32 near a bottom of the transmission housing 12 . The electromechanical armature assembly 50 opens and closes a drain hole or sump drain-back 51 disposed in the separator wall 12 a. The drain hole 51 allows fluid communication between the sump 26 and the secondary reservoir 32 a.
[0037] Turning to FIG. 4 , the electromechanical armature assembly 50 generally includes a coil housing 52 connected to an end cap 54 . A moveable plunger or armature 56 extends out from the end cap 54 . The armature 56 is moveable between a first position, shown in FIG. 5A , and a second position shown in FIG. 5B . Movement of the armature 56 selectively seals the drain hole 51 , as will be described in greater detail below.
[0038] With reference to FIGS. 5A and 5B and continued reference to FIG. 4 , an electrical coil or other resistance element 60 is disposed about or wrapped around an inner sleeve 62 disposed within the coil housing 52 . The coil 60 is connected to a connector port 64 disposed on an outside of the coil housing 52 . The connector port 64 is interconnected to the ETCM 22 or to another power source. The coil 60 is enclosed and protected by the coil housing 52 .
[0039] The armature 56 includes a base portion 66 slidably disposed within the inner sleeve 54 . The base portion 66 is preferably made from steel, iron or another ferro-magnetic material. A neck portion 68 extends out from an end surface 66 a of the base portion 66 . The neck portion 68 is disposed through a bore 54 a formed in the end cap 54 . A distal or end portion 68 a of the neck portion 68 terminates in a plunger head 70 . The plunger head 70 is disposed outside the coil housing 52 and the end cap 54 . The plunger head 70 has an angled front surface 72 that complements an angled surface 74 in the separating wall 12 a surrounding the drain hole 51 .
[0040] A biasing member 76 , such as a spring, is disposed partially within the sleeve 62 and partially within an enlarged section 54 b of the bore 54 a of the end cap 54 . It should be appreciated that other types of biasing members may be employed without departing form the scope of the present invention. In the example provided, the biasing member 76 is disposed around the neck portion 68 of the armature and is in contact with an inner surface 78 of the end cap 54 and with the end surface 66 a of the base portion 66 of the armature 56 . The biasing member 76 biases the armature 56 to the second (i.e. open) position. In the second position, shown in FIG. 5B , the plunger head 70 is not seated in the drain hole 51 .
[0041] To move the armature to the first position (i.e. closed) position, the ETCM 22 commands an electric current through the coil 60 . The electrical current flowing through the coil 60 generates a magnetic field, and the direction of this magnetic field with regards to its North and South Poles is determined by the direction of the current flow within the coil 60 . The strength of this magnetic field can be increased or decreased by controlling the amount of current flowing through the coil 60 . The armature 56 disposed within the coil 60 is attracted towards the center of the coil 60 by a magnetic flux. Thus the armature 56 moves or strokes within the inner sleeve 62 and compresses the biasing member 76 as the armature 56 moves towards the drain hole 51 . When the armature 56 is fully extended and in the closed position, the angled front surface 72 fully contacts the angled surface 74 and seals the drain hole 51 .
[0042] Returning to FIGS. 2 and 4 , the electromechanical armature assembly 50 is connected to the separator wall 12 a of the housing 12 by a bracket 80 and pin or case boss 82 . The bracket 80 and case boss 82 position the electromechanical armature assembly 50 above the drain hole 51 within the secondary reservoir 32 a at a predetermined, fixed height relative to the drain hole 51 . Communication between the sump 26 and the secondary reservoir 32 a is controlled by activation of the electromechanical armature assembly 50 . For example, the fluid level in the sump may be kept reduced by storing fluid within the secondary reservoir 32 a by commanding a current in the coil 60 , thus creating a magnetic flux and moving the armature 56 against the biasing member 76 to seal the drain hole 51 with the plunger head 70 . Closing of the electromechanical armature assembly 50 hydraulically isolates the secondary reservoir 32 a from the sump 26 thereby keeping the fluid level within the sump 26 to a predefined minimum. This predefined minimum is controlled by a distance of the electromechanical armature assembly 50 from a bottom of the sump 26 . When the transmission cools and the current in the coil 60 is reduced, the biasing member 76 moves the armature 56 to the open position, thus unsealing the drain hole 51 . Transmission fluid can then communicate from the secondary reservoir 32 a through the drain hole 51 and into the sump 26 .
[0043] Keeping the level of hydraulic fluid in the sump 26 to a minimum enables components of the gear arrangement 20 such as planetary gear sets, shafts or members, and clutches or brakes to rotate with a minimum of spin losses. The result is a more efficient transmission providing improved fuel economy.
[0044] The description of the invention is merely exemplary in nature and variations that do not depart from the general essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An active electromechanical armature assembly for a transmission is provided. The active electromechanical armature assembly improves fuel economy by storing transmission fluid in areas away from rotating components during hot operation. During other conditions the transmission fluid is kept in the sump. The active electromechanical armature assembly includes a moveable armature or plunger. Movement of the plunger controls the opening and closing of an opening that communicates between the sump and the side or front cover of the transmission. | 5 |
CROSS-REFERENCES TO RELATED PATENT APPLICATIONS
This is a Continuation Application of application Ser. No. 12/574,255, filed Oct. 6, 2009, which is a Continuation Application of Ser. No. 12/348,621, filed Jan. 5, 2009, issued as U.S. Pat. No. 7,616,687 on Nov. 10, 2009, which is a Continuation Application of application Ser. No. 11/873,282, filed Oct. 16, 2007; which is a Continuation Application of application Ser. No. 10/612,013, filed Jul. 3, 2003, and issued on Nov. 6, 2007, as U.S. Pat. No. 7,292,657; which is a Continuation Application of application Ser. No. 09/703,649, filed Nov. 2, 2000, and issued Jan. 20, 2004, as U.S. Pat. No. 6,680,975; which is a Continuation Application of application Ser. No. 08/024,305, filed Mar. 1, 1993, and issued on Jul. 17, 2001, as U.S. Pat. No. 6,263,026; the disclosures of which are incorporated herein by reference. One (1) Reissue application No. 10/609,438, filed on Jul. 1, 2003, of U.S. Pat. No. 6,263,026 has been abandoned. Continuation application Ser. No. 12/338,647, filed Dec. 18, 2008 and issued as U.S. Pat. No. 7,684,490 on Mar. 23, 2010, Continuation application Ser. Nos. 12/343,797, 12/343,839, and 12/343,898, all filed on Dec. 24, 2008 and issued as U.S. Pat. Nos. 7,724,821, 7,724,822, and 7,724,823, respectively, on May 25, 2010, Continuation application Ser. Nos. 12/348,510, 12/348,535, 12/348,539, 12/348,581, 12/348,590, and 12/348,621, all filed on Jan. 5, 2009 and issued as U.S. Pat. No. 7,609,760 on Oct. 27, 2009, U.S. Pat. No. 7,742,527 on Jun. 22, 2010, U.S. Pat. No. 7,724,824 on May 25, 2010, U.S. Pat. No. 7,787,538 on Aug. 31, 2010, U.S. Pat. No. 7,742,522 on Jun. 22, 2010, and U.S. Pat. No. 7,616,687 on Nov. 10, 2009, respectively, and Continuation application Ser. No. 12/497,264, filed on Jul. 2, 2009 and issued as U.S. Pat. No. 7,764,735 on Jul. 27, 2010, are Continuation Applications of Ser. No. 11/873,282.
FIELD OF THE INVENTION
The present invention relates to a signal compressing system. A system according to the present invention is particularly suited for compressing image signals. The present disclosure is based on the disclosure in Korean Patent Application No. 92-3398 filed Feb. 29, 1992, which disclosure is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Image signals may be compressed by motion-compensated interframe discrete cosine transform (DCT) coding such as is defined by a MPEG (Moving Picture Expert Group) international standard. This form of signal compression has attracted much attention in the field of high definition television (HDTV).
FIG. 1 is a block diagram of such a conventional motion-compensated interframe DCT coder. In the shown coder, an image signal is divided into a plurality of sub-blocks. The sub-blocks are all of the same size, for example 8×8, 16×16, . . . . A motion estimator 40 produces a motion vector, defined by the difference between the current image signal and a one-frame delayed image signal, output by a frame memory 30 . The motion vector is supplied to a motion compensator 50 which compensates the delayed image signal from the frame memory 30 on the basis of the motion vector. A first adder 8 a serves to produce the difference between the present frame and the delayed, motion compensated frame. A discrete cosine transform portion 10 processes the difference signal, output by the first adder 8 a , for a sub-block. The motion estimator 40 determines the motion vector by using a block matching algorithm.
The discrete cosine transformed signal is quantized by a quantizer 20 . The image signal is scanned in a zig-zag manner to produce a runlength coded version thereof. The runlength coded signal comprises a plurality of strings which include a series of “0”s, representing the run length, and an amplitude value of any value except “0”.
The runlength coded signal is dequantized by a dequantizer 21 , inversely zig-zag scanned and inversely discrete cosine transformed by an inverse discrete cosine transforming portion 11 . The transformed image signal is added to the motion-compensated estimate error signal by a second adder 8 b . As a result the image signal is decoded into a signal corresponding to the original image signal.
Refresh switches RSW 1 , RSW 2 are arranged between the adders 8 a , 8 b and the motion compensator 40 so as to provide the original image signal free from externally induced errors.
The runlength coded signal is also supplied to a variable length coder 60 which applies a variable length coding to the runlength coded image signal. The variable length coded signal is then output through a FIFO transfer buffer 70 as a coded image signal.
In motion-compensated adaptive DCT coding, the interframe signal can be easily estimated or coded by way of motion compensation, thereby obtaining a high coding efficiency, since the image signal has a relatively high correlation along the time axis. That is, according to the afore-mentioned method, the coding efficiency is high because most of the energy of a discrete cosine transformed signal is compressed at the lower end of its spectrum, resulting in long runs of “0”s in the runlength coded signal.
However, the scanning regime of the aforementioned method does not take account of differences in the spectrum of the motion-compensated interframe DCT signal with time.
A method is known wherein one of a plurality of reference modes is previously selected on the basis of the difference between the present block and that of a previous frame and the image signal is scanned by way of a scanning pattern under the selected mode and suitably quantized. With such a method, however, three modes are employed to compute the energies of the intermediate and high frequency components of the image signal in accordance with the interframe or the intraframe modes in order to determine the appropriate mode. This mode determining procedure is undesirably complicated.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a signal compressing system, comprising coding means for scanning an input signal according to a plurality of different scanning patterns to provided coded versions thereof and selection means for selecting a said scanning pattern which produces efficient coding according to a predetermined criterion and outputting a scanning pattern signal identifying the selected scanning pattern.
Preferably, the input signal is an inherently two-dimensional signal, for example, an image signal.
Preferably, the coding means codes the input signal according to a runlength coding regime.
Preferably, the system includes a variable length coder to variably length code the coded signal, produced by scanning according to the selected scanning pattern.
Preferably, the system includes discrete cosine transformer means to produce said input signal. The transformer means may be a motion-compensated interframe adaptive discrete cosine transformer.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described, by way of example, with reference to FIGS. 2 and 3 of the accompanying drawings, in which:
FIG. 1 is a block diagram of a conventional adaptive interframe DCT coding system employing a motion compensating technique;
FIG. 2 is a block diagram of a coding system embodying the present invention;
FIGS. 3A-3H show various possible scanning patterns according to the present invention; and
FIG. 4 is a block diagram of a decoding system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 2 , an input signal is divided into equal-sized sub-blocks, for example, 8×8, 16×16, . . . . A motion estimator 40 determines a motion vector by comparing the current frame and a one frame delayed signal from a frame memory 30 .
The motion vector is supplied to a motion compensator 60 which, in turn, compensates the delayed frame signal for movement. A first adder 8 a produces a difference signal representing the difference between the present frame and the delayed, motion-compensated frame. A DCT coder 10 DCT-codes the difference signal. The DCT coded image signal is quantized by a quantizer 20 and then dequantized by a dequantizer 21 . The dequantized signal is supplied to a second adder 8 b , via IDCT 11 , which adds it to the output of the motion compensator 11 . This produces a signal corresponding to the original image signal.
The output of the motion compensator 50 is applied to the adders 8 a , 8 b by refresh switches RSW 2 and RSW 1 , respectively.
The quantized image signal is also supplied to a multi-scanner 80 which scans it according to a plurality of predetermined patterns.
A scanner pattern selector 90 selects the scanning pattern which produces the minimum number of bits to represent the current sub-block. The scanning pattern selector also produces selection data which identifies the selected scanning pattern.
The image signal output by the scanning pattern selector 90 is variable length coded by a variable length coder 60 . The variable length coder 60 compresses the image signal output by the scanning pattern selector 90 . The variable length coder 60 operates such that a large proportion of the data samples are each represented by a small number of bits while a small proportion of the data samples are each represented by a large number of bits.
When a discrete cosine transformed image signal is quantized and runlength coded, the number of “0”s is increased over all, while the number of “0”s decreases as the magnitude of the signal increases. Accordingly, data compression is achieved because “0” can be represented by only a few bits and “255” can be represented by a relatively large number of bits.
Both the variable length coded signal and the selection data are supplied to a multiplexer MUX 1 which multiplexes the variable length coded signal and the selection data, and optionally additional information such as teletext.
Since the variable length coded signal has data words of different lengths, a transfer buffer 70 is employed to temporarily store the multiplexed signal and output it at a constant rate.
The original image signal is reconstructed at a remote station by performing the appropriate inverse scanning of the runlength coded signal in accordance with the multiplexed scanning pattern selection data.
FIG. 4 shows a decoding system at a remote station that receives and extracts the encoded data. In FIG. 4 , demultiplexer 100 receives coded data and, in an operation inverse to that performed at the coding system, extracts the variable length encoded data, the scanning pattern information and the additional information that had been multiplexed together at the coding system. Variable length decoder 110 variable length decodes the variable length encoded data, and scanner 120 receives the variable length decoded data and reconstructs the original sub-block using a scanning pattern indicated by the extracted scanning pattern selection signal. The scanner would necessarily have to select one from a plurality pattern that was available for encoding. Using components having the same margin as dequantizers 21 and IDCT 11 in the encoder system, dequantizer 120 dequantizes the signal output from the scanner 120 , and inverse discrete cosine transformer 140 performs an inverse discrete cosine transform function on the output of dequantizer 130 , to output decoded data.
FIGS. 3A to 3H show possible scanning patterns employed by the multi-scanner 80 . Additional scanning patterns will be apparent to those skilled in the art. However, if the number of patterns becomes too large, the coding efficiency is degraded as the selection data word becomes longer.
As described above, according to the present invention, the quantized image signal is scanned according to various scanning patterns, and then the most efficient pattern is selected.
A suitable measure of efficiency is the number of bits required to runlength code the image signal. | A multi-scanner scans a signal according to several different patterns. A scanning pattern selector determines which scanning pattern produced the most efficient coding result, for example, for runlength coding, and outputs a coded signal, coded most efficiently, and a selection signal which identifies the scanning pattern found to be most efficient. | 7 |
TECHNICAL FIELD
The present invention generally relates to flame retardant bedding articles comprising a hydroentangled flame retardant nonwoven component, and more specifically, to bedding articles, including mattresses, pillow covers and mattress pads, comprising a structurally stable, flame retardant nonwoven component, wherein said component comprises at least two layers that have a synergistic relationship so as to maintain the structural integrity of the bedding article upon burning.
BACKGROUND OF THE INVENTION
More than thirty years ago, flammability standards were instituted by the Consumer Product Safety Commission under 16 C.F.R. § 1632. These standards addressed the flammability requirements of mattresses to resist ignition upon exposure to smoldering cigarettes. However, the Code of Federal Regulations failed to address the need for mattresses to resist ignition upon exposure to small open flames, such as produced by matches, lighters, and candles.
Technological advances have proven to provide mattresses, as well as bedding constituents, with significantly better flammability protection. In light of these advancements, California Legislature has mandated that the Consumer Product Safety Commission establish a revised set of standards that will ensure mattresses and bedding pass an open flame ignition test. Known as Assembly Bill 603 (AB 603), California Legislature has further mandated that the revised set of standards go into affect Jan. 1st of 2004.
Flame retardant staple fiber is known in the art. Further, flame retardant fiber has been utilized in the fabrication of nonwoven fabrics for bedding applications. Nonwoven fabrics are suitable for use in a wide variety of applications where the efficiency with which the fabrics can be manufactured provides a significant economic advantage for these fabrics versus traditional textiles. However, nonwoven fabrics have commonly been disadvantaged when fabric properties are compared, particularly in terms of surface abrasion, pilling and durability in multiple-use applications. Hydroentangled fabrics have been developed with improved properties which are a result of the entanglement of the fibers or filaments in the fabric providing improved fabric integrity. Subsequent to entanglement, fabric durability can be further enhanced by the application of binder compositions and/or by thermal stabilization of the entangled fibrous matrix.
U.S. Pat. No. 3,485,706, to Evans, hereby incorporated by reference, discloses processes for effecting hydroentanglement of nonwoven fabrics. More recently, hydroentanglement techniques have been developed which impart images or patterns to the entangled fabric by effecting hydroentanglement on three-dimensional image transfer devices. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, hereby incorporated by reference, with the use of such image transfer devices being desirable for providing a fabric with enhanced physical properties as well as an aesthetically pleasing appearance.
Heretofore, nonwoven fabrics have been advantageously employed for manufacture of flame retardant fabrics, as described in U.S. Pat. No. 6,489,256, to Kent, et al., which is hereby incorporated by reference. Typically, nonwoven fabrics employed for this type of application have been entangled and integrated by needle-punching, sometimes referred to as needle-felting, which entails insertion and withdrawal of barbed needles through a fibrous web structure. While this type of processing acts to integrate the fibrous structure and lend integrity thereto, the barbed needles inevitably shear large numbers of the constituent fibers, and undesirably create perforations in the fibrous structure. Needle-punching can also be detrimental to the strength of the resultant fabric, requiring that a fabric have a relatively high basis weight in order to exhibit sufficient strength.
A need exists for a more cost effective flame retardant bedding comprising nonwoven component that is cost effective, structurally stable, soft, yet durable and suitable for various end-use applications including, but not limited to bedding components, such as mattresses, mattress pads, mattress ticking, comforters, bedspreads, quilts, coverlets, duvets, pillow covers, as well as other home uses, protective apparel applications, upholstery, and industrial end-use applications.
SUMMARY OF THE INVENTION
The present invention is directed to flame retardant bedding articles comprising a hydroentangled flame retardant nonwoven component, and more specifically, to bedding articles comprising a structurally stable, flame retardant nonwoven component, wherein said component comprises at least two layers that have a synergistic relationship so as to maintain the structural integrity of the bedding article upon burning.
In accordance with the present invention, the bedding comprised of nonwoven component comprises at least a first and second layer. The first layer comprises a blend of lyocell fiber and modacrylic fiber. The fibrous blend of the first layer provides the layered nonwoven component with exceptional strength, in addition to a soft hand. Further, the modacrylic fiber is self-extinguishing and known to char rather than melt when burned.
Adjacent the first layer is a second layer, comprising a blend of lyocell fiber, modacrylic fiber, and para-aramid fiber. Incorporating one or more para-aramid fibers maintains the fibrous structural integrity of the fabric, as well as reduces any thermal shrinkage. The composite of fibers utilized within the flame retardant layered fabric has a synergistic relationship to provide a cost effective fabric with exceptional strength, softness, and flame retardancy, wherein upon burning, the fabric chars, yet retains its structural integrity due to the incorporation of para-aramid fiber.
The layered structure of the flame retardant nonwoven bedding article component lends to the aesthetic quality of the bedding. Para-aramid fiber typically adds to the discoloration of the fabric, imparting an undesirable yellow hue. However, the lack of para-aramid fiber in the first layer, which is positioned atop the second layer, masks the discoloration of the second layer. Optionally, the construct may comprise three or more layers, wherein the additional layers may be chosen from nonwovens, wovens, and/or support layers, such as scrims.
The first and second layers of the flame retardant nonwoven bedding component are juxtapositioned and subsequently hydroentangled to form a structurally stable composite fabric. In addition, the nonwoven fabric may be hydroentangled on a foraminous surface, including, but not limited to a three-dimensional image transfer device, embossed screen, three-dimensionally surfaced belt, or perforated drum, suitably further enhancing the aesthetic quality of the fabric for a particular end-use application.
Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of apparatus utilized in accordance with the present invention so as to manufacture the flame retardant nonwoven fabric.
DETAILED DESCRIPTION
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a presently preferred embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
The structurally stable, flame retardant, bedding component of the present invention, which is comprised of nonwoven layered fabric is cost effective, structurally stable, soft, yet durable and suitable for various end-use applications including, bedding articles, such as mattresses, mattress pads, mattress ticking, comforters, bedspreads, quilts, coverlets, duvets, pillow covers, as well as other home uses, protective apparel applications, upholstery, and industrial end-use applications.
U.S. Pat. No. 3,485,706, to Evans, hereby incorporated by reference, discloses processes for effecting hydroentanglement of nonwoven fabrics. With reference to FIG. 1 , therein is illustrated an apparatus for practicing the present method for forming a structurally stable, flame retardant nonwoven bedding component. The lyocell and modacrylic fibrous components are preferably carded and cross-lapped to form first precursor web, designated P, which is consolidated by hydraulically energy to form a nonwoven layered fabric.
In accordance with the present invention, a second precursor web may be formed, designated P′, wherein the second precursor web comprises a blend of lyocell, modacrylic, and para-aramid fibrous components. Subsequently, the second precursor web is placed in juxtaposition to the first precursor web where they are united by hydroentanglement. Optionally, the adjoined first and second precursor webs are further entangled on a foraminous surface, including, but not limited to a three-dimensional image transfer device, embossed screen, three-dimensionally surfaced belt, or perforated drum, suitably further enhancing the aesthetic quality of the fabric for a particular end-use application.
It is in the purview of the present invention, that additional flame retardant fibers be incorporated in either one or both of the precursor webs, these fibers include, but are not limited to melamine fibers, phenolic fibers, such as Kynol™ fiber from American Kynol, Inc., pre-oxidized polyacrylonitrile fibers, such as Panox® fiber, a registered trademark to R.K. Textiles Composite Fibres Limited.
FIG. 1 illustrates a hydroentangling apparatus, whereby the apparatus includes a foraminous forming surface in the form of belt 12 upon which the precursor webs P and P′ are positioned for entangling or pre-entangling by manifold 14 .
The entangling apparatus of FIG. 1 may optionally include an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the lightly entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 22 which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed.
In addition to the first and second layers of the flame retardant nonwoven fabric, it is also contemplated that one or more supplemental layers be added, wherein such layers may include a spunbond fabric. In general, the formation of continuous filament precursor webs involves the practice of the “spunbond” process. A spunbond process involves supplying a molten polymer, which is then extruded under pressure through a large number of orifices in a plate known as a spinneret or die. The resulting continuous filaments are quenched and drawn by any of a number of methods, such as slot draw systems, attenuator guns, or Godet rolls. The continuous filaments are collected as a loose web upon a moving foraminous surface, such as a wire mesh conveyor belt. When more than one spinneret is used in line for the purpose of forming a multi-layered fabric, the subsequent webs are collected upon the uppermost surface of the previously formed web. Further, the addition of a continuous filament fabric may include those fabrics formed from filaments having a nano-denier, as taught in U.S. Pat. No. 5,678,379 and No. 6,114,017, both incorporated herein by reference. Further still, the continuous filament fabric may be formed from an intermingling of conventional and nano-denier filaments.
It has been contemplated that the nonwoven fabric of the present invention incorporate a meltblown layer. The meltblown process is a related means to the spunbond process for forming a layer of a nonwoven fabric is the meltblown process. Again, a molten polymer is extruded under pressure through orifices in a spinneret or die. High velocity air impinges upon and entrains the filaments as they exit the die. The energy of this step is such that the formed filaments are greatly reduced in diameter and are fractured so that microfibers of finite length are produced. This differs from the spunbond process whereby the continuity of the filaments is preserved. The process to form either a single layer or a multiple-layer fabric is continuous, that is, the process steps are uninterrupted from extrusion of the filaments to form the first layer until the bonded web is wound into a roll. Methods for producing these types of fabrics are described in U.S. Pat. No. 4,041,203. Nanofiber fabrics may be utilized as well and are represented by U.S. Pat. Nos. 5,678,379 and 6,114,017, both incorporated herein by reference. The meltblown process, as well as the cross-sectional profile of the meltblown microfiber, is not a critical limitation to the practice of the present invention.
In accordance with the present invention, the structurally stable, hydroentangled, flame retardant, nonwoven bedding component may comprise a film layer. The formation of finite thickness films from thermoplastic polymers, suitable as a strong and durable carrier substrate layer, is a well-known practice. Thermoplastic polymer films can be formed by either dispersion of a quantity of molten polymer into a mold having the dimensions of the desired end product, known as a cast film, or by continuously forcing the molten polymer through a die, known as an extruded film. Extruded thermoplastic polymer films can either be formed such that the film is cooled then wound as a completed material, or dispensed directly onto a secondary substrate material to form a composite material having performance of both the substrate and the film layers.
Extruded films can be formed in accordance with the following representative direct extrusion film process. Blending and dosing storage comprising at least one hopper loader for thermoplastic polymer chip and, optionally, one for pelletized additive in thermoplastic carrier resin, feed into variable speed augers. The variable speed augers transfer predetermined amounts of polymer chip and additive pellet into a mixing hopper. The mixing hopper contains a mixing propeller to further the homogeneity of the mixture. Basic volumetric systems such as that described are a minimum requirement for accurately blending the additive into the thermoplastic polymer. The polymer chip and additive pellet blend feeds into a multi-zone extruder. Upon mixing and extrusion from the multi-zone extruder, the polymer compound is conveyed via heated polymer piping through a screen changer, wherein breaker plates having different screen meshes are employed to retain solid or semi-molten polymer chips and other macroscopic debris. The mixed polymer is then fed into a melt pump, and then to a combining block. The combining block allows for multiple film layers to be extruded, the film layers being of either the same composition or fed from different systems as described above. The combining block is connected to an extrusion die, which is positioned in an overhead orientation such that molten film extrusion is deposited at a nip between a nip roll and a cast roll.
In addition, breathable films can be used in conjunction with the disclosed continuous filament laminate. Monolithic films, as taught in patent number U.S. Pat. No. 6,191,211, and microporous films, as taught in patent number U.S. Pat. No. 6,264,864, both patents herein incorporated by reference, represent the mechanisms of forming such breathable films.
EXAMPLE
In accordance with the present invention, Sample A comprises a first layer of 60% staple length Tencel® lyocell fibers, Tencel® is a registered trademark of Courtaulds Fibres (Holdings) Limited, and 40% PBX® modacrylic fibers, PBX® is a registered trademark to Kaneka, with a basis weight of about 2.0 oz/yd 2 and a second layer comprising a blend of 42% Tencel® lyocell fibers, 37% PBX® modacrylic fibers, and 21% Twaron® para-aramid fibers, Twaron® is a registered trademark of Enka B.V. Corporation, with a basis weight of about 4.0 oz/yd 2 . The layers were consolidated into a composite flame retardant nonwoven composite fabric by way of hydroentanglement. Subsequently, the composite fabric was advanced onto a three-dimensional image transfer device so as to impart a three-dimensional pattern into the fabric. Table 1 shows the physical test results of the aforementioned fabric. Table 2 also comprises physical test results for a flame retardant component made in accordance with the present invention.
TABLE 1
Composition
Sample A
ITD
Tricot
Weight
4.6
oz/yd 2
Bulk
44
mils
Tensile MD-Peak (ASTM D-5035)
80
g/cm
Tensile CD-Peak
48
g/cm
MD Elong.
29.2%
CD Elong.
94.4%
Elmendorf Tear-MC (ASTM D-5734)
3178
g
Elmendorf Tear-CD
2087
g
Air Permeability (ASTM D-737)
147
cfm
Absorbency
7
sec
Thermal Shrinkage, MD (FNA-LB-WI-GL-136)
−1.0
Thermal Shrinkage, CD
−1.0
Modified Vert. Burn
BFT Flame Test
17.1
TABLE 2
Composition
face 61% Tencel ® H215 968
1.5 dpf × 1.5″/39% PBX ®
2.0 dpf × 2″ back 42% Panox ®
SM C051 SSC 2 dpf × 2″/35%
PBX ® 2.0 dpf × 2″/23%
Tencel ® H215 968 1.5 dpf × 1.5″
ITD
Tricot
Weight
oz/yd 2
5.5
Bulk
mils, 1-ply
55
Tensile MD-Peak
lbs.
66
Tensile CD-Peak
lbs.
44
MD Elong.
%
34
CD Elong.
%
92
Elmendorf
grams
2192
Tear-MD
Elmendorf
grams
3515
Tear-CD
Air Permeability
cfm
151
Thermal
% @ 140 C./
−1.0
Shrinkage, MD
1.5 min.
Thermal
% @ 140 C./
0
Shrinkage, CD
1.5 min.
TB 604
% weight loss
0.9
From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims. | A flame retardant bedding article comprises a hydroentangled flame retardant nonwoven component, and more specifically, a bedding article such as a mattress, pillow cover or mattress pad, comprising a structurally stable, flame retardant nonwoven component. The component comprises at least two layers that have a synergistic relationship so as to maintain the structural integrity of the bedding article upon burning. | 3 |
FIELD OF THE INVENTION
This invention is utilized as a safety device to prevent premature detonation and explosion in portable explosive devices such as hand grenades, pocket mines and other munitions.
REFERENCE TO RELATED APPLICATIONS
This application is related to the following commonly assigned applications filed concurrently herewith:
______________________________________Title Ser. No______________________________________Self-Sterilizing Safe-Arm 256,445Device with Arm/Fire FeatureSelectable Lightweight 256,437Attack Munition______________________________________
BACKGROUND OF THE INVENTION
Present applicant's earlier U.S. Pat. No. 3,289,521 patented Dec. 6, 1966 and No. 4,487,128 patented Dec. 11, 1984 are the pertinent examples of prior art in this field.
This invention is a portion of an overall portable munition system and cooperates with other elements which are the subject of the related applications given above. This invention is utilized to provide a safety device to prevent accidental or premature detonation and explosion of the munition while elements of the other inventions cooperate with the action of this invention to provide a complete munition. These related inventions when combined with this invention explain the entire operation of the munition.
SUMMARY OF THE INVENTION
A recessed safety,locking,pull ring in a side face of the munition holds one end of a bar in place within a groove in the top of a munition perpendicular to the side face. This ring provides the primary safety device for the munition in that the end of the bar held by the ring must be released and the bar rotated about its opposite end to permit removing a safety wire in order to arm the munition. An ampule containing electrolyte is also crushed by the full rotation of the bar which energizes a battery to power electronics for the munition control circuitry.
The ring is flexible and is oval shaped and fits in a recess which matches this oval shape. The ring is pivotably connected to the bar. The opposite end of the bar pivots about a rod attached to the top of the munition. A pair of opposed locking lugs extending perpendicularly from the ring at its base engage a rectangular recess in the plane of the ring recess when the ring is secured in its recess. These locking lugs prevent lifting the bar while the lugs are engaged and the lugs are arranged such that they will not release until the ring is rotated 180 degrees from its recessed position.
The end of the ring opposite the pin is secured in the recess by two locking tabs near the end of the ring which extend over the recess in the plane of the side face. The recess for the ring has a centered gap between these locking tabs which extends to a perpendicular surface opposite the top surface which contains the bar. This gap allows the user to press on the end of the ring. The ring is reinforced between the gap area which results in this portion of the deformed ring having a generally fixed configuration which will clear the locking tabs when forced upward. The upper portion of the inner wall of the ring recess is shaped to hold the undeformed ring while the lower portion of the inner wall and the outer wall of the upper portion are shaped to accommodate the deformed ring shape. When the freed ring is rotated 180 degrees from the recessed position the lugs extending from the ring adjacent the bar pivot clear of the rectangular lug recess which permits lifting the end of the bar using the ring as a handle. The pivoted end of the bar is cam shaped and this cam crushes an ampule which is mounted under the pivot point when the bar is rotated 180degrees. Electrolyte held by the ampule is released to energize a battery to power electronic circuitry which controls the munition. Lifting the bar also exposes a safety wire and an indicator light which are located in the groove under the bar, to allow observing the light to determine whether the status of the electronic controls is safe, and to permit removing the safety wire in order to arm the munition.
This locking ring provides excellent safety to prevent accidentally arming this munition in that the ring must first be released from its recess, which can only be accomplished by first deforming the ring, and then simultaneously lifting the ring out of the recess while still in this deformed shape. Even after removing the ring from the recess it still must be rotated a full 180 degrees in order to free the locking lugs extending from the pivoted end of the ring and only then can the bar be rotated using the ring as a handle as the first step in arming the munition. Only after the bar is rotated is the battery for the munition electronic circuitry energized, the status light exposed to show whether arming should proceed, and the safety wire, which must be removed to arm the apparatus, released.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the munition.
FIG. 2 is a side view of the munition.
FIG. 3 is a portion of FIG. 2 showing the ring being depressed.
FIG. 4 is the same portion of FIG. 2 after the ring is lifted out of the recess.
FIG. 5 is the same portion of FIG. 2 showing the ring rotated 180 degrees from the recess.
FIG. 6 is an isometric view showing the relationship of the pull ring, the bar, and the safety wire.
FIG. 7 is a detail showing the crosssection of the ring rotated 180 degrees from its recess.
FIG. 8 is a cross-section of the ring, bar, safety wire, ball, battery and adjacent munition.
FIG. 9 is a detailed fragment showing the ring in cross-section rotated 90 degrees from the recess.
FIG. 10 is the view of FIG. 8 with ring released from the side of the munition and the bar partially rotated about the rod displacing a ball within the battery.
FIG. 11 is a detailed cross-section fragment showing the bar rotated 180 degrees and the battery depressed.
FIG. 12 is an exploded view of the munition.
FIG. 13 is a detail of a groove segment, clip and safety wire.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Munition 10 is shown in FIG. 1 with locking pull ring 12 held in place by tabs 14 which holds the end of bar 16 within a groove 17 in the top surface. FIG. 2 shows tabs 14 secured by screws 18 extending through matching holes in the tabs into mating tapped holes in the side of the munition 10. Pin 20 pivotably secures ring 12 to the end of bar 16 through aligned holes in the ring and bar. Locking lugs 22 extend outwardly from ring 12 which are integral with the ring. Ring 12 is fashioned of spring steel and the end portion of the ring 24 between lugs 14 consists of three layers of spring steel, the purpose of which will be discussed later.
Locking lugs 22 which extend outwardly from ring 12 engage the upper surface of lug recess 28 which prevents the ring from being moved upwardly. This locking action of lugs 22 and holding action of tabs 14 can be seen more clearly in FIG. 8. Here ring 12 is recessed within ring recess 26. Tabs 14 over the lower end of ring 12 hold the ring in this position within recess 26. Land 27 in the center of ring recess 26 is adjacent to ring 12 and protects the ring against anything sliding along the surface which would otherwise tend to remove the ring from the recess. Locking lugs 22 which extend perpendicularly outwardly from the base of ring 12 are located within lug recess 28 which prevents vertical motion of the ring. A safety wire 36 is held under bar 16 with the free end secured in a hole 15 which extends inward from a notch in the lower side of the bar. In FIG. 2 it can be seen that ring 12 fits closely about the upper portion of land 27 and bears against the outer walls of ring recess 26 adjacent tabs 14. In FIG. 3 ring 12 is being deformed by a thumb 30 pressing on the multilayered end portion of ring 24 through a gap 32 between tabs 14. This deformation changes the shape of ring 12 to clear tabs 14 since the end portion of ring 24 essentially retains its shape because it is multilayered and the ring is therefore deformed primarily in its upper single layer which results in the lower edge moving upward and clearing the tabs. The outer wall of ring recess 26 expanded in shape and the inner wall of the lower edge are shaped to permit this deformation. While ring 12 is still in this deformed shape to clear tabs 14, the ring is rotated about pin 20 until it is clear of ring recess 26 and the pressure on the ring can be released as shown in FIG. 4. Lugs 22 have rotated as parts of ring 12 but are still located within lug recess 28 which prevents the ring 12 from being moved upward.
Once ring 12 is free of recess 26 it can be used as a handle to rotate the ring and as a handle to rotate bar 16 as shown in subsequent steps. In FIG. 9 ring 12 is shown rotated approximately 90 degrees from the initial secured position. Here lugs 22 which extend from the lower edge of ring 12 in this position are still partially within lug recess 28 which prevents moving the end of bar 16 vertically.
In FIG. 5 ring 12 is shown rotated 180 degrees from the recessed position and since lugs 22 project from the inner edge of the ring in the recessed position the lugs are now in the outer plane of the ring after rotation. Lugs 22 now clear lug recess 28 and will not prevent moving ring 12 upward. This relationship is also shown in FIG. 7 where lugs 22 have been rotated to a position clear of lug recess 28 and lie outside of munition 10. If desired pin 20 could be located leftward closer to the left surface to permit lugs 22 clearing lug recess 28 before ring 12 is rotated 180 degrees. In FIG. 6 the orientation of ring 12 and bar 16 shown is the same as in FIG. 5 with integral lugs 22 rotated 180 degrees from the recessed position.
In FIG. 10 bar 16 is shown partially rotated about rod 34 by pulling upward on ring 12. As bar 16 is rotated safety wire 36 is freed from hole 15 in the bar because the pivot points for the safety wire and the bar are dissimilar. Rod 34 is secured to munition 10 into matching holes in the orientation shown in FIG. 12. An additional function of the multilayered portion of ring 24 is the under cross-section which will not cut the fingers when the ring is pulled on as a handle. Cam shaped end 38 of bar 16 is configured such that as bar 16 is rotated clockwise ball 40 is forced downward deforming battery 42. Safety wire 36 is also released by the clockwise rotation of bar 16. FIG. 6 shows safety wire 36 having a shorter lever ar than bar 16 but being bent to rotate in the same plane as the bar in a position under the bar. FIG. 8 shows safety wire 36 located within hole 15 when bar 16 is locked in place. Hole 15 is inclined within a notch such that the bent end of safety wire 36 can be readily engaged. FIG. 10 shows that as bar 16 is rotated about rod 34 safety wire 36 will pull free from hole 15 because of the different pivot axes. In FIG. 11 bar 16 is shown rotated 180 degrees from its secured position when recessed in the top of the munition. In this rotated position cam shaped end 38 has fully depressed ball 40 into battery 42. An ampule, not shown, located within battery 42 under ball 40 is fractured by this action and when fractured releases an electrolyte to provide electrical energy for the munition electronic circuitry.
In FIG. 12 the relationship between locking ring 12, bar 16, ring recess 26, rod 34, safety wire 36, ball 40, and battery 42 is shown. Safety wire 36 fits through a hole in a rotor 72 which prevents munition 10 from being armed. Indicator light 47 is visible through a hole 49 in bar slot 17 and is only exposed when bar 16 is rotated around rod 34 out of this slot.
The simple but multi-step procedure necessary to remove this safety, locking, pull ring 12 results in a safety device which is essentially impossible to remove accidentally. Not only must ring 12 be simultaneously deformed and rotated to be removed from ring recess 26 but it must then be rotated a full 180 degrees before locking lugs 22 are freed from lug recess 28 to release bar 16. Even then bar 16 must be rotated a considerable amount to remove safety wire 36 as a separate operation and a full 180 degrees to energize battery 42. While this sequence of events will not occur accidentially they are easy to perform intentionally. Simply deforming ring 12 with a finger or thumb while simultaneously lifting the ring will clear the ring from ring recess 28, then hooking a finger in the ring and rotating the ring 180 degrees and then rotating the bar 180 degrees will complete all remaining steps excepting only removing safety wire 36. Indicator light 47 is then observed to determine if the electronics are operating correctly before the now exposed safety wire 36 is removed to complete the arming process. Bar 16 is removed from rod 34 when rotated as shown in FIG. 11. If the indicator light 47 does not indicate that the munition should be armed then safety wire 36 is not removed but is pressed downward against clip 21 made of steel spring material into groove 17 which will deflect the clip and allow the safety wire to pass. Clip 21 will then spring back to secure safety wire in groove 17 as shown in FIG. 13. All of the items used here are simple mechanical items with reasonable tolerances and yet the result is a very secure safety mechanism.
While this invention has been described with reference to an illustrative embodiment, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiment, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention. | A safety, locking, pull ring for a munition which must be deformed and simultaneously rotated from a protecting locking recess and which must then be rotated 180 degrees from the recessed position in order to free one end of a pivotably attached bar. The bar must then be rotated 180 degrees, using the ring as a handle, to expose both a safety wire which must be removed to arm the munition, and expose an indicator light, which indicates the safe or unsafe condition of the munition, and finally to crush an ampule to release electrolyte to energize a battery which powers the munition electronic circuitry. | 5 |
This application is a division of application Ser. No. 08/641,836, filed May 2, 1996 now U.S. Pat. No. 5,735,345.
BACKGROUND OF THE INVENTION
The field of the present invention is oil well completion tools and techniques.
Wells are conventionally drilled through production zones with casings installed to adjacent the production zones. Such casings may extend through certain production zones where multiple zones exist. In such cases, the casings may be strategically placed or later perforated to provide access to additional zones. Typically a casing does not extend to the bottom of unconsolidated sand in the production zone of the well as drilled. In sandy conditions, the bottom of the well may fill in before completion. Under many circumstances, a liner is to be placed in the well with perforations at the productive zones. Additionally, gravel packing about the liner is common.
Upon the completion of such wells, sand control adapters are frequently employed to seal the joints between the upper ends of the liners and the casings. Such devices prevent sand from being entrained into the production. One such adapter is illustrated in U.S. Pat. No. 5,052,483, the disclosure of which is incorporated herein by reference.
For well completion, it is frequently necessary to clear out the bottom of the hole, insert an appropriate liner, gravel pack the production zone or zones and seal the liner off at the casing. Multiple trips down a well are frequently required to accomplish each of these tasks. The pulling of tools is, of course, expensive. Mechanisms have been designed for accomplishing a variety of tasks with one trip down the well. U.S. Pat. No. 5,425,423, the disclosure of which is incorporated herein by reference, illustrates a well tool which can drill, under ream and gravel pack with one trip down the well. U.S. Pat. No. 5,497,840, the disclosure of which is incorporated herein by reference, discloses another completion system for drilling in, placing and hanging a liner, cementing portions of the well and providing a seal between the casing and the liner. This may be accomplished with one trip down the well. Of course all systems allow for retraction of the drill string. Some equipment may be sacrificed in the well.
The present invention is directed to well completion, minimizing trips down the well. A well may be lined, the liner locked in place, the production zone or zones gravel packed, the well cleaned and the equipment removed, all with a single trip.
Accordingly, it is an object of the present invention to provide improved well completion methods. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a slotted liner and landing adapter shown partially installed with the formation and casing in cross section.
FIG. 2 is a partially cross-sectioned side view of a landing fixture.
FIG. 3 is a partially cross-sectioned side view of an adapter body with an actuator and a shear ring.
FIG. 4 is a detail of the device of FIG. 3 with the actuator in a second position.
FIG. 5 is a side view partially in cross section of a by-pass tool.
FIG. 6 is a side view of the center portion of the by-pass tool of FIG. 5 rotated 90° from that of FIG. 5.
FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 6.
FIG. 8 is a side view of the by-pass tool in partial cross section with the tool configured for flow fully therethrough.
FIG. 9 is a side view of the by-pass tool in partial cross section with the tool configured for gravel pack flow.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, FIG. 1 illustrates a landing adapter, generally designated 10, coupled with a conventional expansion joint 12 which is in turn coupled with a liner assembly, generally designated 14. The entire string is positioned with a casing 16 shown to be in multiple sections. This string may be run into a well and positioned through production zones all in one trip with a by-pass tool used to complete each zone.
The liner assembly 14 has multiple perforated sections 18 and multiple gravel pack port collars 20 most conveniently adjacent the perforated sections 18, respectively. The gravel pack port collars 20 are conventional with a rotatable sleeve within each gravel pack port collar having slots to receive dogs for rotation of the sleeve. The sleeve is rotated 90° one way to open and 90° back to close. A wash-in shoe 22 with stab-in blades 24 is attached at the end of the liner assembly 14. This shoe has ports 26 at the bottom thereof and an annular seal 28 inside of the hollow shoe 22.
Looking to FIG. 2, a landing fixture 30 is illustrated which may be rigidly held in place on a casing pin. The landing fixture 30 is essentially a pipe section with a threaded socket end 32 and a threaded pin end 34. The socket end 32 may be associated with the pin of a casing section to locate the fixture 30 within the well. Additional casing may be added to the threaded pin end 34.
The inside profile of the landing fixture 30 is of specific interest. A landing ring 36 extends inwardly to define a hole 38 extending axially through the fixture 30. At the upper end of the landing ring 36 is an upward landing shoulder 40 which is in the shape of a circular, truncated conical section. At the lower end of the landing ring 36 is a downward landing shoulder 42. The downward landing shoulder 42 lies within a plane normal to the axis of the landing fixture 30. A shallow inwardly facing annular channel 44 is located 10 adjacent to the downward landing shoulder 42. The lower wall of the channel 44 is shown to be tapered.
Turning to FIG. 3, an adaptor body, generally designated 46, is constructed principally as a pipe assembly. The adaptor body 46 includes a two-thread box 48 having square threads 50 for attachment to the lower end of a drill string and the body portion 52 threaded and permanently fixed to the two-thread box 48. The body portion 52 has a pin 54 which may be configured for attachment by conventional means to a liner assembly.
The body portion 52 extends to a pin 56 which is associated with the two-thread box 48. Adjacent to that pin 56 is a thin cylindrical section 58 defining the bottom of a cavity which is an outwardly facing annular channel 60. The channel 60 is bounded on one end by the lower terminal shoulder of the two-thread box 48. At the other end, a thicker cylindrical section 61 defines the lower extent of the annular channel 60. The thicker cylindrical section 61 is beveled at the lower end 62 so as to ensure passage down the well and includes a shoulder 63 at its other end which is normal to the axis of the adaptor body 46. Between the bevel 62 and the shoulder 63, a second cavity which is an outwardly facing annular channel 64 is cut into the cylindrical section 61. Between the shoulder 63 and the annular channel 64, an outwardly facing annular recess 65 provides relief in the outer surface.
An actuator sleeve, generally designated 66, is positioned within the outwardly facing annular channel 60. The sleeve 66 is positionable on the thinner cylindrical section 61 prior to assembly of the two-thread box 48 with the body portion 52. The sleeve 66 has an annular body 67 which specifically fits on the thinner cylindrical section 61 to slide along the surface thereof. The body 67 is shorter in axial length than the annular channel 60 in order that it might take either of two extreme positions, either against the shoulder 63 or against the terminal shoulder of the two-thread box 48.
The actuator sleeve 66 further includes an engagement shoulder 68. The engagement shoulder 68 is shown to be a circular, truncated conical shoulder defined by a thicker cylindrical portion 69 at one end of the actuator sleeve 66.
At the other end of the actuator sleeve 66, an extension in the form of annular skirt 70 extends from one end of the annular body 67. The skirt 70 is sized to extend over the outwardly facing annular recess 65 and is of sufficient length to further extend over the annular channel 64 when the actuator sleeve 66 is positioned against the shoulder 63.
A shear ring 71 is located within the annular channel 64. This shear ring 71 may be of brass, metal or even plastic, depending upon its dimensions and the amount of force at which it is to be sheared. In the current embodiment, the shear strength of the ring may be on the order of 80,000-100,000 pounds. The shear ring 71 is also split and arranged in a relaxed state to have a gap in order that the ring may be compressed. The dimensions of the shear ring 71 are such that a first position is achieved with the shear ring 71 extending outwardly of the annular channel 64 in the relaxed state. In a compressed state, the shear ring 71 assumes a second position which has an outside diameter allowing the ring 71 to be placed within the skirt 70.
Before entry into a well, the adaptor is arranged with the actuator sleeve in the extreme lower position. In this position, the shear ring 71 is compressed and arranged beneath the skirt 70. Shear pins 72 are arranged about the adaptor and extend between the adaptor body and the actuator sleeve. The skirt 70 further fits within the outwardly facing annular recess 65 so that the entire adaptor below the engagement shoulder 68 fits within the hole 38 in the landing ring 36.
In the second extreme position, the annular body 67 is against the lower terminal shoulder of the two-thread box 48. The shear pins 72 are sheared and the skirt 70 has fully disengaged the shear ring 71 so that it may obtain its relaxed state. The axial difference between the annular channel 60 and the annular body 67 is such that the annular skirt 70 is fully displaced from the shear ring 71. The engagement shoulder 68 with the annular body in the upper extreme position is to be distanced from the near side of the shear ring 71 such that the landing ring 36 fits within that space.
In operation, the adaptor is placed down the well with the landing fixture 30 already in place and attached to the well casing. The adaptor body 46 is arranged with the actuator sleeve 66 with the shear pins 72 unbroken and the skirt 70 extending over the shear ring 71. Once the adaptor meets the landing ring 36, the engagement shoulder 68 engages the upward landing shoulder 40. This shears the pins 72 and causes the sleeve 66 to move to its second extreme position. At this time, the actuator sleeve is seated. The shear ring 71 is released so as to extend into the shallow channel 44 below the downward landing shoulder 42. In this way, the landing ring 36 is captured between the engagement shoulder 68 and the shear ring 71. Once positioned, extraction requires a shearing of the shear ring 71. By requiring a shear strength of 80,000-100,000 pounds, the shear ring 71 is only likely to be sheared under intentional upward force applied through the drill string.
Delivered to the well with the liner assembly 14 and landing adapter 10 is a by-pass tool, generally designated 74. Associated with the lower end of the by-pass tool 74 is a stinger 76 (FIG. 1). The stinger fits within and is sealed by the annular seal 28 within the wash-in shoe 22. The stinger is thus in communication with the ports 26.
The by-pass tool 74 includes a main barrel 78. The barrel 78 is substantially cylindrical except for the lower portion which includes a cross section as seen in FIG. 7. A pin 80 is at one end and an interiorly threaded socket 82 is at the other. A barrel extension 84 includes a pin 86 associated with the socket 82. The barrel extension 84 is also generally cylindrical and extends to a pin 88 to which may be attached the stinger 76. A central bore 90 extends through the barrel 78 and the barrel extension 84. Gravel pack cups 92 and 94 are conventionally arranged and accommodated on the exterior of the barrel 78. Similarly gravel pack cups 96 and 98 are associated with the exterior of the barrel extension 84. The cups, 92, 94, 96 and 98 are arranged to either side of a gravel packing section of the barrel 78. A collar 100 is associated with the pin 80 of the barrel 78 for attachment to the drill string.
Diametrically opposed gravel ports 102 extend radially through the barrel 78 at a position between the upwardly sealing pack cups 92 and 94 and the downwardly sealing gravel pack cups 96 and 98. These ports 102 are sized and arranged such that they may be aligned with the ports located in the gravel pack port collars 20 when indexed axially in the bore. Also extending radially through the barrel 76 are upper ports 104 located above the gravel pack cup 92 for communication with the annular space between the liner assembly 14 and the barrel 78. The barrel also includes spring loaded radially outwardly biased dogs 106 which are conventionally employed with the gravel pack port collars 20. With the dogs 106 engaged with a specific port collar 20, the gravel ports 102 are then aligned with the gravel pack port collar 20. Rotation of the string 90° then causes the port collar 20 to open. Rotation in the opposite direction then closes the port collar 20.
Turning to inwardly of the barrel 78, an annular sleeve 108 is positioned concentrically within and displaced inwardly from the barrel 78. The sleeve extends through a first length of the barrel defining a substantially annular side passage 110. At the upper end, a ring 112 closes the side passage 110. This ring 112 is above the upper ports 104 such that the annular side passage 110 is in communication with those upper ports 104. At the lower end of the annular sleeve 108, an annular seat 114 is defined which defines the annular space forming the annular side passage 110 below the annular sleeve 108. The annular seat 114, however, divides the annular side passage 110 into two by-pass passages 116 and 118 extending lengthwise through a portion of the bore of the barrel 78. The annular seat 114 thus defines a portion of the gravel ports 102 by outwardly extending walls 120 as can best be seen in FIG. 7 which form oblong passages from the center of the annular seat to the gravel ports 102. In this way, the annular seat 114 defines by-pass passages 116 and 118 which communicate with the annular side passage 110 to extend communication downwardly around the gravel ports 102 in a manner such that the by-pass passages 116 and 118 are not in communication with the gravel ports 102 extending through both the annular seat 114 and the wall of the barrel 78.
The annular seat 114 has a central bore 122 as can best be seen in FIG. 7. A valve sleeve 124 is positioned within the central bore 122 of the annular seat 114. The valve sleeve 124 itself includes a bore 126 in part defining the central bore 90.
The valve sleeve 124 includes return ports 128 extending radially through the sidewall. Below the return ports, a retainer 130 extends across the bore 126. A one-way valve including a valve seat 132 and a valve ball 134 are provided within the bore 126 of the valve sleeve 124. The retainer 130 keeps the valve ball 134 near the valve seat 132. The one-way valve controls flow through the bore 126. Above the valve ball 134 when positioned on the valve seat 132 are wash-in ports 136.
The valve sleeve 124 moves from a first, closed position as illustrated in FIG. 8 to an open position as illustrated in FIG. 9. Shear pins retain the valve sleeve 124 in the closed position through initial operations. In the closed position, the valve sleeve 124 extends over the gravel ports 102. The return ports 128 are also positioned on the valve sleeve 124 such that they are closed with the valve sleeve 124 in the closed position. The valve sleeve 124 extends downwardly below the annular seat 114 such that the wash-in ports 136 are open with the valve sleeve 124 in the closed position. Also in the closed position, the lower end of the valve sleeve 124 is displaced from the pin 86 of the barrel extension 84 so that communication may flow from the central bore 90 through the central bore 122, out the wash-in ports 136, around the lower end of the closed valve sleeve 124 and again down through the central bore 90 in the barrel extension 84.
The valve sleeve 124 has a second valve seat 138 above the one-way valve. The placement of a valve ball 140 on the valve seat 138 causes pressure to increase in drilling fluid above the ball valve 140. The shear pins fail and the valve sleeve 124 moves to the open position as seen in FIG. 9. In the open position, the valve sleeve 124 is displaced from the gravel ports 102 such that they are in communication with the central bore 90. The return ports 128 also pass downwardly below the bottom of the annular seat 114 and are open to communicate with the by-pass passages 116 and 118. The lower portion of the valve sleeve 124 seats into the pin 86 of the barrel extension 84. Thus, any communication along the central bore 90 across the one-way valve is controlled by the valve ball 134.
In operation, the by-pass tool is assembled with the liner assembly 14 before lowering into the well. The stinger 76 extends through the annular seal 28 to be in communication with the ports 26 of the wash-in shoe 22. The valve sleeve 124 is in the closed position. The condition of the by-pass tool is as seen in FIG. 8 at this time. The well was first drilled, a casing positioned and portions under reamed. Consequently, accumulation of debris is expected to have accumulated at the bottom of the well.
As the combination of the liner assembly 14 and the by-pass tool is lowered to encounter the debris, the fluid is pumped down the drill pipe and through the central bore 90. When the fluid encounters the one-way valve at the bottom of the valve sleeve 124, it is able to flow through the wash-in ports 136, around the bottom end of the valve sleeve 124 and back to the central bore 90 as it extends through the barrel extension 84. The flow continues to the stinger 76 and out through the ports 26 of the wash-in shoe 22. Because of the annular seal 28, the drilling fluid exits through the ports 28 to outwardly of the liner assembly 14. The fluid along with entrained debris flows upwardly in the annular space between the liner assembly 14 and either the well bore or the casing 16. This flow washes out debris and allows the liner assembly 14 to be washed into position at the bottom of the well.
When appropriately positioned, the landing adapter 10 associated with the liner assembly 14 approaches and captures the landing ring 30. The flow of fluid and debris had been proceeding about the landing adapter and up the annulus within the casing 16. However, when the landing adapter 10 seats on the landing ring 30, this circulation is interrupted. The ball valve 140 is then placed in the drill pipe bore where it is conveyed to the valve seat 138. The pressure of the fluid behind the seated valve ball 140 shears the pins associated with the valve sleeve 124 and the valve sleeve 124 assumes the second, open position.
Once the valve ball 140 is in place and the valve sleeve 124 opened, flow can proceed through the pipe bore downwardly through the central bore 90 and out the gravel ports 102. The lowermost zone may then be gravel packed in a conventional manner.
The fluid return during gravel packing may be through the perforated liner sections 18 and up through the stinger 76. The valve ball 134 of the one-way valve allows flow upwardly into the valve sleeve 124. Return fluid may then pass through the return ports 128 to the by-pass passages 116 and 118 and the annular side passage 110. The returning flow then exits through the upper ports 104 to the annulus within the casing 16 to return to surface.
Once the gravel pack has been complete in an under reamed zone, it may be advantageous to clear the liner between the gravel pack cups 94 and 96 and the central bore 90 as well as the drill string. Flow of the drilling fluid can be reversed, delivered down the annulus of the well, past the cups 92 and 94 to the gravel ports 102. The fluid can then return through the central bore 90.
Once this operation has been completed, the by-pass tool can be lifted upwardly to the next gravel pack port collar 20 and the tool positioning, gravel packing and cleaning may be repeated. This process can be repeated for each zone. Once this is accomplished, the tool may be pulled from the well. Manipulation of by-pass tools have tended to lift the liner assembly 14 out of position. Use of the landing adapter 10 prevents such unwanted extraction of the liner assembly 14. With the removal of the by-pass tool, the well is complete.
Accordingly, improved completion equipment and methods have been disclosed. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore is not to be restricted except in the spirit of the appended claims. | A well completion system and method including a landing adapter which can be interlocked with a landing ring. A split ring is retained within a groove in the landing adapter which operates to lock the landing adapter with the landing ring. The groove into which the shear ring is positioned has two effective diameters. A first diameter allows the shear ring to compress and pass within the landing ring. The second diameter prevents extraction without shearing of the ring. A by-pass tool is positioned with a liner assembly 14 having a landing adapter. The by-pass tool includes a valve sleeve having a first position allowing flow down the center bore into a stinger extending to a wash-in shoe. Once the liner assembly has been washed in, the valve sleeve assumes a second, open position. Gravel packing may then occur through the central bore with return through a by-pass passage through the tool. Cleaning of the liner and tool can also occur through reverse flow to the gravel packed area. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. Ser. No. 09/559,993, filed Apr. 27, 2000 and now abandoned, which is a continuation of U.S. Ser. No. 09/074,517, filed May 8, 1998 and now abandoned, which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for bleaching pulp. More specifically, the present invention relates to a method of bleaching pulp using high partial pressure ozone in which the ozone is more effectively dispersed and dissolved in a low consistency pulp.
2. Brief Description of the Prior Art
During the past 10-15 years the bleaching of pulp in the Kraft Process has undergone many changes. These changes were mainly prompted by environmental concerns of the quality of the effluent being discharged from paper mills. Of main concern was the bleach plant effluent, which contained polychlorinated dibenzodioxines and dibenzofurans among other compounds. The measurement of AOX was used as an indicator of the concentration of these compounds and the test was quickly adopted as a standard for legislation.
It was soon determined that the chlorine used in bleaching was a factor in high AOX values, while values could be reduced by lowering the quantity of chlorine used. Chlorine dioxide was substituted for chlorine and reduced AOX values was the result. A typical bleaching sequence became C/D.Eo.D.E.D. with at least 50% of the chlorine being replaced by chlorine dioxide on an equivalence basis. Some paper mills have eliminated chlorine entirely by using, for example, D.Eo.D.E.D. or O.D.Eo.D.E.D. sequences.
Ozone is a powerful bleaching agent used in many bleach plants throughout the world to bleach Kraft Pulp and recycled fibers. It has recently been discovered that ozone can replace chlorine dioxide and achieve the same brightness and pulp quality. It has been found that 1 kg of ozone can essentially replace 2-4 kg ClO 2 . This results in lower cost bleaching sequences such as O.Z/D.Eop.D.E.D, O.D/Z.Eop.D.X.D, D/Z.Eop.D.E.D. and others. The use of ozone (O 3 ) can become more attractive, however, if a more efficient and cost effective method can be found to better disperse and dissolve O 3 into an existing bleaching sequence. The usual method of bleaching with ozone comprises dispersing ozone into a medium consistency pulp using a pump, mixer and retention tube. This is carried out at a pressure of 150 psig and requires a compressor to add the ozone.
Medium consistency pulp generally contains a cellulose fiber suspension of from 8-15%, that when exposed to high shear forces acquires fluid properties that permits it to be pumped. High shear mixers enable gases to be dispersed and dissolved in medium consistency pulps.
A typical medium consistency ozone bleaching process generally consists of pumping pulp to a mixer where ozone is added. The gas dispersion in the pulp is then sent to a vertical retention tube where at least 90% of the ozone dissolves and reacts during a hydraulic residence time of 30 to 60 secs. If the ozone utilization is low, then a second mixer may be added. On discharge from the retention tube, gas is separated from the pulp and the excess ozone in the gas is sent to an ozone destruct unit.
To achieve high utilization of ozone in medium consistency bleaching, a pump and mixer(s) are used that are driven by high HP motors. Typically pulp is bleached with an ozone charge of about 5 kg ozone/ton pulp, and this is added in a single stage. If higher charges of ozone are required then more than a single stage is necessary, e.g. 10 kg/ton requires two stages. The limiting factor in ozone addition is the volume of gas that can be dispersed and dissolved in the pulp with high ozone utilization. For medium consistency processes it has been found that a high utilization of ozone can be achieved if the volume ratio of gas in the total fluid mixture does not exceed 30%. For ozone generated at a concentration of 10% w/w and operating at a pressure of 150 psig, the maximum charge added is 5 kg of ozone/ton of pulp. If the ozone concentration is raised to 12% this charge can be raised to 6 kg/ton with the same ozone utilization.
An alternative to medium consistency pulp technology is that of using high consistency pulp. In this process fibers are dewatered to a consistency of 25-40% by passing medium consistency pulp through a press. As well as dewatering the fibers, the pulp is compressed and then fluffed in order to have good contact between gas and fibers. The pulp is then introduced into a reactor where it is contacted with ozone for a period of 1-3 minutes at a pressure of 5 psig. After ozonation, the pulp is degassed and diluted with wash water before passing on to a washing stage.
When this process was first started there were reports of uneven bleaching, but with improved reactor design this was overcome. An advantage of this process is that it does not require high concentrations of ozone, as using 6.0% w/w works very well. However the high consistency process is not widely accepted because of the mechanical complexity of the equipment and the high power requirement for dewatering the pulp.
Another possible technique for bleaching pulp involves low consistency pulp. Low consistency pulp employs a cellulose fiber suspension of 1 to less than 5 wt % that has a viscosity greater than water, but can be pumped using conventional pumps without the need of a high shearing effect. Chlorination is generally carried out in a low consistency process and in many processes chlorine dioxide is also added to low consistency pulp slurries. Thus, if an effective process for bleaching pulp with ozone at low consistency was available, one could replace the chlorination stages with such ozone stages easily and without a large capital requirement. However there has been little discussion of ozonation at low consistency.
Laboratory studies have been carried out on ozonating pulp in bubble columns using pulp slurries around 0.5% concentration. This method worked well, but with columns of a height of 25 m, the gas residence time was very long and ozone utilization low. Furthermore, ozone concentrations in the gas applied were low, 2-3% w/w.
This low concentration required large volumes of gas to obtain the desired ozone charge. The low concentration also led to low mass transfer rates. The net effect of this was poor ozone utilization, and this together with the dilute pulp slurry has made the consideration of using ozone with low consistency pulp commercially unattractive.
Up to this point, therefore, there has been no commercial process devoted to ozone bleaching of low consistency pulp. While some laboratory studies have been carried out at consistencies of about 0.5% using unpacked columns and adding the ozone by a diffuser at the bottom, such a process is not considered to be practical for commercial use. Furthermore, there are reports that O 3 consumption increases due to decomposition in water. Also, the favored technology for bleaching uses medium consistency pulps and there have been no reported attempts to carry out low consistency ozone bleaching on an industrial scale.
Low consistency pulp, however, is easier to pump. Dispersing ozone onto it, because of its low viscosity, would therefore require less power. This can be done before or after a low consistency D stage or a medium consistency D stage. In the latter case this is carried preferably out in a downflow tower and at the bottom of the tower the pulp is diluted to low consistency in order to pump it to the next process step.
Hence if ozone can be effectively and efficiently dispersed and dissolved in low consistency pulp, the use of low consistency technology with ozonation offers a low cost method which can be used to easily and economically retrofit an existing bleaching process.
Therefore, it is an object of the present invention to provide a novel process and apparatus for bleaching pulp using ozone.
Another object of the present invention is to provide a method for more effectively and efficiently dispersing and dissolving ozone into low consistency pulp so as to make low consistency pulp bleaching technology with ozone viable.
Still another object of the present invention is to provide an efficient process and apparatus for bleaching employing low consistency technology, whereby ozone is used as the bleaching agent.
These and other objects of the present invention will become apparent to the skilled artisan upon a review of the following disclosure, the Figures of the Drawing, and the claims appended hereto.
SUMMARY OF THE INVENTION
In accordance with the foregoing objectives, there is provided a novel process and system for bleaching pulp with gaseous mixtures comprising ozone. The process of the present invention comprises first preparing a slurry of cellulosic pulp of a low consistency, i.e., a consistency of fibers of from about 1 to less than 5 weight %. Ozone is then mixed with the pulp slurry in a contacting device under high shear mixing conditions, with the amount of ozone being added to create a partial pressure of ozone in the contacting device greater than atmospheric, and in particular, greater than 1.4 psi. For it has surprisingly been found that when one uses high (greater than 1.4 psi) partial pressure ozone, in combination with a low consistency medium and high shear mixing conditions, improved results are achieved.
The high shear mixing is achieved using a contacting device or mixer designed for medium consistency pulp bleaching, i.e., a mixer generally used for medium consistency pulps. Such high shear (high-intensity) mixers are well known in the art. Using the high shear mixing conditions has been found to allow the ozone to be effectively and efficiently dispersed and dissolved into the low consistency pulp, even when a high partial pressure of ozone is used. The ozone is then maintained in contact with the cellulosic fibers for a time sufficient to bleach the fibers, before separation occurs.
What is meant by high shear mixing, i.e., the portions of fluid all moving in the same direction, is known and explained, for example, by Otto Kallmes in his article “On the Nature of Shear and Turbulence, and the Difference Between Them”, 1998 West End Operations . As noted above, high shear mixers are well known in the art, and in a preferred embodiment, such a high shear mixer is used as the contacting device. This would be the easiest way to achieve the high shear mixing conditions.
The process of the present invention offers one the energy benefits of using low consistency technology, in combination with the benefits of using ozone to bleach the cellulosic pulp. Surprisingly, it has been found that by using a high partial pressure of ozone, i.e., greater than atmospheric, and in particular greater than 1.4 psi, one can actually increase the amount of ozone dissolved in the medium when using low consistency pulp, which cannot be achieved with medium consistency. The more ozone dissolved, of course, allows for a more effective and efficient bleaching process. Also, all of the ozone can be consumed in the high shear mixer so a retention tube is not actually needed, which is unheard of when employing low consistency pulp.
The ozone bleaching step of the present invention can be combined in an overall bleaching process with other bleaching steps. For example, the ozone bleaching step can be used either before or after a chlorine dioxide bleaching step. The ozone bleaching step can also be followed by a different bleaching step, e.g., with hydrogen peroxide.
Another advantage of the present invention is that ozone has a short half-life before converting to oxygen, therefore, the present invention with its short mixing time helps ensure more ozone is available for bleaching purposes.
In another embodiment, there is provided a system for a reactor for bleaching pulp at low consistency with ozone. The reactor comprises a high shear mixer wherein ozone is dispersed into a pulp slurry at high partial pressure having a consistency in the range of from 1 to up to 5 wt %, and a retention tube connected to the mixer which operates at a pressure of from 20 to 80 psig, and wherein the ozone bleaches the pulp in the pulp slurry.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 of the Drawing depicts a reactor for bleaching pulp at low consistency with ozone, which uses a pressurized ozone generator.
FIG. 2 of the Drawing depicts a reactor for bleaching pulp at low consistency with ozone employing an ozone compressor.
FIG. 3 of the Drawing depicts a low consistency ozone bleaching process carried out before a chlorine dioxide bleaching step.
FIG. 4 of the Drawing depicts an alternative low consistency ozone bleaching process carried out before a chlorine dioxide bleaching step.
FIG. 5 of the Drawing depicts a low consistency ozone bleaching process wherein the ozone bleaching step is carried out after a chlorine dioxide bleaching step.
FIG. 6 of the Drawing depicts an alternative low consistency ozone bleaching process using an ozone bleaching step that is carried out after a chlorine dioxide bleaching step.
FIG. 7 of the Drawing graphically depicts the D/Z delignification efficiency for various reactor/mixers at low consistency (2.5-3.5 wt %).
FIG. 8 of the Drawing graphically depicts ozone solubility vs. ozone pressure, in a comparison of low and medium consistency pulp.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The ozone employed in the process of the present invention can be of any source. Preferably, the ozone is generated on-site using an ozone generator, to thereby produce ozone from oxygen at a concentration in the range of from about 4 to 20 wt %, more preferably in the range of from about 10 to 20 wt %, and most preferably in the range of from about 10 to 14 wt %. Ozone generators are well known, and are generally operated at a pressure in the range of from about 20-60 psig, and more preferably in the range of from 30-40 psig.
The ozone/oxygen mixture is preferably introduced into the contacting device through a valve, which can be used to control the flow of the gas mixture into the high shear mixer or other contacting device. The ozone/oxygen gas mixture can be compressed, if so desired, prior to introduction into the high shear mixer. The ozone compressor generally operates at a pressure ranging from 20-200 psig, and more preferably in the range of from 80-150 psig.
The ozone is added to the pulp in the contacting device to create a partial pressure by ozone greater than 1.4 psi. More preferably, the partial pressure ranges from greater than 1.4 psi up to 43 psi, and most preferably is in the range of from 9.5 psi to 23 psi. It has been found that the use of such an increased partial pressure of ozone, in combination with the low consistency medium and high shear mixing conditions, results in a significant improvement in the bleaching of the pulp. An improvement of at least 0.2 units lower Kappa number have been observed.
The high shear mixing conditions in the contacting device can be generated in any known manner, but are preferably, and most easily generated in a high shear mixer. Any high shear mixer well known to the art of pulp bleaching can be used. Such mixers are described, for example, in Pulp Bleaching —Principals and Practice by Carlton W. Dence and Douglas W. Reeve, TAPPI Press, 1996, pages 549-554. In high shear (high intensity) mixers, the pulp and ozone gas mixture are mixed by passage through zones of intense shear. They induce microscale mixing in the entire volume and not only in specific locations as in a continuous stirred reactor. The high shear is created by imposing high rotational speeds across narrow gap, generally between the rotor blades and reactor casing, through which the pulp suspension flows. Although there are design differences among the high shear mixers conventionally known, they all attempt to fluidize the suspension in the mixture working zone. The high shear rate insures flock disruption and good fiber scale mixing.
The present invention preferably employs a high shear mixer to create the high shear conditions, and many different high shear mixers used for pulp bleaching are known. Some of those known include the Ahlstrom Ahlmix, the Ahlstrom MC pump, the Beloit-Rauma R series, the Ingersoll-Rand Hi-Shear and the Impco Hi-Shear mixer from Beloit Corporation. Others include the Kamry MC, the Kamry MC Pump (Pilot) the Sunds SM and Sunds T mixers. The Quantum mixer is also an acceptable high shear mixer. All such mixers are known in the art and are generally used to mix medium consistency pulp suspensions.
Mixers can be compared based on energy applied (MJ/ton of pulp) and power dissipation (W/m 3 ). J. R. Bourne in Chem. Eng. Sci., 38(1):5 (1983) states that all devices operated at the same power unit volume will generate the same rate of micromixing. This assumes energy applied equals energy dissipated, which is not true for all mixers. The distribution of power throughout the suspension is as important as its total. Examples of different mixers and the energy and power values for a given pulp consistency are as follows:
Consistency
Power Dissipation
Energy
Mixer Type
(wt %)
(W/m 3 )
(MJ/ton)
Hand Mixing
3
2 × 10 4
120
CSTR
2-3
600
5-9
Quantum (high
5
4.5 × 10 5
63
shear) Mixer
High Shear
10
1.8 × 10 6
180
Using the measured energy dissipation rate and a correlation for the apparent viscosity of a pulp suspension given by Bennington in “Mixing Pulp Suspensions”, PhD. thesis, The University of British Columbia, Vancouver, British Columbia, 1988, τ is 0.02 sec. for a 10% consistency in a typical high shear mixer. In a CSTR operating at 3% consistency, τ=0.4 sec., but varies locally with the mixer. τ represents the mean lifetime of turbulent eddies.
The pulp suspension of the present invention that is provided to the contacting device, e.g., high shear mixer, is of low consistency. This means that the amount of pulp contained in the suspension ranges from about 1 up to but less than 5 wt %. More preferably, the amount of pulp in the suspension ranges from 2 to 4 wt %. Preferably, the temperature of the pulp slurry entering the mixer is in the range of from about 20-80° C., more preferably from about 40-60° C. The ozone charge added to the pulp is in the range of from about 2-10 kg/ton, more preferably from about 5-6 kg/ton.
Once in the contacting device, the ozone and pulp suspension are mixed under high shear conditions for a length of time in the range of from about 0.01 second to 1 minute, and more preferably in the range of from about 0.04 second to 1 second. Once the mixing has taken place, the pulp suspension can be passed to a bleaching or reactor station, which is preferably a retention tube, wherein the residence time ranges from about 1 to 10 minutes, more preferably from about 2-5 minutes. It is in the retention tube that the bleaching of the pulp can actually take place by the ozone. Because of the use of the high shear mixing conditions, and the short time in which it takes to dissolve the ozone, as well as the low pressures under which the mixing and retention tube can operate, more ozone is available to do the bleaching of the low consistency pulp. Accordingly, the present invention provides surprising results with regard to excellent bleaching. In fact, the use of a retention tube may not be necessary in spite of using low consistency pulp.
Referring to FIG. 1, there is illustrated a reactor for bleaching pulp at low consistency with ozone by using a pressurized ozone generator. It consists of a medium consistency mixer where ozone is dispersed in the low consistency pulp followed by a retention tube operating at a pressure between 20-60 psig where ozone gradually dissolves and bleaches the pulp.
Air is introduced by line 1 into an air separation unit 2 where oxygen is separated from air. Oxygen passes by line 3 into an ozone generator 4 and is converted to ozone, and this passes through line 5 into a control valve 6 that automatically regulates the gas flow by gas flowmeter 7 . Ozone gas is introduced to the mixer 9 by an inlet line 8 and is dispersed into the low consistency pulp. Pulp slurry passes through line 20 into pump 21 where it is pumped into the mixer 9 and mixed with the ozone-oxygen mixture.
The pulp slurry-gas mixer passes into the column 23 that is held under pressure by a back pressure valve 24 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 24 into line 25 .
The pulp slurry-gas mixture flows into a separator vessel 26 where gases are separated from the pulp and flow through line 27 into an ozone destruct unit 28 , where the ozone is destroyed and the remaining gases leave through line 29 . The pulp slurry leaves the separator through line 30 and flows into pump 31 where it is pumped to the next stage through line 32 .
FIG. 2 illustrates a reactor for bleaching pulp at low consistency with ozone by using an ozone compressor. It comprises generally of a medium consistency mixer where ozone is dispersed in the low consistency pulp, followed by a retention tube operating at a pressure between 20-60 psig where ozone gradually dissolves and bleaches the pulp.
Air is introduced by line 100 into an air separation unit 102 where an oxygen rich stream is separated from air. Oxygen passes by line 103 into an ozone generator 104 and is converted to ozone and this passes through line 105 into an ozone compressor 110 where the gas mixture is compressed. From here it flows to a control valve 106 that automatically regulates the gas flow by gas flowmeter 107 . Ozone gas is introduced to the mixer 109 by an inlet line 108 and is dispersed into the low consistency pulp. Pulp slurry passes through line 120 into pump 121 where it is pumped into the mixer 109 via line 122 and mixed with the ozone-oxygen mixture.
The pulp slurry-gas mixture passes into the column 123 that is held under pressure by a back pressure valve 124 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 124 into line 125 . The pulp slurry-gas mixture flows into a separator vessel 126 where gases are separated from the pulp and flow through line 127 into an ozone destruct unit 128 , where the ozone is destroyed and the gases leave through line 129 . The pulp slurry leaves the separator through line 130 and flows into pump 131 where it is pumped to the next stage through line 132 .
FIG. 3 illustrates a low consistency ozone bleaching process in accordance with the present invention that includes an ozone bleaching stage before a chlorine dioxide bleaching stages. This uses a pressurized ozone generator to compress ozone before adding it to a mixer. This method avoids the use of a compressor to add compressed ozone to the mixer.
In the process, pulp of medium consistency is pumped through line 252 into a storage tank 251 . The pulp flows down the tank into a dilution zone 250 where it is diluted to a low consistency with dilution water added through nozzles 246 and 247 . Agitators 248 and 249 ensure that mixing is complete. The pulp slurry of consistency about 3% passes through line 220 into pump 221 where it is pumped into the mixer 209 and mixed with the ozone-oxygen mixture. Air is introduced by line 201 into an air separation unit 202 where oxygen is separated from air. Oxygen passes by line 203 into a pressurized ozone generator 204 and is converted to ozone and this oxygen-ozone mixture passes through line 205 into a control valve 206 that automatically regulates the gas flow by gas flowmeter 207 . The ozone-oxygen gas mixture is introduced to the mixer 209 by an inlet line 208 and is dispersed into the low consistency pulp.
The pulp slurry-gas mixture passes into the column 223 , that is held under pressure by a back pressure valve 224 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 224 into line 225 . The pulp slurry-gas mixture flows into a separator vessel 226 , where gases are separated from the pulp and flow through line 227 into an ozone destruct unit 228 , where the ozone is destroyed and the resulting gases leave through line 229 . The pulp slurry leaves the separator 226 through line 230 and flows into pump 231 , where it is pumped through line 232 into a mixer 234 where chlorine dioxide is added through line 233 before flowing by line 235 into the bottom of the bleaching tower 236 . The pulp rises to the top of the tower and overflows through line 237 into line 238 to a washer 239 . The pulp is washed with wash water added through line 240 and the washed pulp leaves the washer through line 241 . The dilution water separated from the pulp is collected in storage tank 242 , where it is removed through line 243 by pump 244 and is pumped through line 245 to the nozzles 246 and 247 , where it is added to the dilution zone 250 of the storage tank 251 .
FIG. 4 illustrates a low consistency ozone bleaching process involving an ozone bleaching stage in accordance with the present invention that is carried out before a chlorine dioxide bleaching stage. The process uses a compressor to compress ozone before adding it to the mixer.
In the Figure, pulp of medium consistency is pumped through line 352 into a storage tank 351 . The pulp flows down the tank into a dilution zone 350 where it is diluted to a low consistency with dilution water added through nozzles 346 and 347 . Agitators 348 and 349 ensure that mixing is complete. The pulp slurry of consistency about 3% passes through line 320 into pump 321 where it is pumped through line 322 into the mixer 309 and mixed with the ozone-oxygen mixture. Air is introduced by line 301 into an air separation unit 302 where oxygen is separated from air. Oxygen passes by line 303 into an ozone generator 304 and is converted to ozone, and this oxygen-ozone mixture passes through line 305 into an ozone compressor 310 where it is compressed. From here it flows to a control valve 306 that automatically regulates the gas flow by gas flowmeter 307 . The ozone gas mixture is introduced to the mixer 309 by an inlet line 308 and is dispersed into the low consistency pulp.
The pulp slurry-gas mixture passes into the column 323 , which is held under pressure by a back pressure valve 324 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 324 into line 325 . The pulp slurry-gas mixture flows into a separator vessel 326 where gases are separated from the pulp and flow through line 327 into an ozone destruct unit 328 , where the ozone is destroyed and the gases leave through line 329 . The pulp slurry leaves the separator through line 330 and flows into pump 331 where it is pumped through line 332 into a mixer 334 where chlorine dioxide is added through line 333 before flowing by line 335 into the bottom of the bleaching tower 336 . The pulp rises to the top of the tower and overflows through line 337 into line 338 to a washer 339 . The pulp is washed with wash water added through line 340 and the washed pulp leaves the washer through line 341 . The dilution water separated from the pulp is collected in storage tank 342 . It is removed through line 343 entering pump 344 and is pumped through line 345 to the nozzles 346 and 347 , where it is added to the dilution zone 350 of the storage tank 351 .
FIG. 5 depicts a low consistency ozone bleaching process stage in accordance with the present invention that is carried out after a chlorine dioxide bleaching stage. The process uses a pressurized ozone generator to produce compressed ozone before adding it to a mixer. This method avoids the use of a compressor to add compressed ozone to the mixer.
Pulp of medium consistency is pumped through line 452 into a storage tank 451 . The pulp flows down the tank into a dilution zone 450 where it is diluted to a low consistency with dilution water added through nozzles 446 and 447 . Agitators 448 and 449 ensure that mixing is complete. The pulp slurry, now of low consistency about 3%, passes through line 420 into pump 421 that discharges through line 422 into a mixer 424 where chlorine dioxide is added through line 423 . The pulp slurry-chlorine dioxide mixture passes through line 425 into the bottom of tower 426 , where it flows upwards consuming chlorine dioxide and bleaching the pulp. It overflows from the tower 426 in line 427 flowing into pump 428 , which discharges into mixer 409 where the oxygen-ozone mixture is added.
Air is introduced by line 401 into an air separation unit 402 where oxygen is separated from air. Oxygen passes by line 403 into an ozone generator 404 and is converted to ozone and this passes through line 405 into a control valve 406 that automatically regulates the gas flow by gas flowmeter 407 . Ozone gas is introduced to the mixer 409 by an inlet fine 408 and is dispersed into the low consistency pulp. The pulp slurry-gas mixture passes into the column 429 , which is held under pressure by a back pressure valve 430 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 430 into line 431 . The pulp slurry-gas mixture flows into a separator vessel 432 , where gases are separated from the pulp and passed through line 433 into an ozone destruct unit 434 , in which the ozone is destroyed and the resultant gases leave through line 438 . The pulp slurry leaves the separator through line 436 and flows into pump 437 , where it is pumped to the washer 439 through line 460 . The pulp is washed with wash water added through line 440 and leaves through line 441 . The washings are collected in tank 442 and leave through line 443 entering pump 444 and discharges via line 445 through nozzles 446 and 447 into the dilution zone 450 of the medium consistency storage tank 451 .
FIG. 6 illustrates a low consistency ozone bleaching process in accordance with the present invention that is carried out after a chlorine dioxide bleaching step. The process uses a compressor after the ozone generator to compress ozone before adding it to a mixer.
Pulp of medium consistency is pumped through line 552 into a storage tank 551 . The pulp flows down the tank into a dilution zone 550 where it is diluted to a low consistency with dilution water added through nozzles 546 and 547 . Agitators 548 and 549 ensure that mixing is complete. The pulp slurry, now of consistency about 3%, passes through line 520 into pump 521 and discharges through line 522 into a mixer 524 where chlorine dioxide is added through line 523 . The pulp slurry-chlorine dioxide mixture passes through line 525 into the bottom of tower 526 , where it flows upwards consuming chlorine dioxide and bleaching the pulp. It overflows from the tower in line 527 flowing into pump 528 and discharges into mixer 509 where the oxygen-ozone mixture is added. Air is introduced by line 501 into an air separation unit 502 where oxygen is separated from air. Oxygen passes by line 503 into an ozone generator 504 and is converted to ozone, and this passes through line 505 into a compressor 510 where the gas is compressed. The oxygen-ozone mixture passes through control valve 506 , which automatically regulates the gas flow by gas flowmeter 507 . The ozone gas mixture is introduced to the mixer 509 by an inlet line 508 , and is dispersed into the low consistency pulp.
The pulp slurry-gas mixture passes into the column 529 , which is held under pressure by a back pressure valve 530 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 530 into line 531 . The pulp slurry-gas mixture flows into a separator vessel 532 , where gases are separated from the pulp and flow through line 533 into an ozone destruct unit 534 , wherein the ozone is destroyed and the resultant gases leave through line 535 . The pulp slurry leaves the separator through line 536 and flows into pump 537 where it is pumped to the washer 539 through line 538 . The pulp is washed with wash water added through line 540 and leaves through line 541 . The washings are collected in tank 542 and leave through line 543 entering pump 544 and discharges via line 545 through nozzles 546 and 547 into the dilution zone 550 of the medium consistency storage tank 551 .
The invention will be illustrated in greater detail by the following specific example. It is understood that the example is given by way of illustration and is not meant to limit the disclosure or the claims to follow. All percentages in the examples, and elsewhere in the specification, are by weight unless otherwise specified.
EXAMPLE 1
It has been found that most pulps bleach well giving increased brightness with little strength loss for an ozone charge of 5 kg of ozone/ton pulp. Taking this is as the basis of a design for a reactor, and assuming ozone is generated at a concentration of 12% w/w, the oxygen requirement is estimated as follows:
O 2 required=100*5/12=41.7 kg/ton of pulp.
This produces a mixture of O 2 +O 3 =5 kg O 3 +36.7 kg O 2 .
The volume of the gases at a pressure of 760 mms Hg, and temperature of 0° C. is 2.76 m 3 O 3 +30.40 m 3 O 2 .
Total gas volume=33.16 m 3 /ton of pulp.
If this is to be dispersed and dissolved in a pulp slurry having a consistency of 3%, volume of pulp slurry=100/3 m 3 /ton of pulp=33.3 m 3 /ton of pulp.
This consists of 1.0 m 3 pulp+32.3 m 3 of dilution water.
Hence it is required to dissolve and disperse 33.16 m 3 of gas in 33.3 m 3 of pulp slurry.
The ratio of gas to pulp slurry=33.16:33.3=about 1:1.
If all the O 3 dissolved in the dilution water, the solubility of the O 3 would have to be 5 kg/32.3 m 3 , or 155 g/m 3 .
If this reaction takes place at 50° C., the solubility of 12% w/w O 3 in water is as follows:
Total Pressure
Partial Pressure 0 3
Solubility 0 3
(psia)
(psia)
(g/m 3 )
14.7
1.22
13.2
24.7
2.05
22.2
164.7
13.67
147.9
If this is compared to dispersing ozone in medium consistency pulp having a consistency of 10%:
Volume=1.0 m 3 pulp+9.0 m 3 dilution water=10.0 m 3 pulp slurry.
If 5 kg O 3 ton of pulp is dispersed and dissolved in the dilution water, O 3 applied=5 kg/9 m 3 =555 g/m 3 .
The gas to liquid ratio at a pressure of 760 mms Hg and 0° C. is 33.16:9, which is 3.7:1.
At a pressure of 150 psig, this ratio becomes 0.33:1
If this medium consistency equipment disperses ozone satisfactorily at a ratio of 0.33:1 for medium consistency pulp, it will be able to do the same for low consistency. Hence to reduce the gas:slurry ratio from 1:1 to 0.33, the gas volume must be reduced by a ratio of 1/0.33 m 3 . This corresponds to a pressure of 30 psig.
Based on the above calculations, it was decided that medium consistency equipment can be used for dispersing ozone into low consistency pulp at a pressure of 30 psig. This was confirmed by testing carried out in the Laboratory as follows:
Laboratory Studies
Trials were carried out in a Quantum Mark-5 Laboratory Mixer/Reactor. This was originally designed and operated with medium consistency pulp. For each run 90 grams of pulp having Kappa No=25.5 was used and a first bleaching stage at a temperature of 40° C. with a constant chlorine dioxide dosage of 14.5 kg/ton was carried out. Following this, 4.0-5.5% w/w ozone-oxygen mixture was then introduced at a pressure of 50-70 psig at a temperature of 40° C. During the ozone addition, the pulp was mixed for 5 seconds at high intensity using a Quantum mixer followed by subsequent intermittent mixing at a lower intensity (using a CSTR) for 5 minutes. The results are shown in Table 1 below:
TABLE 1
0 3 Charge
0 3 Consumed
0 3 Reacted
Retention Time
Pressure
(kg/t)
(kg/t)
(%)
(mins)
(psig)
2.4
2.2
93.0
5
46
4.0.
3.9
95.0
5
55
6.1
5.8
95.1
5
52
7.3
7.0
95.9
5
65
This illustrates that equipment designed for dispersing gases in medium consistency pulp can also be used successfully for O 3 bleaching of low consistency pulp with high ozone utilization.
EXAMPLE 2
Tests were carried out on a Pilot Plant that was originally designed to use ozone to bleach a medium consistency pulp slurry. It consists of a pump that pumps the pulp into a pressurized high shear mixer. Ozone of concentration 12% w/w is compressed and added to the pulp slurry at the inlet of the mixer. The ozone gas mixture is dispersed in the pulp slurry where it reacts with the lignin. The slurry-gas mixture discharges into a column where the remaining ozone is consumed.
Results for a Softwood Pulp having Kappa No 31, carried out at temperature 40° C. and a pulp consistency of 3.5%, are shown in Table 2 below:
TABLE 2
Pressure
Ozone
Ozone Charge
Ozone Pressure
Bottom
Consumed
Ozone Consumed
to pulp
inlet Mixer
Tower
in Mixer
top Tower
(kg/t)
(psig)
(psig)
(%)
(%)
6.3
30
20
87
99
6-3
90
80
94
99
6-3
110
100
99
99
These results demonstrate that a Mixer designed for dispersing ozone into a medium consistency pulp slurry can be used successfully for a low consistency pulp slurry and that it is possible to operate at lower pressures with good results.
EXAMPLE 3
Two runs of an ozone stage were performed on a brown stock kraft pulp at low consistency in a Pilot plant using a high intensity mixer. The runs were made to verify if the ozone stage efficiency (degree of delignification) and the consumption were equivalent for low and medium consistency pulp. The pulp used was a softwood kraft with an initial kappa number of 30.8 and ISO brightness of 27.9%.
In each run, the washed pulp was received at 33% consistency and diluted to 3.8% consistency in an agitated feed tank. Pulp slurry was then preheated to 40° C. with the injection of steam in the feed tank. At that temperature, concentrated (98%) sulphuric acid was added to the tank to adjust the pH of the pulp suspension to 2.5 before the ozone stage. Pulp slurry was pumped directly to the hopper of the positive displacement pump. This pump introduced pulp in the high pressure section of the pilot plant, where ozone gas was mixed with the pulp in a Impco high intensity mixer. The flow of the pulp into the high pressure section and the ozone charge and concentration were kept constants.
After compression, the ozone gas stream was introduced into the pulp suspension trough a sintered metal sparger (20 micron porosity) located between the feed pump discharge and the Impco high intensity mixer inlet. The residence time in that mixer was approximately 0.05 second. The conditions for each run are described in Table 3.
The pulp was sampled approximately 1 meter from the ozone injector point after passing through the high intensity mixer. Gas samples were removed at the exit of the high intensity mixer, at the medium consistency pulp sampling point and at the top of the tower. Each gas sample was analyzed for residual concentration by gas chromatography. The ozonated pulp for the second run was analyzed for kappa number (CPPA standard, G.18) and ISO brightness (CPPA standard, E.1). The results are shown in Table 4 below.
The efficiency of delignification was approximately 1 kappa number drop per kg ozone. This observation is comparable to the efficiency observed at medium consistency and demonstrates the successful and efficient use of a high shear mixer with ozone and low consistency pulp.
TABLE 3
Z-stage conditions
Conditions
First Run
Second Run
Consistency, %
3.8
3.8
Temperature, ° C.
40
40
pH
2.4
2.4
Ozone charge, % o.d. pulp
0.551
0.566
Ozone concentration, %
12.85
13.21
Pressure
30
90
Residence time, min
6.4
6.4
TABLE 4
Results
First Run
Second Run
Results
Bottom
Top
Bottom
Top
Ozone residual, % on o.d. pulp
0.072
0.001
0.037
0.001
Ozone consumed, % on o.d. pulp
0.479
0.550
0.530
0.565
Kappa
27.0
24.1
Brightness ISO, %
31.4
32.2
Viscosity, CP
25.3
23.3
Initial kappa: 30.8 and brightness % ISO: 27.9, 39.5 CP
EXAMPLE 4
The performance of continuously stirred tank reactors (CSTR) of different types was compared to a high shear mixer for delignification efficiency in a D/Z process at low consistency. The performances were compared on the basis of OXE (oxidation equivalent, with 1 OXE=quantity of substance which receives 1 mole electrons when the substance is reduced. ClO 2 =74.12 OXE/Kg and O 3 =125.00 OXE/Kg). All of the CSTRs considered were similar in setup in terms of ozone pressure, concentration and duration.
The various reactors/mixers run, with the results are as follows.
CRL:(D/Z)Ep, SKP, initial kappa No. 23.3, final kappa No. 3.6, 14.0 kg ClO 2 ton for 6.3 kg O 3 /ton
AL:(D/Z)Eop, SKP, initial kappa No. 24.0, final kappa No. 7.9, 8.0 kg ClO 2 /ton, 6.33 kg/O 3 /ton
ECONOTECH:(D/Z)Ep, SKP, initial kappa No. 23.3, final kappa No. 3.6, 14.0 kg ClO 2 /ton, 6.0 kg O 3 /ton
CTP:(D/Z)Ep, SKP, initial kappa No. 25.4, final kappa No. 5.1, 15.0 kg ClO 2 /ton, 5.3 kg O 3 /ton
QUANTUM:(D/Z)Ep, SKP, initial kappa No. 25.5, final kappa No. 4.5, 10.0 kg ClO 2 /ton, 4.0 kg O 3 /ton
ROBIN:(D/Z)Ep, SKP, initial kappa No. 25.4, final kappa No. 9.0, 9.3 kg ClO 2 /ton, 8.1 kg O 3 /ton
The delignification efficiency for the various reactors is graphically depicted in FIG. 7 . The results clearly demonstrate the superiority of using a high shear mixer in connection with ozone at low consistency, as compared to other reactors which are conventionally used with low consistency pulp.
EXAMPLE 5
Runs were made comparing ozone solubility at different pressures in low consistency and high consistency pulps. The results are graphically depicted in FIG. 8 . As can be seen therefrom, the combination of high partial pressure ozone with a high shear mixer can provide better results using low consistency pulp than those even possible with medium consistency pulp. For example, the graph of FIG. 8 shows that one can achieve an ozone solubility of 6 kg/metric ton of pulp at low consistency at 70 psig O 3 , which one cannot achieve when using medium consistency pulp.
EXAMPLE 6
Runs were made to show the Kappa number drop when high partial pressure O 3 is used in combination with low consistency pulp and a high shear mixer. The results are shown in Table 5 below:
TABLE 5
Pilot Plant D/Z Trial
DZ
DZEp
Ozone
O 3
charge
Partial
O 3
Total
Ozone
ISO
ISO
%, od
Pressure
Gas Conc.
Pressure
uptake %,
Kappa
Brightness
Kappa
Brightness
Run
pulp
(psi)
(% wt)
psi
Location
od pulp
number
%
number
%
1
0.49
10.3
12.85
80
Top tower
N.A.
8.1
50.4
4.2
56.5
Bottom
0.43
8.4
2
0.615
10.4
13
80
Top tower
0.600
7.8
49.5
4.0
57.5
Bottom
0.555
7.9
3
0.575
3.9
13
30
Top tower
0.56
9.0
47.8
5.0
55.3
Bottom
0.536
9.1
4
0.44
3.9
13
30
Top tower
0.400
9.6
45.4
5.3
54.3
Bottom
0.36
9.9
5
0.434
10.6
13.2
80
Top tower
0.40
8.5
48.7
4.5
56.9
Bottom
0.43
8.8
For all runs:
Do-stage: KF:0.163, 3.4% consistency, pH: 2.5, 50° C. and 40 minutes
Z-stage: 3.4% consistency, pH: 2.5, 50° C., high shear mixing: 3600 RPM, 5 minutes
Ep-stage: NaOH: 1.25% on od pulp, H 2 O 2 : 0.24% on od pulp, 10% consistency, 70° C. and 120 minutes.
Generally, a Kappa drop of up to at least 0.2, and preferably, one unit is possibly achieved by using high partial pressure ozone.
While the invention has been described with preferred embodiments, it is to be, understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and the scope of the claims appended hereto. | Provided is a process for bleaching pulp with ozone. The process involves preparing a slurry of cellulosic pulp having a consistency in fibers of from 1 up to 5 weight %. Such a low consistency slurry is then mixed with high partial pressure ozone under high shear conditions. The ozone is then maintained in contact with the cellulosic fibers to effect bleaching of the fibers. The present process offers the advantages of bleaching using a low consistency slurry, with the added advantages of employing ozone. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a connecting device for installation of the sash of a house skylight in the casement, whereby the sash is axially fixed to the side pieces, but it has connecting parts which pivot and holding elements for the casement, that assemble perpendicularly in a form fitting manner.
When a skylight is installed in a roof, it is advantageous, because of the weight of the window, to install the casement and the sash in sequence. For this purpose, connecting elements of a connecting device must be present that make it possible to install the sash into the already installed casement from the inside in the simplest possible way.
A connecting device of the kind mentioned in the introduction is known from DE-GM 8,490,192. This connecting device consists of arc shaped guides attached to the casement and arc shaped slide rails that are arranged so as to rotate at the window sash. The parts must be fitted together when the sash is installed and secured later by another part to be screwed on. This connection device is unsuitable for simple and rapid installation of the sash in the casement, especially if the sash is to be attached to positioning arms that swing.
A house skylight is known from DE-P 2,519,856, in which the sash is connected to the casement by means of the positioning arms. The positioning arms are linked to the upper edge of the casement on one end and in the middle of the length of the side pieces of the sash on the other end. In the region of the upper third of the length of each of the side pieces, an axle hub is mounted that is intended to slide along the upper edge of the casement. If the sash is attached to the positioning arms, the sash moves when opened in a hinged motion about the linking axle of the positioning arms, which is located above it on the casement side. If the sash is detached from the positioning arms, the axle hubs on the casement slide while the positioning arms are lifted down from the casement. Thus, the linking of the positioning arms about which the sash can be swung is located in a high position, and the free viewing height is increased. The sliding movement of the axle hubs is limited by insertion of a strike insert.
The invention is based on the task of further developing a connecting device of the type mentioned in the introduction in such a way that a sash can be connected from the inside simply and rapidly, with swinging positioning arms mounted on the casement.
SUMMARY OF THE INVENTION
The task is solved according to the invention by having the connecting parts in a U-shaped cross section, accept swinging positioning arms that serve as holding elements, and these connections being lockable by attachment elements that can be activated without tools.
The sash is inserted, e.g., from the inside through the casement built into the roof, placed on the upper edge of the casement and brought into the correct position with respect to the casement. Here, for example, the axle hubs on the sash sides lay on the strike pieces and determine the correct positioning. Now, however, the connecting parts and the positioning arms are connected together, for example, by pushing the sash side with the U-shaped cross section over the free end of the positioning arm, which has a special rectangular cross section. This connection between connection parts and positioning arm can then be secured by a hand activated attachment element.
The connection device according to the invention can be produced economically as a piece punched from sheet metal, and it can be mounted with few hand movements. Even with sashes of larger dimensions, the work of installing the sash can be done by one person, especially if the axle hubs lie on the strike inserts.
The attachment elements can be constructed in various ways. A simple solution can be built from a bolt that can be inserted into a hole that goes through both the connecting part and the positioning arm in the desired position.
In a preferred manner, at least one bolt is mounted with a spring so that it can not be lost, which can be pulled back when the positioning arm is inserted into the U-shaped cross section with an insertion bevel on the connection parts and engages in the locked position with an indentation in the connection part in a form fitting manner. This embodiment has the advantage that the parts automatically engage with one another in the locked position, and the installation step is basically limited to bring the positioning arms to cover the connecting parts, whereby the insertion of the positioning arms into the U-shaped cross section in the connecting parts is made easier by insertion bevels on the connecting parts.
A further embodiment of the attachment elements consists of providing latches that effect a locking of the connecting parts and the positioning arms in the coupled end position.
In a favorable manner, the latches on the positioning arms are mounted so as to swing, whereby they engage in the locked position with at least one closing knob in corresponding indentations in the connecting parts. It is appropriate to make the indentations in the form of a slit and to provide each of the closing knobs with at least one bevel, by which means insertion of the closing knobs into the corresponding indentation of the U-shaped cross section is made easier, and a fit between connecting part and positioning arm is achievable to press the adjustment into the locked position completely against the bottom of the U-shaped cross section of the cross section. By implementing the attachment elements with swinging latches, it is possible to achieve locking with a simple hand action. In this way, no tool is needed for installation of the sash and securing the connection between connecting part and positioning arm.
By means of a strike plate arranged on the positioning arm, which corresponds to a curved indentation of the rod, the range of motion of the latch can be limited to the installation position or the locked position.
Inadvertent unlocking is prevented by having the latches, after installation of the sash, attached by bringing an upper weatherstripping to be attached to the positioning arm in the locked position.
An adjustment possibility can be added to the connecting device, in which the position of the connecting part can be shifted lengthwise with respect to the positioning arm by means of an eccentric bolt.
Preferably, the eccentric bolt runs between two positioning arms perpendicular to the lengthwise axis; it is arranged within the limits applied to the connecting parts, and the eccentric shaft is connected to the positioning arm. With this adjustment possibility, the position of the sash can be set with respect to the casement. Thus, setting of the position of the sash along the positioning arm as well as a perpendicular setting is possible, in order to provide easy access even to a casement installed at a steep angle.
Inserts can also be provided that also secure the position of the connecting parts on the positioning arm and, in particular, serve to keep it held reliably on the positioning arm after unlocking by loosening by attachment element of the sash.
The window frame, which is generally made of wood, is usually protected against moisture by weatherstripping. Here, an upper weatherstripping can also cover the positioning arm and a lower weatherstripping must engage with it and cover the lower portion of the window frame. With such an embodiment with the ends of adjoining weatherstripping overlapping, the connecting part is provided with free spaces that form a free space for access to the end region of the lower weatherstripping when the sash swings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a skylight embodying the present invention with positioning arms partially pivoted related to the casement and the sash;
FIG. 2 is an enlarged fragmentary view of the skylight of FIG. 1 with a first example of an embodiment of the connecting device;
FIG. 3 is a cross sectional view of an embodiment of an attachment element;
FIG. 4 is a top view of a second embodiment of a connecting device;
FIG. 5 is a fragmentary side elevational view of a third embodiment of a connection device; and
FIG. 6 is a bottom view of the third embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The skylight in FIG. 1 consists of the casement (12), onto which a pair of positioning arms 5 is mounted so they can swing, the free ends of which hold a sash 1 that can be swung. The sash 1 is provided with connecting members (3) on both its side rails 2, which have a U-shaped cross section 4, in which accept the positioning arms 5 with their free ends in a form fitting manner. An attachment element (6) locks the connection between the connecting part (3) and the associated positioning arm (5). The connecting part (3) is attached by a plate (26), which can be seen in FIG. 2, which is attached to the side rail 2. The U-shaped body portion (4) and the axle (11) are mounted to the plate (26) so that the connecting member pivots thereabout.
Above the positioning arm (5) and the upper part of the casement (12) there is an upper weatherstripping (18) formed to provide a U-shaped channel. In the region of the connecting members (3), the upper weatherstripping (18) covers with its lower end, the upper end of a lower weatherstripping (24), which protects the edges of the sash (1) in the lower region. The lower weatherstripping (24) ends above the axle (11), whereby the connecting members (3) are provided with free spaces (25) in such a way that the axle (11) of the swinging sash (1) can complete its motion without the upper ends of the lower weatherstripping (24) colliding with the connecting members (3).
When the sash (1) swings open, the axle hubs (31) on the side rolls 2 of the sash, slide onto the front surface of the casement (12) from below, whereby the axis of rotation of the sash, which consists of the axle (11), is lifted from the casement (12). When the axle hubs (31) lie on the strike piece or catches (32), the sash (1) is in the cleaning position, in which the outer side of the sash (1) is accessible from the inside.
The enlarged representation according to FIG. 2 is to be understood so that the U-shaped back portion (4) of the connecting member (3) receives the positioning arm (5) with its free ends in a form fitting manner. A bolt (7) serves as the mounting element (6), which locks the positioning arm (5) to the connecting member (3). The bolt (7) can have a head for security, and on the other side it can be held by means of a securing such as a nut or the like.
The connecting member (3) in FIG. 3, which is provided with a U-shaped body portion (4), is positioned in the region of a mounting element (6) with insertion bevels outwardly flowing edge portions 10 to facilitate. Adjacent the free ends of the positioning arms (5), there are two bolts (7) as mounting elements (6) against the pressure of a spring (8) placed there between in the profile of the positioning arms so that they can be pressed into the connecting member 3. The bolts (7) have an enlarged head (33) in a bore (34) in the free cross section of the insert (35) which is pushed into the positioning arm (5). The insert (35) which has the shape of a rectangular tube, and the bore 34 also accepts the spring (8). When the positioning arms (5) are brought in to the connecting members (3), the bolt (7) is pushed back into the positioning arms (5) by the cam surfaces (10) against the force of the spring (8). When the positioning arms (5) reach their desired position in which the positioning arm (5) abuts the bottom surface or web (29) of the connecting member (3) connected to the free shaft (3) in the U-shape shaped cross section (4), then the bolts (7) are aligned with the apertures (9) made in the side walls (30) of the U-shaped body portion (4), the bolts (7) automatically engage therein through the force of the spring (8). This embodiment is especially simple and appropriate, since simple insertion is sufficient and the mounting elements (6) automatically engage in the locked position.
In the connection device according to FIG. 4, the positioning arm (5) has only one bolt (7), and the connecting member (3) is provided with two flared end wall portions (10) and two openings or apertures (9), so that the U-shaped body portion (4) can be inserted on the left and right. In addition, the connecting member (3) has two inserts (23 and 23'). The insert (23) is inserted at the front end of the positioning arm (5) in such a way that it lies opposite the bottom surface or web (29) of the U-shaped body portion (4) of the connecting member (3). This insert (23) serves as a guide for determining the correct arrangement of the connecting member (3) with respect to the positioning arm (5) in connecting these parts (3, 5) and also in disconnecting them, even after unlocking by loosening the attachment elements (6) as an additional security means, in order to prevent the connecting member (3) from sliding away from the positioning arm (5). Inserts 23' are attached to the U-shaped body portion (4) and engage its open side in such a way that the positioning arm (5) is almost completely enclosed on all sides in this position.
At the bottom surface (29) of the U-shaped body portion (4), the connecting member (3) is brought into an elongated aperture (28) that has side edges (22, 22') that lie perpendicular to the long axis of the positioning arm (5). An eccentric bolt (21) is mounted between in the aperture 28 between the side edges 22, 22'), the eccentric shank (20) of which is riveted to the positioning arm (5) so it can rotate. Both the bolt (7) in the opening (9), which serves as an mounting element (6), and the insert (23) have play, so that a shift of the connecting member (3) on the positioning arm (5) in its long direction is possible by moving the eccentric bolt (21). The position of the sash (1) is thereby adjustable with respect to the casement (12). By positioning the eccentric bolts (21) on the two positioning arms (5) in equivalent positions, the spacing between the upper and lower edges of the sash (1) and the casement (12) can be regulated. By means of various positions of the two eccentric bolts (21), a correction of the diagonal position of the sash (1) is possible.
In FIG. 4, the axle (11) of the connecting member (3) is also shown at the side rail (2) of the sash (1). The sash (1) with the side piece (2) is only fragmentarily illustrated. The plate (26) serves to attach the axle (11) of the connecting member (3) to the side rail (2), whereby this plate (26) is shaped as a plate that is attached to the side rail (2) with screws through it. Additional fitting pins serve for precise attachment. The axle (11) forms at the same time an axis for the swinging of the sash (1), around which the sash (1) swings while attached to the positioning arm (5).
In the examples of embodiments in FIGS. 5 and 6, locking between the positioning arm (4) and connecting member (3) takes place by means of an attachment element (6), which is constructed as a swinging latch (13), which is mounted on the bottom side of the positioning arm (5). This latch (13) has two closing projections (14 and 14'), which in the locked position engage in corresponding slots (15, 15') in the side walls (30) of U-shaped body portion 4 of the connecting member (3). These slots (15, 15') are made in the form of elongated slots, and the closing projections (14, 14') have accurate cam surfaces (16) that serve for easy insertion or assure that the positioning arm (4) is also pressed with pushing moment against the bottom surface (29) of the U-shaped body portion (4). An insertion cam surface (19) on the positioning arm (5) engages with an arc shaped indentation in the latch (13) and limits its swinging motion. In FIG. 6, the swinging motion of the latch (13) is limited in the locked position.
The latch (13) has an activation handle (17), which protrudes sideways from the positioning arm 5, even in the locked position, and can thereby be reached easily. The upper weatherstripping (18), which also covers the positioning arm (5), is constructed in such a way that it also extends sideways over the activation handle. Swinging motion of the latch (13) is thereby prevented during mounting of the upper weatherstripping (18), so that, for safety reasons, unlocking between the connecting members (3) and the positioning arm (5) when the skylight has been installed in the roof cannot occur even accidentally.
Each connecting device is provided with an eccentric bolt (21) that has an eccentric shaft (20), which is brought to the inner side of the positioning arm (5) used for the sash (1) and engages in an elongated aperture (28) in the side wall (30) of the U-shaped body portion (4) of the connecting member (3), whereby the elongated aperture (28) has the limiting side edges (22, 22'). The function is as described above. This arrangement of the eccentric bolt (21) has the advantage that later adjustment of a skylight installed in the roof can be made easily from the inside. | A connecting assembly for installing the sash of a house skylight to the sides of its casement, has connecting parts that can pivot relative to each other, and the casement has holding elements that have cross sections which will engage therewith. This assembly allows the window sash to be inserted from the interior rapidly and in a simple manner by engagement with the positioning arms on the casement. This is achieved by the connecting parts (3) having a U-shaped cross section (4), which accept swinging positioning arms (5) which serve as the holding elements, and these connections can be locked by self-engaging attachment elements (6) that can be engaged without tools. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field
[0002] The present invention generally relates to storage containers. More specifically, the present invention relates to insulated storage containers.
[0003] 2. Background
[0004] Insulated storage containers are well known in the art and are commonly used to isolate their contents from the external environment. To cool the contents of the container, ice or a sealed gel refrigerant may be used to suppress the internal temperature of the container below ambient temperature. Alternatively, a sealed gel heat pack may be used to elevate the internal temperature of the container above ambient. Sportsmen, campers, picnickers, and mothers of newborns have found insulated containers to be particularly useful when electrically powered refrigerators and food warmers are unavailable.
[0005] Several attempts have been made to enhance the functionality of insulated containers. For instance, U.S. Pat. No. 5,305,544 describes a bait storage cooler and tackle holder used to store bait and food. This insulated container has a lower portion that is divided into two compartments by a non-insulated wall and includes a lid having recesses to receive and support beverage cans. The non-insulated wall permits the two compartments to be maintained at a similar temperature while preventing intermingling of the contents. For instance, bait in one compartment can be separated from food contained in the other compartment.
[0006] Separating the contents of the two compartments may be desirable in some applications to maintain the two compartments at approximately the same temperature. However, this device is not well suited for insulating the two compartments relative to one another where it is desirable to maintain the two compartments at different temperatures. An insulated container constructed in accordance with the teachings of the '544 patent would facilitate thermal homeostasis rather than prevent it.
[0007] Another drawback of the container described in the '544 patent is that it is often difficult to clean. Typically, the size of insulated containers render them difficult to wash and incapable of being placed within a standard dishwasher or household sink for easy cleaning. Many users find it necessary to clean such coolers outside with a garden hose. Aside from being a laborious task, cleaning the container outdoors with a garden hose substantially limits the degree of cleaning possible. Outdoors debris and contaminants may find their way into the container when cleaning in this manner. This may be particularly undesirable where maintaining a sanitary environment is critical. The device described in the '544 patent also does nothing to securely fasten beverage containers such as bottles or cans in an upright orientation. Accordingly, these beverage containers would be free to tip over and leak if the insulated container happens to be jarred or tipped over.
[0008] Another attempt to advance the art of insulated containers is disclosed in U.S. Pat. No. 4,759,467. This patent discloses a disposable cooler liner made from a flexible, impermeable material provided with an adhesive to attach the liner within the chest. The liner includes thin inner walls to provide separate compartments such that the contents may be separated from one another while maintaining each compartment at approximately the same temperature.
[0009] Once again, this device does not thermally isolate the separate compartments. Additionally, the use of a flexible impermeable liner allows for easy removal and disposal, but frustrates the user's ability to easily clean and reuse the liner. If the user desires to wash the flexible liner in a dish washer it would be difficult to keep the liner open so that it can be fully cleaned. This would present a substantial problem in applications where maintaining a sanitary environment is critical. Moreover, once the liner has been removed and cleaned the adhesive is likely to be compromised.
[0010] One application in which insulated storage containers are utilized is by mothers of newborn babies. Often when they leave home for an extended period of time it is desirable to bring along milk, juice or formula for the baby. In such applications the mother may desire to refrigerate some bottles to prevent the contents from souring. However, the mother may also wish to simultaneously warm some of the other bottles so that the contents of the bottle are approximately body temperature for feeding. If the above noted devices were utilized the insulated container would be incapable of simultaneously refrigerating some of the bottles while warming the other bottles. Additionally, the bottles would be permitted to tip over and, as is common with baby bottles fitted with nipples, the bottle could spill its contents within the container. Babies have underdeveloped immune systems; therefore, it is critical to be able to sterilize items which are commonly used to care for the baby. If the above noted containers were utilized by a mother, it would difficult to efficiently sterilize the container thus unnecessarily risking the health of the baby.
SUMMARY OF THE INVENTION
[0011] An object of the present invention is to overcome the deficiencies present in the prior art.
[0012] In accordance with one exemplary embodiment constructed in accordance with certain teachings of the present disclosure, an insulated container id disclosed including a container body with a lid fitted to the container body. The insulated container also includes a liner fitted within the container body and is configured to be removable and reusable. In one embodiment, the liner is constructed from a rigid flexible material so that it is washable. In another embodiment of the present invention, the liner has an inwardly angled configuration in order to shed fluids. In yet another embodiment, the liner may have a latch to releasably secure the liner to the container body. In yet still another embodiment, the liner includes an insulated partition. The insulated partition allows for the insulated container to have two thermally isolated regions so that items may be simultaneously stored in the insulated container at dissimilar temperatures. Each of the above embodiments provide features which provide a multifunctional liner which provides unique advantages over the prior art.
[0013] In another embodiment of the present invention, the liner includes at least one coupling cavity. The coupling cavity is configured to securely retain a bottle or can in an upright orientation within the insulated container. Unlike prior art containers which do not positively secure the contents in an upright orientation, in one embodiment of the present invention, the insulated container prevents bottles or cans from tipping over and spilling their contents inside the container.
[0014] These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims. For a better understanding of the invention, its operating advantages and the specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed that the present invention will be better understood from the following description of embodiments taken in conjunction with the accompanying drawings, in which like reference numerals identify identical elements and wherein:
[0016] FIG. 1 is a perspective view of the insulated container of the present invention with the lid in a closet orientation;
[0017] FIG. 2 is a perspective view of the insulated container of the present invention with the lid in an open orientation;
[0018] FIG. 3 is a perspective view of the insulated container of the present invention with a can and two bottles supported by the lid;
[0019] FIG. 4 is an exploded perspective view of the insulated container;
[0020] FIG. 5 is a perspective view of a liner of the present invention;
[0021] FIG. 6 is a top plan view of the insulated container;
[0022] FIG. 7 is a cross-sectional view of the insulated container though line A-A of FIG. 6 through one of the coupling cavities;
[0023] FIG. 8 is a perspective view of an insulating layer of the present invention;
[0024] FIG. 9 a is a partial perspective view of the container body about the first locking member;
[0025] FIG. 9 b is a perspective view of the second locking member;
[0026] FIG. 10 is a partial cross-section along line B-B of FIG. 6 about the hinge assembly about the anchor which pivotably engages the outer shell of the insulated container.
DESCRIPTION OF EMBODIMENTS
[0027] As best appreciated with reference to FIG. 1 , the present invention provides an insulated container 10 having a container body 12 with a lid 14 covering the container body 12 . The insulated container also has a handle 16 attached to the container body 12 via a pair of anchors 18 which are fitted into a pair of corresponding apertures 20 to provide a pivotable connection between the handle 16 and container body 12 . Alternatively, the handle 16 may be attached to the container body 12 via a variety of other mechanisms. For instance, the handle 16 may be integrally formed into the sides of the container body 12 or lid 14 (not shown). The handle 16 could also be connected to the container body 12 or lid via a sliding connection with a boss which travels within a track (not shown).
[0028] FIG. 2 shows the insulated container 10 with the lid 14 in an open configuration exposing the internal cavity 22 of the insulated container 10 . Various bottles 24 a, 24 b, 24 c and cans 26 may be secured within the internal cavity 22 as explained in further detail below. The lid 14 is pivotably connected to the container body 12 via a hinge 28 . With particular reference to FIGS. 2 and 3 , the lid 14 has ledges 30 to prevent inadvertent contact with the anchors 18 when the lid 14 is in the closed orientation. To open the lid 14 , the lid 14 has a recess 32 where the user may grasp the lid 14 to pivot the lid 14 . An upper surface 34 of the lid 14 has domed portions 36 to secure a can 26 or bottle 24 . Alternatively, the upper surface 34 may also include recesses (not shown) to secure a can 26 or bottle 24 to the lid 14 . As seen in FIG. 2 , a lower surface 38 of the lid 14 has a rib 40 which separates the lower surface 38 into two regions 42 a and 42 b. To prevent the bottles 24 from tipping over when located within insulated container 10 , the lower surface 38 of the lid 14 has concave portions 44 which receive at least a portion of a can 26 or bottle 24 . A bead or gasket 46 extends from the lower surface 38 of the lid 14 to releasably seal the internal cavity 22 .
[0029] As shown in FIG. 4 , the container body 12 includes an outer shell 48 an insulated layer 50 fitted within the outer shell 48 and a liner 52 releasably secured within the insulating layer 50 . The liner is formed from a flexible rigid plastic material or any other cost-effective, easily manufacturable, durable material. Turning to FIG. 5 , the liner 52 has two chambers 54 a, 54 b. Of course the insulated container 10 could be further divided into additional chambers without departing from the spirit or scope of this invention. Each chamber 54 a, 54 b is defined by a bottom surface 56 and four side walls 58 . Surrounding the side walls 58 is a lip 60 . The side walls 58 are inwardly tapered from the lip 60 towards the bottom surface 56 . Rather than having to wash the entire insulated container which is often cumbersome and difficult to perform reliably, the liner 52 of the present invention may be removed and cleaned separate from the outer shell 48 and the insulated layer 50 . The tapered configuration of the side walls 58 allows the liner 52 to shed water when inverted thus facilitating thorough cleaning when inverted and placed in a common household washing machine.
[0030] Formed into the bottom surface 56 are coupling cavities 62 . Preferably, each coupling cavity 62 is configured to receive multiple different bottles 24 or cans 26 . A pair of latches 64 are formed into the liner 52 adjacent the lip 60 . Each latch 64 has a flexible arm 66 with a hook 68 to secure the liner 52 to the outer shell 48 . The liner 52 is separated into the two chambers 54 a, 54 b by an elongate channel 70 . To enhance the structural rigidity of the liner 52 a rib 72 is formed between the chambers 56 within the elongate channel 70 .
[0031] As shown in FIGS. 6 and 7 , each coupling cavity 62 is configured to receive different sized cans 24 or bottles 26 . Each coupling cavity 62 has a first cylindrical cross-section 74 of about approximately 2.6 inches in diameter, a second cylindrical cross-section 76 of about approximately 2.3 inches in diameter, a third cylindrical cross-section 78 of about approximately 2.0 inches in diameter. Between the first cylindrical cross-section 74 and the second cylindrical cross-section 76 , is a first taped portion 80 . Between the second cylindrical cross-section 74 and the third cylindrical cross-section 76 is a second tapered portion 82 . Adjacent the third cylindrical cross-section 78 is a third tapered portion 84 . The purpose of this configuration is to permit cans 24 and bottles 26 of differing dimensions to be securely retained within the coupling cavities 62 . This unique feature of the invention in combination with the concave portions 44 in the lid 14 prevents a can 26 or bottle 24 from tipping over and spilling its contents within the internal cavity 22 . This overcomes one of the most problematic features of transporting bottles 24 . If a baby bottle tips over, it may result in spilling its contents creating not only creating a mess but also an unsanitary condition which is particularly undesirable when used for babies with underdeveloped immune systems.
[0032] With reference to FIG. 8 , the insulating layer 50 may be constructed from a variety of materials such expanded polystyrene foam commonly sold under the trademark Styrofoam or any other insulating material capable of providing an insulation. The insulating layer 50 has chambers 86 a, 86 b corresponding to the chambers 54 a, 54 b of the liner 52 . The insulated layer 50 has a bottom wall 90 wit a pair of side walls 92 , a front wall 94 and a rear wall 96 extending from the bottom wall 90 . Separating the chambers 86 a, 86 b is an insulated partition 98 . This insulated partition 98 thermally isolates the chambers 86 a, 86 b from one another. This unique feature of the invention permits items to be stored in the same insulated container at different temperatures. For instance, a caregiver for a newborn baby may wish to refrigerate bottles 24 containing formula within one of the chambers 86 a or 86 b while simultaneously warm another bottle 24 in the other chamber 86 a or 86 b. Of course this feature may also have multiple other applicants. For instance, a camper may wish to store beverages at a cool temperature within one of the chambers 86 a or 86 b while also storing a soup, casserole or other item simultaneously at a heightened temperature. These examples are merely exemplary and a multitude of other applications could utilize the unique features of the present invention. In either of the above examples, one of the chambers 86 a, 86 b could be cooled by ice or an enclosed gel refrigerant and the other chamber 86 a, 86 b could be warmed by a enclosed gel heat pad.
[0033] The insulated layer 50 has a groove 100 to engage with rib 40 and scalloped portions 102 to egage with the coupling cavities 62 in order to maintain proper alignment between the insulated layer 50 and the liner 52 . Channels 104 are formed on the side walls 92 to provide clearance for the latches 64 . Through holes 106 are formed in the bottom surface 90 of the insulated portion 98 in order to permit affixing the insulated layer 50 to the outer shell 48 as will be explained in further detail below. Yet another unique feature of the present invention is that it includes vents 108 . The vents 108 allow for air trapped between the liner 52 and insulated layer 50 to be vented as the liner 52 is inserted adjacent the insulated layer 50 in order to easy assembly and reduce wear on the insulated container 10 . The vents 108 also allow for air to seep into the region between the liner 52 and the insulated layer 50 in order to depressurize this region as the liner 52 is removed.
[0034] FIGS. 9 a and 9 b, show the locking mechanism utilized to secure the insulated layer 50 to the outer shell 48 . The locking mechanism includes a first member 110 integrally molded to the outer shell 48 . The first member 112 has a base portion 114 with a cylindrical portion 116 extending therefrom. The cylindrical portion 116 has an octagonal inner bore 118 . The second member 120 has a planar portion 122 with a cylindrical portion 124 extending therefrom. The cylindrical portion has an octagonal inner bore 126 with a projection 128 extending within the inner bore 126 . To assemble the body, the inner layer 50 is aligned within the outer shell 48 such that the first members 112 extend upward into the through holes 106 in the insulated layer 50 . To secure the insulated layer 50 in place, second members 120 are pressed down onto corresponding first members in order to lock the insulated layer 50 in place. Of course a suitable adhesive could also be utilized without departing from the unique aspects of this invention.
[0035] As best appreciated with reference to FIG. 11 , the hook 68 of the latch 64 engages a slot or depression 130 formed in the outer shell 48 to releasably secure the liner 52 within the inner layer 50 . The latches 64 may be released in order to permit the removal of the liner 52 by pressing the flexible arms 66 inwardly to disengage the hooks 68 from the outer shell 48 . Due to the flexible nature of the latches 64 , the hooks 68 will automatically reengage the slots 130 when fully inserted into location. A band 132 extends from the outer shell 48 and includes the aperature 20 which receives the anchor 18 formed on the handle 16 . The aperature 20 and anchor 18 are cylindrical in shape so that the handle 16 is free to pivot relative to the body 12 .
[0036] Although particular embodiments of the present invention have been illustrated and described, modifications may be made without departing from the teachings of the present invention. For instance, the present invention has described the particular configuration of the first valve, the second valve, and the one-way valve. The principle operation of these devices is to permit airflow in one direction and resist airflow in the opposite direction. One of ordinary skill in the art can best appreciate that the there are a variety of devices which can achieve this function such as duck bill valves, one-way flapper valves, pumps and the like. The present invention anticipates the substitution of these various other devices without departing from the teachings of the present invention. Accordingly, the scope of the invention shall be limited only by the following claims. | The present invention comprises an insulated container having a liner fitted therein. The liner is removable, reusable, and washable. The insulated container also has an insulated partition defining a pair of thermally isolated compartments to maintain different temperatures in each compartment. To secure the liner in place, a latch is provided, and to vent trapped air, the liner includes a channel. The liner is also configured to shed water when inverted in a washing machine so that the liner can be easily sterilized. An additional unique feature of this invention is that the liner also includes coupling cavities configured to accept various bottles and cans to prevent the bottle or can from tipping over inside the insulated container. | 0 |
FIELD OF THE INVENTION
The following invention relates to an apparatus for supporting fireworks for enhanced view by spectators. More specifically, this invention relates to a collapsible fireworks display stand designed to raise stationary fireworks to a height readily visible by an audience and to allow sparks emitted from the fireworks to fall a further distance from the elevated height. The falling sparks naturally burn out as they fall to the ground, further increasing their visibility and burn duration.
BACKGROUND OF THE INVENTION
Many fireworks products are designed to rest on the ground and then be ignited to provide the desired fireworks display. When these products are on the ground, they are not as easily viewed by a crowd, especially children and other viewers of limited height. Also, any sparks which are emitted by the products on the ground land rather quickly and then are either snuffed out or merely burn on the ground. Supporting fireworks upon an apparatus just prior to ignition has long been common practice in the art, especially for rocket-type products. Typically, a rigid stand is erected a safe distance from spectators and the fireworks positioned on or in the stand. The stand serves as a launch platform from which the fireworks propel themselves into the air after ignition.
Such prior art stands have several drawbacks. The launch platforms for high energy fireworks are generally complex, rigid structures that are inappropriate for use with the less energetic fireworks. They are primarily designed to serve as a temporary holder for the fireworks. Also, they are not designed for the spectator to watch the fireworks as they burn on the stand. In fact, if one or more of the highly energetic fireworks remained in the stand, the result could be a conflagration of fireworks igniting prematurely in an uncontrolled fashion. The need to withstand the structural stress induced by highly energetic fireworks, requires that the stand be rigid, heavy, or need additional support as by driving a stake in the ground and supporting the stand through the use of the stake. This makes the use of prior art stands for lower energy stationary fireworks devices inappropriate, cumbersome, and ineffectual.
Alternatively, simply allowing lower energy fireworks to burn up on the ground results in premature burnout and inability of all but a few people to be in the viewing zone. Accordingly, a need exists for an apparatus that can be easily and quickly constructed, will increase the viewing zone of the audience, and will prevent premature burnout of the fireworks.
SUMMARY OF THE INVENTION
The fireworks display stand of this invention solves the problems associated with stand rigidity, the need to increase the viewing zone of fireworks spectators, and extending the burn duration of the sparks emitted from the fireworks. Specifically, the stand incorporates design characteristics that address each problem. First, the display stand is collapsible. Collapsibility is made possible by a combination of components such as slits, folds, and reinforcing parts that permit the length and width of the stand to be reduced when in the folded position and rigid when in the unfolded position.
Second, the stand unfolds from its collapsed position to a height substantially larger than its folded height. Atop the stand is a cap that serves as a holder for the fireworks. The increased height of the fireworks product magnifies the viewing zone of spectators, particularly those having other spectators between them and the fireworks display. The increased height also raises the height of spark emissions and allows the emitted sparks to travel a greater distance and burn out naturally as they fall to the ground. As such, the spark burn duration is increased and therefore the fireworks visuals are magnified.
A typical use of the stand is as follows. A relatively level fireworks display site is selected. The fireworks display stand and fireworks are brought to the site. The display stand is removed from a package containing the stand and all parts necessary for final assembly. The stand is preferably configured to be assembled by: a) unfolding the first of two vertical panels; b) placing reinforcement strips across the two inside folds of the vertical panel; c) unfolding and reinforcing the second panel in like manner to the first panel; d) positioning the base of the first panel above an upper end of the second panel such that a central axis of the first base is essentially perpendicular to a center axis of the upper end; e) aligning a lower slit of the first panel with an upper slit of the second panel; f) sliding the first panel downward over the second panel while maintaining the established relative orientation of the panels until the upper ends and bases of the two panels are essentially flush with each other; and, g) sliding an open end of a cap over the joined upper ends of the two panels.
Once assembled, the stand is placed at the fireworks site and the fireworks placed on the top surface of the cap. After the fireworks products are lit and begin burning, the spectators can view the fireworks show from a safe distance.
The fireworks display stand described above constitutes the basic invention. However, there are some alternatives that may be desireable. One alternative is a clamp reinforcement part in lieu of the rigid strips. These clamp reinforcement parts would slide over both outside edges of each panel. Other alternatives include having the reinforcement strips adhere to the outside surface of the vertical panel or having them adhere to both the outside and inside surfaces simultaneously.
OBJECTS OF THE INVENTION
Accordingly, a primary object of the present invention is to provide a fireworks display stand that is collapsible.
Another object of the present invention is to provide a fireworks display stand that is compact before assembly.
Another object of the present invention is to provide a fireworks display stand that increases the field of view of the spectators.
Another object of the present invention is to provide a fireworks display stand that extends the burning time of the fireworks and the sparks they emit.
Another object of the present invention is to provide a fireworks display stand that allows the fireworks sparks to burn out naturally as they fall to the ground.
Another object of the present invention is to provide a fireworks display stand that is easy to package.
Another object of the present invention is to provide a fireworks display stand that is easy to transport.
Another object of the present invention is to provide a fireworks display stand that does not require a support stake to hold it in place.
Another object of the present invention is to provide a fireworks display stand that supports fireworks at the highest point on the stand.
Another object of the present invention is to provide a fireworks display stand that can be made in shapes and sizes of various characters and objects.
Another object of the present invention is to provide a fireworks display stand that enhances the visual appeal of a fireworks show by depicting colorful characters and objects which relate to the patriotic themes.
Other further objects of the present invention will become apparent from a careful reading of the included drawing figures, the claims and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of the collapsible display stand of this invention exhibiting the major components of the stand and their general arrangement when the stand is fully assembled.
FIG. 2 is a front, exploded, perspective view of the stand exhibiting the major components of the stand and their interrelationships during assembly.
FIG. 3 is a front perspective view of the second vertical panel which is essentially fully collapsed but is just beginning to be opened from its fully collapsed position.
FIG. 4 is a front perspective view of the second vertical panel positioned approximately halfway between its fully collapsed and fully opened positions.
FIG. 5 is a front perspective view of the second vertical panel in its fully open position with clamps and rigid support strips in place.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, wherein like reference numerals represent like parts throughout the various drawing figures, reference numeral 10 (FIG. 1) is directed to a collapsible fireworks display stand for holding fireworks while they are burning. The stand 10 elevates the fireworks to a height that makes a fireworks show more readily visible to a larger number of spectators. The stand 10 also allows the sparks to free fall to the ground, thereby increasing their burn duration and the magnitude of the fireworks show.
In essence, and with particular reference to FIGS. 1 and 2, the stand 10 preferably includes a first vertical panel 30, a second vertical panel 40, a cap 50, and at least two strips 70. The first and second panels 30, 40 each have respective first and second bases 34, 44 that make contact with the ground to provide support and stability for the stand 10 after it is fully assembled. In addition, the panels 30, 40 have first and second upper ends 32, 42 opposite said first and second bases 34, 44. The upper ends 32, 42 form a cruciform shaped surface upon which the cap 50 rests after the stand 10 is assembled. The fireworks are placed on a top surface 52 of the cap 50.
More specifically, and with particular reference to FIG. 2, details of the stand 10 are provided. The first vertical panel 30 has a periphery in the preferred embodiment of this invention shaped to define a planar cross-section similar to the shape of a rocket. The second vertical panel 40 has a like peripheral shape. However, numerous other peripheral shapes may be utilized in alternate embodiments. Such shapes include the hand and torch of the Statue of Liberty, the Liberty Bell, the flag, animals, cartoon characters and virtually any shape that can be defined by an enclosed periphery. The panels 30, 40 in the preferred embodiment of this invention are preferably made of a cellulosic material such as corrugated cardboard. However, any material that is relatively lightweight, hingable, and is relatively easy to form and cut, is acceptable for the purposes of this invention.
The first base 34 of the first panel 30 is defined by the portion of the periphery at the bottom of the panel 30. The base 34 periphery is parallel to the ground up to the maximum width of the base 34. At approximately the midpoint of this portion of the periphery, there exists a discontinuity that defines the beginning of a lower slit 36 in the first panel 30. The lower slit 36 extends essentially perpendicularly from this discontinuity in the periphery to a point approximately halfway between the upper and lowermost points on the periphery of the first panel 30. The width of the lower slit 36 of the first panel 30 is slightly larger than the thickness of the second vertical panel 40 in order to accommodate the second panel 40 when the two panels 30, 40 are joined. The lower slit 36 ends in a juncture point with an upper hinge line 37 and a first hinge line 38.
The upper hinge line 37 begins where the lower slit 36 ends and extends vertically upward from the juncture point to the topmost point on the periphery. The first hinge line 38 extends laterally outward from this juncture point to the lateral periphery of the first panel 30. As such, the first hinge line 38 is essentially parallel to the ground when the stand 10 is fully assembled. In the preferred embodiment of this invention, the upper hinge line 37 and first hinge line 38 are hingable due to the foldability inherent in the corrugated cardboard. However, any form of hinging is acceptable to provide a means to fold the panel 30.
When the first panel 30 is fully extended, at least one strip 70 is preferably adhesively joined to the first panel 30 to support the panel 30 and maintain the vertical posture of the panel 30. The strip 70 in the preferred embodiment of this invention is made of a corrugated cardboard and has a rectangular shape and rectangular cross-section. However, any material such as metal, plywood, plastic or press board that provides adequate rigidity to prevent the first panel 30 from folding back over itself along the first hinge line 38 is acceptable. Additionally, the shape and cross-section of the strip need not be rectangular. The shape could take virtually any form that provides sufficient surface area on either side of the hinge line 38 to properly maintain the rigidity of the first panel 30.
The second panel 40 has several parts analogous to the parts of the first panel 30. The second base 44 of the second panel 40 is defined by the portion of its periphery at the bottom of the second panel 40. However, there is no discontinuity at the approximate midpoint of this portion of the second panel 40 periphery. Instead, there is an end of a lower hinge line 47. The lower hinge line 47 extends essentially perpendicularly from this periphery midpoint to a point approximately halfway between the upper and lowermost points on the periphery of the second panel 40. The lower hinge line 47 ends in a juncture point with an upper slit 46 and a second hinge line 48. The upper slit 46 begins where the lower hinge line ends and extends vertically upward from this juncture point to the topmost point on the periphery. The upper slit 46 intersects the upper periphery of the second panel 40, thereby creating a discontinuity in the periphery.
The upper slit 46 is slightly wider than the thickness of the first panel 30 in order to accommodate the first panel 30 when the two panels 30, 40 are joined together. The second hinge line 48 extends laterally outward from this juncture point to the lateral periphery of the second panel 40. As such, the second hinge line 48 is approximately parallel to the ground when the stand 10 is fully assembled. When the second panel 40 is fully extended, rigidity is maintained by joining at least one strip 70 to the panel 40 in a manner essentially the same as is done for the first panel 30.
The topmost peripheries of the first upper end 32 of the first panel 30 and the second upper end 42 of the second panel 40 form a cruciform surface when the panels 30, 40 are unfolded and joined. A cap 50 rests on this cruciform surface. The cap 50 is essentially disc shaped having a circular planar top surface 52 upon which fireworks may be placed and an open end 54 that rests on the cruciform surface created by the upper ends 32, 42 of the panels 30, 40. A side rim 56 extends down slightly from the top surface 52 and outboard of the panels 30, 40 to help prevent the cap 50 from sliding laterally off of the panels 30, 40.
An alternative embodiment of this invention incorporates clamps 60 in lieu of strips 70 or along with the strips 70 for rigid support of the first and second panels 30, 40. Each clamp 60 has a gap 66 slightly smaller than the thickness of the panels 30, 40. The clamp 60 is preferably made of resilient plastic. The gap 66 is formed by a first jaw 62 and a second jaw 64. The gap 66 is positioned over the lateral periphery of the panels 30, 40 such that a portion of vertical length of the clamp 66 is above the hinge lines 38, 48 and a portion is below. The clamp 66 is pushed toward the centerline until it slides no further, thereby inducing stress in the jaws 62, 64 that tend to hold the clamps 60 in place. One clamp 60 is positioned at each end of the hinge lines 38, 48.
With particular reference to FIGS. 2-5, the use and operation of the stand 10 are provided. In a typical use of the stand 10 a fireworks display site is chosen and the stand 10 is transported to that site. Upon reaching the site, the stand 10 is removed from a carrying container in which the stand 10 and its associated parts have been folded and stored (FIG. 3). The stand 10 is then unfolded, assembled, and used for its intended purpose (FIGS. 3-5).
After removing the stand 10 from the carrying container, the first and second panels 30, 40 are unfolded and the strips 70 attached. The unfolding process is essentially identical for both panels 30, 40. Therefore, the unfolding process for only the second panel 40 will be described (FIGS. 3, 4 and 5). The second panel 40 is removed from the carrying container in a fully folded position. This position is most nearly depicted in FIG. 3. The unfolding is initiated by pulling apart the halves of the panel 40 at the outermost lateral periphery in the direction of the Arrow A, such that the halves of the panel 40 rotate pivotably about the lower hinge line 47. Concurrently, two halves of the second upper end 42 are separated from two halves of the second base 44 in the direction of the Arrows B. The halves of the upper end 42 rotate pivotably about the second hinge line 48 (FIG. 3). The second panel 40 continues to be unfolded by moving the parts in the directions A and B (FIG. 4) until the panel 40 is fully unfolded and erect (FIG. 5).
Once the panel 40 is erect, the strips 70 are joined adhesively to the panel 40 such that there is one on either side of the lower hinge line 47. The strips 70 are positioned vertically so that a portion of each strip 70 is above the second hinge line 48 and a portion of each strip 70 is below the second hinge line 48. A like procedure is followed for the first panel 30. After both panels 30, 40 are assembled, the two panels 30, 40 are joined. This is accomplished by: 1) aligning the lower slit 36 of the first panel 30 with the upper slit 46 of the second panel 40; and, 2) sliding the first panel 30 toward the second base 44 of the second panel 40 until the juncture points of the two panels 30, 40 meet. At this point, the topmost and bottom most peripheries of the two panels 30, 40 are flush with respect to each other. The cap 50 open end 54 is then placed upon and supported by the cruciform surface formed by the first and second upper ends 32, 42 of the panels 30, 40. The collapsible fireworks display stand 10 is now fully assembled and ready for use. The user can place the fireworks product on the top surface 52 of the cap 50 and begin the show (FIG. 1).
This disclosure is provided to reveal a preferred embodiment of the invention and a best mode for practicing the invention. Having thus described the invention in this way, it should be apparent that various different modifications can be made to the preferred embodiment without departing from the scope and fair meaning of this disclosure. When structures are identified as a means to perform a function, the identification is intended to include all structures which can perform the function specified. | A fireworks display 10 is provided for easy transport to display sites in compact form where it can be unfolded and assembled to place fireworks in an elevated position. The elevated position of the fireworks increase the viewing zone for spectators and allows the fireworks sparks to burn longer as they free fall to the ground. The stand 10 includes first and second vertical panels 30, 40, reinforcing strips 70 for increasing rigidity of the panels 30, 40, and a cap 50 for displaying the fireworks. | 5 |
BACKGROUND
[0001] The present invention relates generally to a filtering respirator.
[0002] Related art respirators have a variety of uses, including protecting a user from harmful bacteria or particles contained within unfiltered air. However, existing respirators do not adequately account for various situations, such as when a user wants to replace the respirator's filter or change the flow of air into and out of the respirator, without becoming exposed to unfiltered air, and/or wants to separate air flow between the nose and mouth.
SUMMARY
[0003] Exemplary embodiments of a respirator comprise a first chamber, a second chamber and a filtration system. The filtration system includes an inhale valve and an exhale valve, so that air may be inhaled into the first chamber, and exhaled through the second chamber.
[0004] Additionally, in some embodiments, the filtration system can be reversed so that inhale valve allows air to be inhaled into the second chamber and so that exhale valve allows air to be exhaled from the first chamber. This can prove especially useful, for example, if a user needs to sneeze. If the user has the inhale valve positioned with respect to the second chamber, the user can quickly change to the exhale valve if the user needs to sneeze. This will allow the user to sneeze without needing to remove the respirator, thereby avoiding becoming exposed to unfiltered air.
[0005] Some embodiments may include a replaceable filter. The replaceable filter includes a supply canister including a supply of filter material, a take-up canister that receives used filter material, and a crank, annular engaging mechanism, or the like. The filter material is passed over the inhale and/or exhale valves and the user may engage the crank, annular engaging mechanism, or the like to roll used material into the take-up canister so as to place a fresh portion of the filter material over the inhale and/or exhale valves.
[0006] Embodiments of the respirator can have a variety of uses. For example, medication or anesthesia could be applied to a filter within the filtration system. Additionally, the respirator could be used to regulate breathing to help with sleep apnea.
[0007] These and other objects, advantages and salient features of the invention are described in or apparent from the following description of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Exemplary embodiments will be described with reference to the accompanying drawings, in which like numerals represent like parts, and wherein:
[0009] FIG. 1 is a side view of an embodiment of a filtering respirator with nasal and oral separation;
[0010] FIGS. 2-4 illustrate a filtering respirator with an exemplary embodiment of a reversing member during rotation;
[0011] FIG. 5 is a front view of an embodiment of a respirator with a replaceable filter;
[0012] FIG. 6 is an exploded view of the replaceable filter shown in FIG. 3 ; and
[0013] FIG. 7 is a front view of an embodiment of a respirator with two replaceable filters.
DETAILED DESCRIPTION OF EMBODIMENTS
[0014] An exemplary embodiment of a respirator is shown in FIG. 1 . The respirator 100 can be worn over the nose and mouth of a user and can be secured to the user by a fastener 150 . While the fastener 150 in this exemplary embodiment uses two elastic straps, various fasteners can be used. For example, the respirator 100 can be secured to the user by a single tied string, or by a Velcro strap. As another example, the respirator 100 can be attached to or incorporated into a protection helmet, hood, face shield, goggles or the like.
[0015] The respirator 100 comprises a first chamber 110 , a second chamber 120 and a filtration system 130 . The first chamber 110 and the second chamber 120 are isolated from each other by a separator 140 so that the air in the first chamber 110 is not intermixed with the air in the second chamber 120 .
[0016] The filtering system 130 includes a base member 131 , a reversing member 133 , an inhale valve 135 and an exhale valve 137 . The inhale valve 135 and exhale valve 137 are one-way valves that may be covered with filters 160 , 170 . The filters 160 , 170 may be replaceable. The inhale valve 135 allows air to enter the first chamber 110 or the second chamber 120 without air being able to exit through the inhale valve 135 . Conversely, the exhale valve allows air to exit the first chamber 110 or the second chamber 120 without allowing air to enter through the exhale valve 135 . The base member 131 has an opening (not shown) that allows air to pass between the inhale valve 135 or the exhale valve 137 and the first chamber 110 , and an opening (not shown) that allows air to pass between the inhale valve 135 or the exhale valve 137 and the second chamber 120 .
[0017] The replaceable filters 160 , 170 may be made of any suitable filtering material and may be located on the first chamber 110 , the second chamber 120 , or both. The filtering material may be scented or flavored, so that the user can have a pleasant experience while wearing the respirator. Additionally, or alternatively, medication can be provided on the filter so that the mask can be used to deliver medicine during a medical procedure or treatment, or to kill harmful bacteria.
[0018] FIGS. 2-4 show an exemplary embodiment of a reversing operator of the respirator 100 . The reversing member 133 can be rotated with respect to the base member 131 , via a pin 132 , an annular engaging mechanism (not shown), or the like. The annular engaging mechanism would include parts formed respectively on the base member 131 , the reversing member 133 , or the like. Rotating the reversing member 133 places the inhale valve 135 and the exhale valve 137 in communication with either the first chamber 110 or the second chamber 120 .
[0019] FIG. 2 shows the filtering system 130 at a first position. The inhale valve 135 is positioned to be in communication with the first chamber 110 , and only allows air to enter the first chamber 110 , as shown by arrow I. The exhale valve 137 is positioned to be in communication with the second chamber 120 , and only allows air to exit the second chamber 120 , as shown by arrow E.
[0020] FIG. 3 shows the filtering system 130 during rotation. The base member 131 remains stationary, and the reversing member 133 rotates in either a clockwise or counterclockwise direction to reposition the inhale valve 135 and exhale valve 137 .
[0021] FIG. 4 shows the filtering system 130 at a second position. The inhale valve 135 is positioned to only allow air to enter the second chamber 120 , as shown by arrow I. The exhale valve 137 is positioned to only allow air to exit the first chamber 110 , as shown by arrow E.
[0022] When a user wears the respirator 100 , the user can be protected from harmful bacteria or particles in the unfiltered air outside the respirator. For example, a filter could be provided only on the inhale valve 135 . Additionally, or alternatively, any bacteria or germs that are carried by the user can be contained by the respirator 100 by providing a filter over exhale valve 137 , and therefore protect individuals around the user.
[0023] The uses of the respirator 100 are not limited to protection from bacteria or particles. For example, an athlete can train his or her breathing using respirator 100 . For example, if the athlete wishes to train to breathe in through his or her nose and out through his or her mouth, he or she could adjust the reversing member 133 to be in a position where the inhale valve 135 is in communication with the first chamber 110 and the exhale valve 137 is in communication with the second chamber 120 . Alternatively, if the athlete wishes to train to breathe in through his or her mouth and out through his or her nose, he or she could adjust the reversing member 133 to be in a position where the inhale valve 135 is in communication with the second chamber 120 and the exhale valve 137 is in communication with the first chamber 110 .
[0024] Another example of a use for the respirator 100 is in aiding individuals who suffer from sleep apnea. The user can adjust the reversing member 133 to regulate his or her breathing by moving the reversing member 133 so that the inhale valve 135 and the exhale valve 137 are located at a desired position. Additionally, tubing and/or an air pressurizing device could be attached to the respirator 100 to help regulate the flow of air to the user.
[0025] FIGS. 5-6 show a second exemplary embodiment of a respirator 300 . The second exemplary embodiment comprises a first chamber 310 , a second chamber 320 , and a filtration system 330 with replaceable filters 360 , 370 . The second exemplary embodiment differs from the first exemplary embodiment with respect to replaceable filter 360 .
[0026] Replaceable filter 360 comprises a first canister 361 , a second canister 362 , and a crank 365 . Filter material 369 is rolled and placed in first canister 361 , passed over inhale valve 335 , and wound around crank 365 by engagement with an engager 368 . When the filter material 369 needs to be changed, a user may turn the crank 365 to roll used material into the second canister 362 and around crank 365 . This allows the user to place a fresh portion of filter material 369 over inhale valve 335 . Instead of or in addition to the crank 365 , a motor may be provided to place a fresh portion of filter material 369 over inhale valve 335 either based on elapsed time or some other indicator, such as manual indication by the user, that the filter material 369 needs to be changed. While FIG. 5 shows replaceable filter 360 being located on inhale valve 335 , replaceable filter 360 may be instead located on exhale valve 337 .
[0027] FIG. 6 shows an interior view of replaceable filter 360 and a roll of filter material 369 . The replaceable filter 360 is divided into first filter casing 363 and a second filter casing 364 . The first filter casing 363 contains a first portion 361 a of first canister 361 and a first portion 362 a of second canister 362 . The second filter casing 364 contains a second portion 361 b of first canister 361 and a second portion 362 b of second canister 362 . The first filter casing 363 is attached to second filter casing 364 by a hinge 366 . The hinge 366 allows the first filter casing 363 to pivot with respect to the second filter casing 364 . The replaceable filter 360 may be placed in a closed position by swinging first filter casing 363 so that the first portions 361 a , 362 a of the first and second canisters 361 , 362 come into contact with the second portions 361 b , 362 b of the first and second canisters 361 , 362 . The first and second filter casings 363 , 364 may then be secured by securing member 367 .
[0028] FIG. 7 shows a third exemplary embodiment. The third exemplary embodiment differs from the second exemplary embodiment in that replaceable filters 560 , 570 are provided on both the inhale valve 535 and the exhale valve 537 .
[0029] While the invention has been described in conjunction with a specific embodiments, these embodiments should be viewed as illustrative and not limiting. Various changes, substitutes, improvements or the like are possible within the spirit and scope of the invention.
[0030] For example, the shape and location of the inhale and exhale valves can be changed. Specifically, the inhale and exhale valves could be square, oval, or any other shape. As another example, the inhale and exhale valves could be located diagonally with respect to each other. | A respirator includes a first chamber, a second chamber, and a separator that separates the first chamber and the second chamber. A filtration system includes an inhale valve that only allows air to enter the respirator and an exhale valve that only allows air to exit the respirator. The system can be reversed so that the inhale valve and exhale valve may be positioned on either the first or second chamber. A replaceable filter can be provided that includes a supply canister including a supply of filter material, a take-up canister that receives used filter material, and a path between the supply canister and the take-up canister that guides the filter material across the respirator's inhale valve, exhale valve, or both the inhale and exhale valves. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. § 371 from international application PCT/US2005/043311, filed Dec. 1, 2005, which claims priority under 35 U.S.C. § 119 from U.S. Provisional Patent Application No. 60/633,220, filed Dec. 3, 2004, both of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the lubrication of mammalian joints.
[0003] Rheumatoid arthritis (RA) and post-traumatic knee joint synovitis (KJS) are common forms of joint disease. Factors which contribute to the development of RA and KJS include previous damage to the joint through injury or surgery and the age of the joint (i.e., “wear and tear” of the articulating surfaces of the joint). Current methods of treatment are directed to relieving pain and other symptoms of RA or KJS by administering, for example, analgesics and anti-inflammatory drugs.
[0004] Also described for the treatment of injured or diseased joints are methods in which a lubricant is applied directly to the injured or arthritic joint. Lubricin, also known as proteoglycan 4 (PRG4), articular cartilage superficial zone protein (SZP), megakaryocyte stimulating factor precursor, or tribonectin (Ikegawa et al., Cytogenet. Cell. Genet. 90:291-297, 2000; Schumacher et al., Arch. Biochem. Biophys. 311:144-152, 1994; Jay and Cha, J. Rheumatol., 26:2454-2457, 1999; and Jay, WIPO Int. Pub. No. WO 00/64930) is a mucinous glycoprotein found in the synovial fluid (Swann et al., J. Biol. Chem. 256:5921-5925, 11981). Lubricin provides boundary lubrication of congruent articular surfaces under conditions of high contact pressure and near zero sliding speed (Jay et al., J. Orthop. Res. 19:677-87, 2001). These lubricating properties have also been demonstrated in vitro (Jay, Connect. Tissue Res. 28:71-88, 1992). Cells capable of synthesizing lubricin have been found in synovial tissue and within the superficial zone of articular cartilage within diarthrodial joints (Jay et al., J Rheumatol. 27:594-600, 2000).
[0005] In U.S. patent application Ser. No. 10/038,694 are described methods of promoting lubrication between two juxtaposed biological surfaces using lubricin, or fragments thereof. In U.S. Pat. No. 6,743,774 are described lubricin (tribonectin) analogs and methods for lubricating a mammalian joint. In a recent report (Englert et al., Trans. Orthop. Res. 29:189, 2003), the reduction of integration of opposing cartilage surfaces by components in synovial fluid was described and it was suggested that this reduction in integration was, at least in part, lubricin mediated.
[0006] Synovial fluids (SF) aspirated from patient populations diagnosed with KJS or RA exhibit compromised SF boundary lubricating ability, which is provided by lubricin. The SF aspirates from these patient populations show a release of articular cartilage damage markers (Elsaid et al., Osteoarthritis Cartilage 11:673-680, 2003). In addition, the elimination of the lubricating activity of molecules of the synovial fluid by trypsin has been described (Jay and Cha, J. Rheumatol., 26:2454-2457, 1999).
SUMMARY OF THE INVENTION
[0007] Described herein is the loss of synovial fluid's boundary lubricating ability and chondroprotection in patients with RA and KJ due to the action of cathepsin B (CB) and/or neutrophil elastase (NE) S. It is proposed that inhibition of one or both of these enzymes, or other protease inhibitors that degrade the lubricating ability of lubricin, may retard the loss of SF's boundary lubricating ability and that this inhibition, alone or in combination with the application of lubricin to a mammal's articulating joint as a lubricating agent, is useful for the treatment of patients suffering from joint disease or injury.
[0008] Accordingly, in a first aspect, the invention features a method of lubricating a joint in a mammal that includes contacting the joint with lubricin and administering to the mammal a compound that inhibits an enzyme selected from the group consisting of neutrophil elastase, cathepsin B, cathepsin K, cathepsin L, cathepsin S, papain, trypsin, chymotrypsin, subtilisin, pepsin, bromelain, ficin, Protease A, Protease B, Protease D, granzyme A, granzyme B, granzyme K, pepsin, thermolysin, pronase, dipeptidyl peptidase IV, and pancreatin. Preferably, the joint is an articulating joint of a human.
[0009] The compound can be administered orally, rectally, intravenously, subcutaneously, or as an inhalant. Preferably, the compound is administered locally at the site of the injured or diseased joint, such as, for example, by direct injection into synovial fluid at the region of interest. The compound can be administered before, during, or after treatment of the joint with lubricin.
[0010] In another aspect, the invention features a method of inhibiting adhesion formation between a first surface and a second surface in a mammal that includes placing lubricin between the first and second surfaces in an amount sufficient to prevent adhesion of the surfaces and administering to the mammal a compound that inhibits an enzyme selected from the group consisting of neutrophil elastase, cathepsin B, cathepsin K, cathepsin L, cathepsin S, papain, trypsin, chymotrypsin, subtilisin, pepsin, bromelain, ficin, Protease A, Protease B, Protease D, granzyme A, granzyme B, granzyme K, pepsin, thermolysin, pronase, dipeptidyl peptidase IV, and pancreatin.
[0011] In one embodiment, the first surface and the second surface are both injured tissues. In another embodiment, the first or second surface is an artificial device, such as, for example, an orthopedic implant. In another embodiment, the first and second surfaces are tissues injured due to a surgical incision. In yet another embodiment, the first and second surfaces are tissues injured due to trauma.
[0012] In another aspect, the invention features a pharmaceutical composition comprising lubricin; a compound that inhibits an enzyme selected from the group consisting of neutrophil elastase, cathepsin B, cathepsin K, cathepsin L, cathepsin S, papain, trypsin, chymotrypsin, subtilisin, pepsin, bromelain, ficin, Protease A, Protease B, Protease D, granzyme A, granzyme B, granzyme K, pepsin, thermolysin, pronase, dipeptidyl peptidase IV, and pancreatin; and a pharmaceutically acceptable excipient.
[0013] Therapeutic formulations may be in the form of liquid solutions or suspensions. In one embodiment, the composition is in the form of a membrane, foam, gel, or fiber. Methods well known in the art for making formulations are found, for example, in Remington: The Science and Practice of pharmacy (20th ed., ed. A. R. Gennaro A R.), Lippincott Williams & Wilkins, 2000. Biocompatible, biodegradable lactide polymer, lactide/glycolide copolymer, or polyoxyethylene-polyoxypropylene copolymers may be used to control the release of formulation components.
[0014] In an embodiment of any of the aspects of the invention, the compound inhibits cathepsin B. Cathepsin B inhibitors are known to those skilled in the art and include aldehydes, alpha-ketocarbonyl compounds, halomethyl ketones, diazomethyl ketones, (acyloxy)methyl ketones, ketomethylsulfonium salts, epoxy succinyl compounds, vinyl sulfones, aminoketones, and hydrazides (see Schirmeister et al., Chem. Rev. 97:133-171, 1997). Specific inhibitors include E-64, Z-Leu-Leu-Leu-fluoromethyl ketone (Z-LLL-FMK), Z-Phe-Phe-fluoromethyl ketone, calpain inhibitor I, calpain inhibitor II, antipain, biotin-Phe-Ala-fluoromethyl ketone, cystatin, CA-074, CA-074 methyl ester, chymostatin, leupeptin, N-methoxysuccinyl-Phe-homoPhe-fluoromethyl ketone, or a procathepsin B fragment.
[0015] In another embodiment of any of the aspects of the invention, the compound inhibits neutrophil elastase. Examples of elastase inhibitors include phenylmethanesulfonyl fluoride (PMSF), ICI 200,355, secretory leukoproteinase inhibitor, MeOSuc-Ala-Ala-Pro-Ala-CMK, Boc-Ala-Ala-Ala-NHO-Bz, and MeOSuc-Ala-Ala-Pro-Val-CMK.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a photograph of the friction apparatus used in some of the experiments described herein
[0017] FIG. 2 is a schematic diagram of a modified Stenton pendulum
[0018] FIG. 3 a is a Western blot analysis of purified human lubricin following treatment with 0.5 U/mL of cathepsin B (CB) and probed with polyclonal anti-lubricin IgG (J108) and peanut agglutinin (PNA) linked to peroxidase. Lubricin (5 μg per well) was treated with CB to a final concentration of 0.5 U/mL, reconstitutued in 0.25 M Na acetate buffer, pH 5.5 at 37° C., and sampled after 2, 4, 6, 12, and 24 hours of treatment. The enzymatic reaction was stopped by adding E-64 to a final concentration of 100 μM. Blots were probed with PNA-peroxidase and pAb J108.
[0019] FIG. 3 b is a Western blot analysis of purified human lubricin treated with 0.5 U/mL neutrophil elastase (NE). Lubricin (5 μg per well) was treated with NE to a final concentration of 0.5 U/mL reconstituted in 10 mM Tris-HCl, 100 mM CaCl 2 , pH 8.8 at 37° C., and sampled after 2, 4, 6, 12, and 24 hours of treatment. The enzymatic reaction was stopped by adding PMSF to a final concentration of 1 mM. Blots were probed with PNA-peroxidase and pAb J108.
[0020] FIG. 4 is a graph showing changes in coefficient of function (Δμ±S.D.) of pooled knee joint synovitis (KJS) synovial fluid (SF) aspirates, rheumatoid arthritis (RA) SF aspirates, osteoarthritis (OA) SF aspirates supplemented with purified human lubricin and normal SF aspirates following treatment at 37° C. for 24, 48, and 96 hours. The Δμ values were an average of two experiments, each with four distinct measurements of Δμ. A “*” symbol indicates that the Δμ lubricin-supplemented, pooled KJS SF aspirates were significantly higher than the Δμ of normal SF aspirates following 24, 48, and 96 hour treatments at 37° C. (P<0.001). A “**” symbol indicates that the Δμ lubricin-supplemented, pooled RA SF aspirates were significantly higher than the Δμ of normal SF aspirates following 24, 48, and 96 hour treatments at 37° C. (P<0.001). A “***” symbol indicates that the Δμ lubricin-supplemented, pooled OA SF aspirates were significantly higher than the Δμ of normal SF aspirates following 96 hour treatments at 37° C. (P<0.001).
[0021] FIG. 5 is a graph showing cathepsin B activity in knee joint synovitis (KJS) synovial fluid (SF), rheumatoid arthritis (RA) SF, and osteoarthritis (OA) SF aspirates. A “*” symbol indicates that the cathepsin B activity in KJS SF was significantly higher than the cathepsin B activity in OA SF (P<0.005). A “**” symbol indicates that the cathepsin B activity in RA SF was significantly higher than the cathepsin B activity in OA SF (P<0.001) and KJS SF (P<0.005).
DETAILED DESCRIPTION
[0022] The proteolytic degradation of lubricin in a mammal's articular joint increases friction between cartilage surfaces. This may lead to damage and wear, thereby predisposing the joint to the development of a degenerative disease. Secondary osteoarthritis (OA) has been shown to be predisposed by joint trauma (Gelber et al. Ann. Intern. Med. 133:321-328, 2000), obesity, or strenuous occupations. Inhibition of the cascade of events leading to the subsequent development of OA may lie in the initial loss of boundary lubrication observed following knee injury (Jay et al., J. Rheumatol. 31:557-564, 2004). Lubricin appears susceptible to proteolytic degradation by enzymes that are secreted extracellularly during the initial inflammatory phase, leading to a loss of SF's boundary lubrication evidenced in KJS SF aspirates (Jay et al., J. Rheumatol. 31:557-564, 2004).
[0023] The loss of SF boundary lubrication is also evident in RA. KJS and RA represent opposite ends of an inflammation continuum in the synovium (Pando et al., J. Rheumatol. 27:1848-1854, 2000). Infiltration of polymorphonuclear (PMN) cells is common to both clinical conditions. It is therefore plausible that proteases secreted from synoviocytes and infiltrating PMN cells are responsible for the early loss of SF's boundary lubricating ability observed in KJS, as well as the loss observed in RA. Described herein are experiments showing that CB and NE can proteolytically degrade lubricin in a time-dependent manner
Methods
Protease Treatment of Purified Human Lubricin and Whole BSF
[0024] Human lubricin was purified from pooled SF aspirates of patients undergoing total knee replacement as described previously (Jay et al., Gluconj. J. 18:807-815, 2001). BSF was aspirated percutaneously from the lateral aspect of radiocarpal joints of freshly slaughtered cattle with sterile 18 gauge needles after cleansing the skin with alcohol swabs. The cattle were 1 year old and of both sexes (PelFreeze Corp., Little Rock, Ark.). The BSF was centrifuged at 20,000 g at 4° C. to remove cell debris and the BSF was stored at −20° C. Aliquots of purified human lubricin (1 mL, 250 μg/1 mL), and BSF (1 mL) were subjected to protease treatments with CB, NE, α-chymotrypsin, or trypsin. These enzymes were utilized as follows: 1) 0.5 U/mL of CB (Sigma-Aldrich, Saint Louis, Mo., one unit liberates 1 nanomole of 7-amino-4-methylcoumarin from Z-Arg-Arg 7-amido-4-methylcoumarin per min at pH 6.0 at 40° C.) reconstituted in 0.25 M Na acetate buffer, pH 5.5; 2) 0.5 U/mL NE (Sigma-Aldrich, one unit is defined as the release of 1 mole of p-nitrophenol per sec at 37° C.) reconstituted in 100 mM Tris-HCl, 100 mM CaCl 2 , pH 8.8; 3) 0.5 U/mL of TPCK-treated trypsin (Sigma-Aldrich, one unit causes a change in A 253 of 0.001 per min at pH 7.6 at 25° C. using BAEE as a substrate) reconstituted in 50 mM Tris HCl, 20 mM CaCl 2 , pH 8.0; and 4) 0.5 U/mL of α-chymotrypsin (Sigma-Aldrich, one unit hydrolyzes 1.0 μmole of BTEE per min at pH 7.8 at 25° C.) reconstituted in 80 mM Tris-HCl, 100 mM CaCl 2 , pH 7.8.
[0025] Aliquots of digested human lubricin and BSF (200 μL) were removed after 2, 4, 6, 12, and 24 hours and the reaction was stopped by adding E-64 (L-trans-epoxysuccinyl-leucyl-amido-(4-guanidino)-butane, Sigma-Aldrich) to a final concentration of 100 μM (CB) or phenylmethanesulfonyl fluoride (PMSF, Sigma-Aldrich) to a final concentration of 1 mM (NE).
[0026] Electrophoresis was performed on pre-cast SDS-PAGE 4-15% gels (BioRad, Hercules, Calif.) under reducing conditions. High molecular weight standards (BRL, Gaithersburg, Md.) were electrophoresed simultaneously with the treated human lubricin or BSF. Electrophoresis was performed at 150 V for 90 min until the wave front exited from the bottom of the gel. Western transfer to nitrocellulose was carried out under semi-dry conditions at 20 V for 40 min. The blot was blocked overnight at 4° C. with 2% (w/v) BSA in phosphate buffer saline (PBS).
[0027] Probing was performed using pAb J108, which recognizes an epitope; FESFERGRECDAQCKKYDK, encoded by exon 3 within the amino-terminus of human lubricin/SZP and present in all alternatively spliced isoforms (Jay et al., J. Orthop. Res. 19:677-687, 2001). Incubation with pAb J 108 was conducted at 1:5,000 dilution in PBS+2% Tween-20 for 60 min at room temperature. Following washing with PBS+2% Tween-20, peroxidase-linked goat anti-rabbit immunoglobulin was added at a dilution of 1:10,000 for 60 min. Following exhaustive washing with PBS+2% Tween-20 and PBS, chemiluminescent substrate (Pierce, Rockford, Ill.) was added. Immunopositive bands were detected in a darkroom on BioMax film (Kodak, Rochester, N.Y.). Probing with peanut agglutinin (PNA) from Arachis hypogaea conjugated to peroxidase (Sigma-Aldrich) was performed at a concentration of 0.5 mg/mL in PBS+2% Tween-20 for 60 min at room temperature. Following exhaustive washing with PBS-2% Tween-20, and PBS, chemiluminescent substrate was added, and the blot was developed as described above.
In Vitro Friction Assay of Human Lubricin and BSF
[0028] The boundary lubricating abilities of protease-treated human lubricin and BSF were measured using a friction apparatus as reported by Davis et al., J. Biomech. Eng. 101:185-192, 1979. The apparatus is shown in FIG. 1 . Lubricant (200 μL) was applied between a bearing of latex and a ring of polished glass with a contact area of 1.59 cm 2 . The latex was oscillated, under a pressure of 0.35×10 6 N/m 2 , against the polished glass with an entraining velocity of 0.37 mm/sec. The bearing system was axially loaded within a gimbals system free to rotate around two perpendicular horizontal axes. The friction apparatus recorded displacements of the gimbals system around the vertical loading axis through a linear displacement voltage transducer, where the output was directly proportional to the frictional torque (F). A bearing load of 70 newtons (N) was related to the coefficient of friction (μ) via Amonton's law, F=μN.
[0029] The μ of the lubricant was recorded at room temperature and was preceded by a baseline measurement of μ with normal saline (NS). Lubrication was manifested by a reduction in μ by the lubricant relative to that of NS. Negative Δμ (−Δμ) values indicate lubrication whereas positive Δμ (+Δμ) indicate friction. Addition of 200 μL of lubricant was followed by bringing the bearing surfaces close enough so that the solution wet both surfaces. After 5 min for equilibration, the latex-coated bearing was brought to rest on the glass as it was oscillating. Voltage measurements were recorded at 1, 3, and 5 min. After 5 min, the surfaces were separated for 2 min and then brought back together for three additional 5 min session. The 3 and 5 min μ values of the last two 5 min session were recorded and averaged, and data were later combined with another duplicate experiment providing 8 distinct measurements of μ.
Pooling of OA, RA, and KJS SF Aspirates, Lubricin Supplementation, and Treatment with Protease Inhibitors
[0030] The SF aspirates from patients diagnosed with a Noyes criteria grade III or IV OA (n=60), with RA (n=20), or with KJS (n=23) were pooled in equal proportions. Pooled OA, RA, and KJS SF aspirates were supplemented with purified human lubricin until normal μ values were obtained. The lubricin-supplemented pooled OA, RA, and KJS SF aspirates were treated at 37° C. and sampled after 24, 48, and 96 hours. The friction analysis of the sampled SF was conducted as described above. Normal human SF was obtained from cartilage allograft donors and was utilized as a control.
[0031] Lubricin-supplemented pooled RA and KJS SF aspirates were treated with the following protease inhibitors: 1) E-64 to a final concentration of 10 μM; 2) Z-LLL-FMK (Sigma-Aldrich) to a final concentration of 20 μM; 3) PMSF (Sigma-Aldrich) to a final concentration of 25 μM; and 4) EDTA (Sigma-Aldrich) to a final concentration of 10 mM. The treatments were performed at 37° C., and SF was sampled at 24, 48, and 96 hours post-treatment. The in vitro friction assay of sampled SF was performed as described above.
Ex Vivo μ of Excised Murine Joints Following Protease Treatment
[0032] Murine joint friction measurements were performed ex vivo in a modified Stanton pendulum configuration (Chamely, New Scientist 6:60, 1959) illustrated in FIG. 2 . Excised murine joints, from 8 week old Svev129 mice, weighing approximately 20 grams (Taconic, Germantown, N.Y.), were stripped of supporting connective tissue and musculature, while the synovium was left undisturbed. The femur and tibia were severed mid-length and covered with connecting plexiglass tubing. The center of the joint served as the axis of rotation of a 1 Hz pendulum. The joints were loaded with 20 grams and allowed to oscillate. The pendulum was set in motion at an angle of 30° off the perpendicular axis. The pendulum motion was videotaped and post-hoc analysis was performed to establish baseline μ. The deceleration of the pendulum, a=dv/dt, was used to calculate μ. Velocity (v) was calculated from the equation: v=(2 gh) 1/2 where h is the height from where the pendulum reached apogee to the point of maximum velocity at a=0. The μ of murine joint was calculated to be equal a/g. Presently, this calculation neglects aerodynamic drag and assumes g equals 9.81 m/s 2 . A 5 μL protease solution containing 0.05 U of CB, NE, α-chymotrypsin, or trypsin was delivered intra-articularly. The limbs were treated at room temperature for 2 hours and the limbs were subsequently allowed to oscillate to estimate μ following treatment with the protease.
Measurement of CB Activity in OA, RA, and KJS SF Aspirates
[0033] Specific CB activity was assayed in a manner similar to the one reported previously (Huet et al., Clin. Chem. 38:1694-1697, 1992). Aliquots of OA, RA, and KJS SF (20 μL) were mixed with 40 μL of 300 μM fluorogenic substrate, Z-Arg-Arg-7-amino-4-methylcoumarin (AMC), in 0.25 M sodium acetate buffer, pH 5.5, containing 2 mM EDTA, 0.25 g/L Brij 35 and 1.25 mM dithiothreitol. The mixture was incubated for 10 min at 37° C. The reaction was stopped by adding 60 μL of a solution of 0.1 M iodoacetic acid and sodium acetate. Release of AMC was measured by a fluorocounter (Packard Instruments, Meriden, Conn.), using 360 nm and 485 nm as the excitation and emission wavelengths, respectively.
[0034] In a separate set of assays, E-64, a CB inhibitor (10 μM, Sigma-Aldrich), was included in the assay buffer to quantify CB activity. A standard curve was constructed from serial dilutions of AMC and the activity was expressed in units, where 1 unit corresponds to the release of 1 μmole of AMC per min.
Statistical Analysis
[0035] Changes in μ of purified human lubricin and whole BSF following protease treatment are reported as average±standard deviation. CB activities in SF from OA, RA, and KJS SF are represented by box plots. The solid line represents the median, the box represents the middle 50% of the values, the error bars represent the 10 th and 90 th percentile and individual points represent outlying values. Significance testing was conducted by Student's t-test. The significance level was determined a priori to be α=0.05.
Results
Effects of CB, NE, α-Chymotrypsin, and Trypsin on Purified Human Lubricin
[0036] Treatment with 0.5 U/mL CB or NE resulted in a time-dependent degradation of lubricin, as illustrated by diminishing band intensities at 2, 4, 6, 12, and 24 hours post-treatment ( FIGS. 3 a and 3 b ). PNA positive bands were still detectable up to 6 hours after treatment of CB with human lubricin. However, at 12 and 24 hours, PNA reactivity was lost, indicating that β(1-3)Gal-GalNAc O-linked to the central exon 6 was completely degraded. On the contrary, no pAB J108 immunoreactive bands were detectable following treatment with CB for four hours, even with prolonged exposure (˜30 min) ( FIG. 3 a ). Similar results were obtained with NE ( FIG. 3 b ). In NE-treated human lubricin, no pAb J108 immunoreactive bands were detected following treatment for 2 hours at 37° C. Treatment with α-chymotrypsin or trypsin resulted in complete loss of PNA and J108 reactivity after 2 hours of treatment (data not shown). In all treatment experiments with human lubricin, no low molecular weight lubricin degradation products were detected using either PNA or pAb J108.
Effects of CB, NE, α-Chymotrypsin, and Trypsin on In Vitro Lubricating Ability (Δμ of Human Lubricin and BSF
[0037] The Δμ values of human lubricin and BSF following time-dependent treatment using 0.5 U/mL of CB, NE, α-chymotrypsin, or trypsin are reported in Tables 1 and 2. The boundary lubricating ability of human lubricin progressively deteriorated following CB or NE treatment, as evidenced by a +Δμ following 12 and 24 hours treatment. A +Δμ was observed following 2 hour treatment with 0.5 U/mL of either α-chymotrypsin or trypsin, and continued to indicate friction for the duration of the treatment (Table 1). By contrast, the untreated control of human lubricin continued to exhibit a consistently −Δμ value over the same 24 hour period.
[0038] Treatment of human lubricin with CB resulted in a significant increase in Δμ at 4, 6, 12, and 24 hours, compared to undigested human lubricin control (P<0.001). Treatment of human lubricin with NE, α-chymotrypsin, or trypsin also resulted in a significant increase in Δμ at 2, 4, 6, 12, and 24 hours, compared to control (P<0.001).
[0039] The lubricating ability of BSF progressively diminished, as evidenced by a +Δμ following treatment with CB for 12 and 24 hours; following treatment with NE for 4, 6, 12, and 24 hours; following treatment with α-chymotrypsin for 6, 12, and 24 hours; or following treatment with trypsin for 6, 12, and 24 hours (Table 2). Treatment of BSF with CB, NE, α-chymotrypsin, or trypsin resulted in a significant (P<0.001) increase in Δμ at 2, 4, 6, 12, and 24 hours, compared to a BSF control.
[0000]
TABLE 1
Changes in coefficient of friction (Δμ ± S.D.) of purified human lubricin following
treatment with 0.5 U/mL of cathepsin B, neutrophil elastase, α-chymotrypsin, or trypsin.
Cathepsin B
Neutrophil Elastase
α-Chymotrypsin
Trypsin
(0.5 U/mLl)
(0.5 U/mL)
(0.5 U/mL)
(0.5 U/mL)
Lubricin+
Δμ ± S.D.*
Δμ ± S.D.*
Δμ ± S.D.*
Δμ ± S.D.*
Δμ ± S.D.*
0 hrs**
−0.068 ± 0.005
−0.068 ± 0.005
−0.068 ± 0.005
−0.068 ± 0.005
−0.068 ± 0.005
2 hrs
−0.061 ± 0.004
−0.048 ± 0.006
−0.038 ± 0.005
0.035 ± 0.006
0.025 ± 0.006
4 hrs
−0.059 ± 0.004
−0.025 ± 0.005
−0.019 ± 0.004
0.036 ± 0.003
0.032 ± 0.005
6 hrs
−0.059 ± 0.002
−0.012 ± 0.003
0.004 ± 0.001
0.041 ± 0.003
0.038 ± 0.001
12 hrs
−0.061 ± 0.009
0.008 ± 0.001
0.015 ± 0.003
0.043 ± 0.003
0.046 ± 0.005
24 hrs
−0.060 ± 0.004
0.051 ± 0.004
0.054 ± 0.006
0.043 ± 0.003
0.049 ± 0.005
*Latex: glass bearing system Δμ values: an average of two experiments, each with 4 distinct Δμ measurements.
**Sampling was performed at 2, 4, 6, 12, and 24 hours following treatment with enzymes.
[0000]
TABLE 2
Changes in coefficient of friction (Δμ ± S.D.) of bovine synovial fluid (BSF) following
treatment with 0.5 U/mL of cathepsin B, neutrophil elastase, α-chymotrypsin, or trypsin.
Cathepsin B
Neutrophil Elastase
α-Chymotrypsin
Trypsin
(0.5 U/mL)
(0.5 U/mL)
(0.5 U/mL)
(0.5 U/mL)
BSF+
Δμ ± S.D.*
Δμ ± S.D.*
Δμ ± S.D.*
Δμ ± S.D.*
Δμ ± S.D.*
0 hrs**
−0.061 ± 0.005
−0.061 ± 0.005
−0.061 ± 0.005
−0.061 ± 0.005
−0.061 ± 0.005
2 hrs
−0.057 ± 0.004
−0.046 ± 0.001
−0.039 ± 0.001
−0.033 ± 0.006
−0.031 ± 0.005
4 hrs
−0.054 ± 0.002
−0.029 ± 0.002
0.007 ± 0.001
−0.012 ± 0.004
−0.015 ± 0.002
6 hrs
−0.056 ± 0.002
−0.017 ± 0.007
0.009 ± 0.001
0.006 ± 0.001
0.005 ± 0.001
12 hrs
−0.052 ± 0.003
0.004 ± 0.016
0.010 ± 0.001
0.010 ± 0.004
0.009 ± 0.003
24 hrs
−0.049 ± 0.001
0.048 ± 0.006
0.013 ± 0.002
0.013 ± 0.005
0.012 ± 0.004
*Latex: glass bearing system Δμ values: an average of two experiments, each with 4 distinct Δμ measurements.
**Sampling was performed at 2, 4, 6, 12, and 24 hours following treatment with enzymes.
Effects of CB, NE, α-chymotrypsin, and Trypsin on Ex Vivo Lubricating Ability (μ) of Excised Murine Joints
[0040] The μ values of excised murine joints before and after intra-articular injection of 0.05 U each of CB, NE, α-chymotrypsin, and trypsin are illustrated in Table 3. Treatment with CB resulted in an average 73.7% increase in μ compared to an average 27.3% increase in μ following NE injection, an average 128.6% increase in μ following α-chymotrypsin injection, and an average 88.9% increase in μ following trypsin injection. There was a significant increase in μ of excised murine joints following CB injection (P<0.001), α-chymotrypsin injection (P<0.001), and trypsin injection (P<0.001), compared to the respective controls.
[0000]
TABLE 3
Friction coefficients (μ) measurements of excised murine joints (n = 4) using
Stanton modified pendulum before and after intra-articular injection of 5 μl normal
saline and 5 μl containing 0.05 U each of cathepsin B (CB), neutrophil elastase
(NE), α-chymotrypsin, and trypsin followed by a 2 hour treatment at room temperature.
Saline
CB
NE
α-Chymotrypsin
Trypsin
μ ± S.D.
μ ± S.D.
μ ± S.D.
μ ± S.D.
μ ± S.D.
Before
0.0017 ± 0.0004
0.0019 ± 0.0005
0.0022 ± 0.0005
0.0021 ± 0.0005
0.0018 ± 0.0001
After
0.0017 ± 0.0002
0.0033 ± 0.0005
0.0028 ± 0.0008
0.0048 ± 0.0003
0.0034 ± 0.0003
Effect of Protease Inhibitors on In Vitro Lubricating Ability (Δμ) of Pooled KJS and RA SF Aspirates Following Lubricin Supplementation
[0041] Normal lubrication of SF in pooled KJS, RA, and OA aspirates was established by the addition of lubricin. The time-dependent changes in lubricating ability of lubricin-supplemented KJS, RA, and OA SF following treatment at 37° C. for 24, 48, and 96 hours are illustrated in FIG. 4 . The lubricin-supplemented pooled KJS and RA SF aspirates progressively lost their lubricating ability as demonstrated by +Δμ values following treatment for 48 and 96 hours. By contrast, the lubricin-supplemented OA SF aspirates continued to exhibit −Δμ values following treatment for 24, 48, and 96 hours, indicating lubrication.
[0042] The lubricin-supplemented KJS and RA SF aspirates exhibited a significantly higher Δμ value following 24, 48, and 96 hours treatment at 37° C., compared to normal SF treated for equivalent time intervals (P<0.001, FIG. 4 ). The lubricin-supplemented OA SF aspirates exhibited a significantly higher Δμ value following 96 hours of treatment at 37° C., compared to normal SF treated for equivalent time intervals (P<0.001, FIG. 4 ).
[0043] Changes in the lubricating ability of lubricin-supplemented pooled KJS SF aspirates in the presence of E-64, Z-LLL-FMK, PMSF, or EDTA are shown in Table 4. Treatment with E-64 resulted in an average 32.7% increase in Δμ at 24 hours, compared to an average 38.5% increase at 48 hours and an average 42.4% increase at 96 hours. Treatment with Z-LLL-FMK resulted in an average 41.7% increase in Δμ at 24 hours, compared to an average 48.3% increase at 48 hours and an average 53.3% increase at 96 hours. Treatment with PMSF resulted in an average 45.0% increase in Δμ at 24 hours, compared to an average 50.0% increase at 48 hours and an average 55.0% increase at 96 hours. Treatment with EDTA resulted in an average 50.0% increase at 24 hours, compared to an average 80.0% increase at 48 hours and an average 85.0% increase at 96 hours.
[0044] Treatment with E-64, Z-LLL-FMK, or PMSF preserved lubricating ability in lubricin-supplemented pooled KJS SF aspirates at 24, 48, and 96 hours. In each case, −Δμ was significantly (P<0.001) lower compared to controls without enzyme inhibitors. Treatment with 10 mM EDTA also resulted in a significant (P<0.01) decrease in Δμ compared to lubricin-supplemented pooled KJS SF aspirates at 48, and 96 hours. However, the preservation of lubricating ability was not as marked as observed in the treatments of aspirates with enzyme inhibitors.
[0045] The changes observed in lubricating ability of lubricin-supplemented pooled RA SF aspirates in the presence of E-64, Z-LLL-FMK, PMSF, and EDTA are provided in Table 5. Treatment with E-64 resulted in an average 11.7% increase in Δμ at 24 hours, compared to an average 60.0% increase at 48 hours and an average 76.7% increase at 96 hours. Treatment with Z-LLL-FMK resulted in an average 18.3% increase in Δμ at 24 hours, compared to an average 68.3% increase at 48 hours and an average 91.7% increase at 96 hours. Treatment with PMSF resulted in an average 85.0% increase in Δμ at 24 hours, compared to an average 86.3% increase at 48 hours and an average 85.0% increase at 96 hours. Treatment with EDTA resulted in an average 90.0% increase at 24 hours, compared to an average 88.3% increase at 48 hours and an average 128.3% increase at 96 hours.
[0046] Treatment with E-64, Z-LLL-FMK, or PMSF resulted in a significant decrease in Δμ, compared to lubricin-supplemented pooled RA SF aspirates at 24, 48, and 96 hours (P<0.001). Treatment with EDTA resulted in a significant decrease in Δμ, compared to lubricin-supplemented pooled RA SF aspirates at 48, and 96 hours (P<0.01).
[0000]
TABLE 4
Changes in coefficient of friction (Δμ ± S.D.) of pooled
knee joint synovitis (KJS) synovial fluid (SF) aspirates supplemented
with purified human lubricin in the presence of protease inhibitors.
Pooled KJS SF
Pooled KJS SF
Pooled KJS SF
Pooled KJS SF
Pooled KJS SF
(n = 23) +
(n = 23) +
(n = 23) +
(n = 23) +
(n = 23) +
Purified
Purified
Purified
Purified
Purified
Lubricin +
Lubricin +
Lubricin +
Lubricin +
Lubricin
E-64
Z-LLL-FMK
PMSF
EDTA
(*Δμ ± S.D.)
(*Δμ ± S.D.)
(*Δμ ± S.D.)
(*Δμ ± S.D.)
(*Δμ ± S.D.)
0 hrs**
−0.060 ± 0.006
−0.059 ± 0.004
−0.060 ± 0.002
−0.060 ± 0.001
−0.060 ± 0.003
24 hrs
−0.029 ± 0.004
−0.042 ± 0.005
−0.035 ± 0.002
−0.033 ± 0.006
−0.030 ± 0.001
48 hrs
0.006 ± 0.002
−0.039 ± 0.007
−0.031 ± 0.003
−0.030 ± 0.005
−0.012 ± 0.003
96 hrs
0.009 ± 0.001
−0.034 ± 0.002
−0.028 ± 0.002
−0.027 ± 0.005
−0.009 ± 0.001
*Latex: glass bearing Δμ values: an average of two experiments, each with 4 distinct Δμ measurements.
**Sampling was performed at 24, 48, and 96 hours after treatment with inhibitors.
[0000]
TABLE 5
Changes in coefficient of friction (Δμ ± S.D.) of pooled
rheumatoid arthritis (RA) synovial fluid (SF) aspirates supplemented
with purified human lubricin in the presence of protease inhibitors.
Pooled RA SF
Pooled RA SF
Pooled RA SF
Pooled RA SF
Pooled RA SF
(n = 45) +
(n = 45) +
(n = 45) +
(n = 45) +
(n = 45) +
Purified
Purified
Purified
Purified
Purified
Lubricin +
Lubricin +
Lubricin +
Lubricin +
Lubricin
E-64
Z-LLL-FMK
PMSF
EDTA
(*Δμ ± S.D.)
(*Δμ ± S.D.)
(*Δμ ± S.D.)
(*Δμ ± S.D.)
(*Δμ ± S.D.).
0 hrs**
−0.060 ± 0.002
−0.060 ± 0.002
−0.060 ± 0.002
−0.060 ± 0.002
−0.060 ± 0.002
24 hrs
0.001 ± 0.009
−0.053 ± 0.004
−0.049 ± 0.002
−0.009 ± 0.009
−0.006 ± 0.004
48 hrs
0.027 ± 0.002
−0.024 ± 0.002
−0.019 ± 0.001
−0.008 ± 0.004
0.007 ± 0.004
96 hrs
0.025 ± 0.002
−0.014 ± 0.004
−0.005 ± 0.003
−0.009 ± 0.001
0.017 ± 0.001
*Latex: glass bearing Δμ values: an average of two experiments, each with 4 distinct Δμ measurements.
**Sampling was performed at 24, 48, and 96 hours after treatment with inhibitors.
CB Activity in KJS, OA, and RA SF Aspirates
[0047] The CB activities in the SF aspirates from patients with KJS, OA, and RA are illustrated in FIG. 5 . The CB activity in KJS SF aspirates was significantly higher than that observed in OA SF aspirates (P<0.005). On the other hand, the CB activity in RA SF aspirates was significantly higher than that observed in KJS aspirates (P<0.005) or OA aspirates (P<0.001).
Discussion
[0048] CB or NE can proteolytically degrade lubricin in a time-dependent manner, as shown electrophoretically in the protease treatment of human lubricin and BSF, by a diminishing ˜240 KDa lubricin band intensity when probed with pAb J108 and PNA. The loss of the N-terminal exon 3 likely precedes damage to the central exon 6 as indicated by complete loss of pAb J108 epitope following 4 hours of CB and 2 hours following NE treatment. By contrast, the central exon 6 was still detectable following 6 hours of treatment with either enzyme. The boundary lubricating ability of purified lubricin treated with CB or NE continued to decline until it was completely lost by 12 hours. After 6 hours of CB or NE treatment, the ability of lubricin to lubricate was still evident by a −Δsupplemented value, albeit to a diminished extent. It therefore appears that boundary lubricating ability of lubricin is not dependent on the N-terminus. Loss of boundary lubricating ability of lubricin is more likely associated with loss of central exon 6 integrity and/or the C-terminus following CB and NE treatments. This is in agreement with previous reports that linked lubricating ability to β(1-3)Gal-GalNAc O-linked to threonine residues in the central exon 6 (Jay et al., Gluconj. J. 18:807-815, 2001).
[0049] Results of CB or NE treatment of BSF were similar to these of purified human lubricin. The proteolytic activity of these enzymes appeared to be restrained in BSF as CB or NE-treated BSF continued to lubricate at 12 hours post-treatment. This can be explained by 1) the presence of a myriad of other proteins that can serve as substrates to these enzymes, such as, for example, fibronectin; 2) the viscous nature of BSF, which may hinder proper interaction between the enzyme and substrate; and 3) the presence of endogenous proteolytic inhibitors. The increase in whole joint μ following intra-articular delivery of CB offers corroborating evidence of the ability of CB to digest lubricin in not only aspirated SF, but also in excised joints under load. These supporting experiments are important as they demonstrate the ability of CB to increase friction between loaded articular surfaces in their natural environment. Loss of SF's boundary lubricating ability has been considered thus far a surrogate indicator of the frictional properties within opposed and pressurized articular surfaces of the diarthrodial joint. The effects of CB on whole joint friction point to the prominent role that lubricin plays in maintaining low whole joint μ values.
[0050] Supplementation of KJS and RA SF aspirates with purified human lubricin did not re-establish normal lubricating ability over a 48 hour period of treatment at 37° C. By contrast, lubricating ability of similarly treated OA SF aspirates did not significantly change over 48 hours. This result indicates that lubricin is being degraded by proteases in KJS and RA SF aspirates that are in significant abundance compared to their levels in OA SF aspirates.
[0051] There is a significant contribution from cysteine proteases to the proteolytic destruction of lubricin by pooled KJS and RA SF aspirates. The compound E-64 (Barrett et al., Biochem. J 201:189-198, 1982), a broad spectrum irreversible inhibitor of cysteine proteases, prevented loss of boundary lubrication of lubricin-supplemented KJS and RA SF aspirates over 96 hours. In the present invention, E-64 was used at a concentration that would inhibit cysteine proteases, but would not be expected to inhibit either NE or metalloproteinases. Although the compound Cbz-Leu-Leu-Leu-fluoromethylketone (Z-LLL-FMK) possesses both CB and cathepsin L inhibitory activity, the similar effect of Z-LLL-FMK on the boundary lubricating ability of lubricin-supplemented KJS and RA SF aspirates is probably due to CB and not cathepsin L. Although cathepsin B and L expression is increased in the synovium of patients in early RA (Cunnane et al., Rheumatology 38:34-42, 1999), CB is detected in higher levels in SF from RA patients compared to cathepsin L (Ikeda et al., J. Med. Invest. 47:61-75, 2000). Furthermore, cathepsin L requires low pH to be activated, contrary to CB, which is proteolytically active near neutral pH. Compared to EDTA, NE inhibition by PMSF retarded the loss of boundary lubricating ability of lubricin-supplemented KJS and RA SF aspirates. This indicates that NE plays a more significant role in the proteolytic degradation of lubricin in these disease states compared to metalloproteinases. The results provided herein demonstrate that inhibition of CB or NE activity may prevent the proteolytic degradation of lubricin and the resultant loss of the SF's chondroprotective properties.
[0052] All publications and patents cited in this specification are hereby incorporated by reference herein as if each individual publication or patent were specifically and individually indicated to be incorporated by reference. Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be readily apparent to those of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims. | The invention features pharmaceutical compositions that include lubricin, a compound that inhibits an enzyme selected from the group consisting of neutrophil elastase, cathepsin B, cathepsin K, cathepsin L, cathepsin S, papain, trypsin, chymotrypsin, subtilisin, pepsin, bromelain, ficin, Protease A, Protease B, Protease D, granzyme A, granzyme B, granzyme K, pepsin, thermolysin, pronase, dipeptidyl peptidase IV, and pancreatin, and a pharmaceutically acceptable excipient. Another aspect of the invention features methods of lubricating a joint in a mammal by contacting the joint with a pharmaceutical composition of the invention. The invention also features methods of inhibiting adhesion formation between a first surface and a second surface in a mammal (e.g., between injured tissues or between injured tissue and an artificial device). | 0 |
BACKGROUND OF THE INVENTION
The function of a papermachine headbox is to receive rawstock from the inlet manifold and to deliver the stock to the slice and forming region of a paper machine at the proper velocity, and in uniformly mixed condition so that there is a minimum of variation with respect to fiber distribution, consistency, volume and velocity.
As machine speeds and widths have increased, headbox design has become a factor of increasing importance. The old conventional open type box has given way to radically new designs. On high speed machines, the headboxes have become essentially hydraulic nozzles equipped with flow spreading devices which bring the stock in and distribute it at several points across the full width of the papermachine. The problems encountered in the design of a headbox for a high speed papermachine are in many ways similar to hydraulic problems in other industries. However, the problem of spreading paper making stock uniformly in a thin film across the width of a modern, high speed papermachine is a very difficult problem from the hydraulic standpoint alone, and when coupled with the additional demands of maintaining the suspended paper making fibers in the proper state of distribution, it becomes probably the most difficult and complex process in the whole paper making operation.
Most of the designs of modern flow systems are aimed at breaking up flocculation by increasing the intensity of turbulence and shear rate, followed by a reduction in the scale of turbulence. In the pressure type flow nozzle, perforated rolls, as well as cross current rectifiers are used to (1) create turbulence, and (2) even out velocity distribution or profile. If the intensity of turbulence at the rectifier roll or rolls is sufficiently high, flocs are broken up, and subsequently, the scale of this turbulence is then reduced by turbulence decay which follows the perforated roll.
Pressure pulsations in the approach piping to the headbox are not a factor in flocculation or fiber dispersion, but they do produce flow variations in the slice and show up as cyclic short term variations in basis weight of the paper in the machine direction. Thus it is extremely important to prevent pressure fluctuations at the slice if a uniform basis weight is to be obtained.
SUMMARY OF THE INVENTION
The present invention relates to papermachine headboxes, and particularly to an apparatus for delivering a uniform, metered quantity of stock and water to the slice region of the headbox while imposing a high intensity shear field on the stock to break up the flocculation that normally occurs.
Papermachine headboxes are conventionally provided with an inlet manifold located at one end of the papermachine for the stock flowing into the headbox. In the prior art headboxes, attempts have been made to equalize the flow velocity profile and to homogenize the pulp slurry in the headbox by placing one or more flow resistances, causing a loss of pressure, after the inlet pipe system. The task of these resistances is to correct those faults which occur in the flow supplied by the inlet pipe system. Such faults include differences in pressure and flow rate in the direction across the headbox and fiber flocculation in the pulp slurry itself. The usual solution is to place within the headbox one or more perforated rolls or rectifier rolls in such manner that the pulp slurry or paper making stock on its flow path from the input portion to the discharge portion, or the so-called slice aperture, is compelled to pass through these rotating rolls. Thus the rectifier rolls or perforated rolls serve two functions in a modern paper machine headbox. They even out non-uniformities in the approach flow to the slice region and they also introduce turbulence to break up flocs and provide a uniform formation. However, because dead or non-flow areas are created by the rotation of the rectifier rolls, they only do a partial job of flow evening and they also are very inefficient as deflocing devices since they depend for that purpose primarily on the pressure drop through the roll.
A variety of rectifier rolls have been proposed involving various combinations of hole diameters and open areas to achieve the best compromise. In other cases, the rectifier rolls have been provided with complex systems for varying the open area ratio of the rolls through adjustable devices while others have placed eddy generating devices within the slice region. And finally, proposals have been made for installing barrel or squirrel cage type rolls to produce the same purpose. However, the prior proposed systems have presented such great difficulties of design and manufacture, in the case of papermachines with a large width, and their operational characateristics have been so highly sensitive to errors in control, that designers have been compelled to look for other devices constituting solutions by which the same aims might be attained. In this regard, the headbox described in applicant's prior U.S. Pat. No. 3,328,236 was developed.
In the aforementioned patent, either all perforated rolls or a portion of them are replaced by a stationary bundle of tubes, with appropriate choice of the diameter of an individual tube and of the tube length enabling pressure drops of the desired magnitude to be obtained to effect the desired effects on the pulp flow passing through the tubes. The result of such an arrangement effectively prevents the formation of cross flows and other flow irregularities by immediately confining the flow as it leaves the supply manifold to a plurality of smaller controlled streams and then maintains this condition throughout the system of the slice where the smaller streams are ejected to form a single compound jet. As far as design is concerned, no difficulties have been encountered in connection with such a structure even in papermachines of great width and the operation of the bunched tube headbox is not dependent upon the adjustment of controls by the persons operating the machine. However, from a functional point of view, it may be seen that the velocity profile of the stock just prior to the slice is pre-defined by the tube battery since no additional equilizing elements are used. Accordingly, the present invention was designed for use either in conjunction with the bunched tube headbox described in the aforementioned patent, or for use in a headbox having a singular stock flow nozzle to provide improved defloccing and a more uniform velocity profile across the width of the papermachine. In each case, the apparatus of the present invention serves to inhibit cross flows and localized velocity differentials in the headbox while inducing the required amount of small scale turbulence to produce a pulp slurry having a uniform consistency with no evidence of flocculated fiber bundles in the suspension. Thus, it is the general object of the present invention to provide a stable and uniform velocity profile in the headbox and particularly at the slice opening of a paper making machine.
It is another object of the present invention to even out non-uniformities in the approach flow to the slice region and introduce small scale, high intensity turbulence to the stock flow to break up any flocs in the pulp suspension and produce a uniform formation.
The invention achieves the above objectives by providing at least one set or a pair of metering rolls in the headbox and immediately adjacent the slice region to perform two functions (1) deliver a uniformly metered quantity of paper making stock and water to the slice region, and (2) to impose a high intensity shear field on the stock containing solution to break up the flocculation that normally occurs.
The device of the present invention could be used as a replacement for existing headboxes on any single wire or multiple wire fourdrinier. In addition, the device of the present invention could be used in a new headbox for a new papermachine.
In carrying out the objects of the present invention, a pair of lobed rotors, which extend the full width of the headbox, are mounted for rotation within a housing located in the headbox. As the rotors are rotated, the lobes create a positive displacement pumping action which withdraws the papermaking stock from the manifold distribution system and pumps the stock to the discharge nozzle of the headbox. The manifold distribution system could take the form of those described in applicant's prior U.S. Pat. No. 3,164,513 and No. 3,171,775. However, since the general construction of inlet manifolds is well known to those skilled in the art, and since the invention herein relates primarily to an improvement in a headbox which could be used with a variety of inlet manifold constructions, the inlet manifold is shown only schematically. Similarly, the discharge nozzle of the headbox of the present invention could take any form well known in the art. However, the three embodiments illustrated and described in detail herein include a substantially fixed nozzle with and without a plurality of tapered plates, and a bunched tube discharge system such as the one fully disclosed in applicant's prior art U.S. Pat. No. 3,328,236.
DESCRIPTION OF DRAWING
FIG. 1 is a typical sectional elevational view of the stock distribution system according to one embodiment of the present invention showing a manifold distribution system, the improved headbox construction and a fixed nozzle stock distributor;
FIG. 2 is a top view of the stock distribution system of FIG. 1 with the upper part of casing 3 removed to show the lobed rotor 1;
FIG. 3 is a typical sectional elevational view similar to FIG. 1 showing a bunched tube stock distributor;
FIG. 4 is a typical sectional elevational view similar to FIG. 1 showing a tapered plate stock distributor;
FIG. 5 is a partial sectional view taken along line 5-5 of FIG. 3;
FIG. 6 is a partial sectional view taken along line 6--6 of FIG. 3;
FIG. 7 is a partial sectional view taken along line 7--7 of FIG. 4; and,
FIG. 8 is a view similar to FIG. 7 taken along line 8--8 of FIG. 4.
DETAILED DESCRIPTION
In carrying out the objectives of the present invention, the headbox is provided with a pair of lobed rotors which act as a high shear positive displacement pump to even out the flow distribution of the paper making stock and eliminate flocculation of the fibers. In this regard, the two rotors may both be driven externally via independent drives, or one rotor may be driven externally (as shown) and it in turn will drive the other rotor. However, in the most probable application, external meeting gears will mechanically couple the rotors. The rotors may be solid or hollow and may be equipped with controlled deflection devices to control the clearance at the nip created between the lobes of adjacent rotors or the lobes and the internal housing.
The principle of operation of the present invention depends in part on the lobed rotors and their relationship to one another but also depends upon the relationship between the lobed rotors and the internal housing of the headbox. Thus as paper making stock enters the headbox and becomes entrapped in the traveling cavities created between each lobe and the internal housing of the headbox, the shear that is caused by the relationship of a stationary housing and a moving rotor produces high intensity scale turbulence whose maximum scale or size is controlled by the size of the traveling cavity. The positive displacement pumping action of the lobed rotors is achieved by withdrawing stock from the stock receiving cavity and delivering it in the form of a succession of travelling discrete cavities in a uniform manner to the stock discharging cavity. Thus the cavities created between the lobes of the rotors which extend from side to side over the complete width of the headbox provide the desired defloccuation, create a uniform velocity profile not achieved with prior art headboxes, and at the same time serve to inhibit large scale secondary flows.
In the embodiment of the present invention shown in FIG. 1, reference numeral 5 indicates generally a papermachine headbox having an inlet manifold 10 attached to one side thereof and a distribution nozzle 15 attached to the opposite side. Disposed within the headbox 5 is an internal housing 3 and enclosed within the housing 3 are the lobed rotors 1 and 2 which produce the shearing and pumping action of the present invention. The lobed rotors 1, 2 extend the entire width of the headbox 5 and are adapted to be driven independently or together, as noted hereinbefore in carrying out of the present invention.
The inlet manifold 10 is shown only schematically and could take the form of the inlet manifolds disclosed in applicant's prior U.S. Pats. Nos. 3,164,513 and 3,171,775. The distribution nozzle 15 is of more or less conventional design and consists of a fixed and tapered chamber leading to the adjustable nozzle 16 which defines the slice opening 17. The internal housing 3 is fitted in close proximity to the lobed rotors 1 and 2 at both the top and bottom thereof and forms a receiving chamber at 4 and a discharge chamber at 13. The receiving chamber 4 is bounded at the rear by wall 6 of housing 3, at the top and bottom by the tangent points 7 and 8 formed between the lobed rotors 1 and 2 and the housing, and at the front by the nip point 9 formed at the interface between the lobed rotors 1 and 2. Thus, paper making stock that enters the receiving chamber 4 from the manifold distributor 10 is metered into traveling cavities 11 that are alternately formed between the individual lobes 12 of the lobed rotors 1, 2 and the housing 3 as the lobed rotors rotate. The stock is then carried around the housing 3 and discharged into the discharge chamber 13. Discharge chamber 13 is bounded by the nip point 9 and tanagent points formed by the individual lobes 12 and the front of the housing 3, and by the perforated plate 14. Accordingly, as the paper making stock is carried around the housing 3 in the traveling cavities 11, a high intensity shearing action is set up between the rotors 1, 2 and the housing walls which effectively deflocs the stock and produces a uniform suspension. Meanwhile, as the stock is pumped into the discharge cavity 13, any pressure fluctuations that are inherently developed by virtue of the alternate discharging of stock from the traveling cavities 11 are dampened by the perforated plate 14. These semi-traveling cavities 11 mechanically control the bulk of the papermaking stock, inhibit large scale secondary flows and force a uniform flow into discharge chamber 13. After passing the perforated plate 14, the paper making stock having a uniform velocity profile and suspension is then delivered through the fixed nozzle 15 and past the adjustable slice lip 22 to the slice opening 17. A pivot point at 23 is provided about which the adjustable slice lip 22 is rotated to control the basis weight of the formed sheet of paper in the cross direction profile. As shown schematically in FIG. 1, the slice opening 17 is immediately above the adjacent to and fourdrinier wire 18 and the breast roll 19 is the conventional manner. The adjustable portion 16 of nozzle 15 is opened or closed to accomodate basis weight of the paper or consistency changes in the paper making stock by moving the upper lip 22 about the pivot point 23. The slice opening 17 can thus be operated collectively or selectively in the cross direction by applying any known slice adjusting device. Applicant's prior U.S. Pat. No. 3,328,236 illustrates schematically a slice adjusting device that would be suitable for the invention herein.
The lobed rotors 1, 2 are shown as being solid, however the rotors could be hollow and could be equipped with any known bending device to provide controlled deflection of the rotors within the scope of the present invention. Controlled deflection rolls are well known and used for instance in the wet presses and on the calender stacks of papermachines and in paper finishing operations. In the wet press, controlled deflection is necessary in some cases to offset the natural sagging which occurs in the press rolls. In addition, the controlled deflection press rolls can provide a variation in the moisture content of the web in the cross direction to compensate for uneven drying conditions in the dryer section of the papermachine. Similarly, by controlling the deflection of the lobed rotors 1, 2 of the present invention, one would offset the natural sagging tendency of the rolls in a headbox of great width, and the amount of paper making stock delivered in the cross direction from the discharge chamber 13 could be made more uniform. In addition controlling the deflection of the rotors 1, 2 would tend to vary the clearance in the nip 9 and between the lobes 12 of the rotors 1, 2 and the internal housing 3 to provide gross cross directional flow adjustment. It may be seen that the lobed rotors illustrated in FIG. 1 function substantially like a positive displacement external gear pump. However, the invention herein is not limited to the specific shape or mode of operation that is characterized by an external gear pump. For instance, the lobed rotor construction disclosed could readily be altered and formed like a positive displacement vane pump where the space between the housing and rotor is divided by flat vanes. In its vane pump modified form, the invention herein would trap a fluid suspension, such a paper making stock, between the vanes and the housing wall and then pump the stock from the inlet manifold to the stock distribution nozzle. In like manner, the shear pump disclosed herein could take the form of a lobed-element pump or an internal gear or Gerotor pump. In the former type pump the construction is similar to a gear pump but one having an unusual gear shape. In the latter pump, the gears are mounted concentrically with both gears being driven and the inner gear having one less tooth than the outer gear. Positive displacement pumps of the type disclosed above are well known and are shown schematically in the publication Machine Design, Volume 42, May 14, 1970 at page 186.
The pumping action of the device of the present invention is developed as a result of a difference in pressure between the receiving chamber 4 and discharge chamber 13 that is created by the rotation of lobed rotors 1, 2 in opposite directions to mesh at the nip point 9. Thus with top rotor 1 rotating in a clockwise direction and bottom rotor 2 rotating in a counter clockwise direction, papermaking stock enters the receiving chamber 4 which has a low pressure created at the outgoing area of nip 9 where the individual lobes 12 meet. As the lobes separate from their meshed condition at 9 and move into close proximity to the walls of housing 3 at tangent points 7 and 8, traveling cavities 11 are formed between the lobes 12 and the housing 3 which receive paper making stock from receiving chamber 4. In turn paper making stock is withdrawn from the inlet manifold distributor 10 into the low pressure area of receiving chamber 4. Meanwhile, as pointed out hereinbefore, paper making stock entrapped in the traveling cavities 11 is subjected to shear conditions by its passage around the inside of internal housing 3. The shearing action creates the high intensity, small scale turbulence of the present invention that prevents flocculation of the papermaking fibers. The maximum scale or size of turbulence created is controlled by the size of the traveling cavities 11. At the opposite side of nip point 9, the intermeshing of lobes 12 at the ingoing nip and concurrent elimination of the traveling cavities 11 causes the cavities to void to discharge their stock into the discharge chamber 13 creating a high pressure region in chamber 13. Accordingly, the difference in the pressures in the receiving chamber 4 and discharge chamber 13 creates the pumping action mentioned before and the intensity of the pumping action is determined by the variation in the nip clearance at 9, the clearance between the lobes 12 and the internal housing 3, and the rotational speed of the lobed rotors 1, 2.
For a typical installation, where the slice opening at 17 was approximately two inches, the lobed rotors 1, 2 would be approximately 20 inches in diameter with lobe heights on the order of from 1.0 to 3.0 inches. Suggested dimensions for clearances in the nip region 9 and between the lobes 12 and the housing 3 would be about 1/16 inch and 1/8 inch respectively. Of course all of the dimensions and clearances mentioned above would be highly variable and dependent upon such factors as machine width and speed, the throughput of the headbox and the consistency of the paper making stock. The discharge through the slice opening 17 would be controlled by the interaction between the total head developed in receiving chamber 4 as a result of the velocity and pressure in the distributor manifold 10, and the rotational speed of the lobed rotors 1, 2. In a general manner as the lobe height is reduced to a dimension less than the slice opening at 17, the rotors 1 or 2 will be required to operate at higher rotational speeds and higher intensity turbulence will be created via higher shear between the traveling cavities 11 and the internal housing 3. This inherent action is extremely desirable for existing papermachines where at a given stock consistency, larger slice openings are required for heavier basis weight papers, and particularly for the slower operating machines which have reduced agitation in the forming section and thus generally poorer formation.
FIG. 2 illustrates a typical installation of the headbox as it appears from a top view and shows the lobed rotors 1, 2 extending the full width of the headbox with at least one of the rotors connected to an external drive means. The manifold distributor system 10 is connected to the headbox 5 via a series of rows of pipes 30 and in the embodiment shown consists of a tapered manifold although any other conventional type of manifold could be used. Referring further to FIG. 2, it may be seen that the paper making stock indicated by the letter P flows from a suitable supply (not shown) into the tapered manifold 10. The dilute paper stock is then subjected to a flow division wherein a portion flows through each of the series of pipes 30 connecting the manifold 10 and the headbox 5. Then, because of the presence of the lobed rotors 1, 2 in the housing 3 of headbox 5, the paper stock is drawn into the low pressure region of the receiving chamber 4 and pumped through the discharge chamber 13, past the perforated plate 14 and into the nozzle 15. The critical relationship between the manifold 10 and the headbox 5 is more completely disclosed in applicant's prior U.S. Pat. No. 3,164,513 and No. 3,171,775 and since it is not a part of the present invention, it is not discussed in greater detail here.
FIG. 3 illustrates a shear pump headbox substantially as shown in FIGS. 1 and 2 except that the headbox employs the bunched tube stock delivery system disclosed in applicant's prior U.S. Pat. No. 3,328,236. Accordingly, in place of the perforated plate 14 and fixed nozzle 15 shown in FIGS. 1 and 2, FIG. 3 shows a tube sheet 25, a plurality of tubes 26 and a second tube sheet 27. In the embodiment shown in FIG. 3, the tube sheet 25 would have an open area substantially less than 50% and more on the order of 30% to inhibit the stapling of long fibers in the stock. The tubes 26 would be on the order of from 1/2 inch to 1 and 1/4 inches in diameter and would be arranged in one, two or multiple rows. The tube sheet 27 would have an open area of at least 50% and preferably greater to promote the blending of the jets. Accordingly, stock pumped into the discharge chamber 13 of FIG. 3 by the traveling cavities 11 would pass through the tube sheet 25, the tubes 26, the second tube sheet 27 and out into the adjustable nozzle 16, then through the slice 17 and onto the wire 18 as in FIG. 1 embodiment. As more fully described in the aforementioned U.S. Pat. No. 3,328,236, the function of the tube bundle 26 is to straighten out any remaining vestiges of cross direction flow in the headbox while assuring a uniform velocity profile to the flow going to the slice.
FIG. 4 shows yet another modification for the headbox of the present invention wherein the stock delivery system takes the form of a plurality of tapered plates 28 which define flow passages 29. The tapered plates 28 extend the full width of the headbox system and bound the flow passages 29 in such a way that the flow passages may either expand, contract or be parallel over the length of the plates in the machine or stock flow direction of the headbox. The open area of the assembly of tapered plates 28 at the upstream end is preferably substantially less than 50%, and on the order of around 30% to inhibit stapling of fibers over the ends of the tapered plates which bound immediately on the discharge chamber 13 of the headbox. At the downstream end of the array of tapered plates 28, the open area would be essentially 100% to promote uniform merging of the stock streams in the flow passages 29. As in the case of the bunched tube delivery system of FIG. 3, the tapered plate array would straighten out any final vestiges of large scale turbulence within the headbox.
The cross sectional views 5, 6, and 7, 8 are more or less self explanatory and are added to show the approximate relationship between the relative open areas described hereinbefore.
A stock distributor system that is designed in accordance with the principles described hereinbefore would produce the desired shearing and pumping action necessary to break up flocs in the papermaking stock and provide a uniform velocity profile at the slice. It should be appreciated however, that changes in the specific embodiments disclosed could very well be made without departing from the spirit and general concept of the invention as disclosed. Accordingly, the invention is not intended to be limited by the illustrations or description herein, or in any other manner, except insofar as may specifically be required. | An improved headbox for a papermachine is provided wherein a pair of lobed rotors which extend the full width of the headbox are mounted for delivering paper making stock to rotation in the headbox. As the rotors are rotated, the lobes create a pumping action which withdraws the paper making stock from the distributor manifold and delivers it to the discharge nozzle of the headbox. Simultaneously, the lobes, acting in concert with a closely fitted housing also located within the headbox introduce a shear force on the paper making stock which produces high intensity small scale turbulence in the stock. In this regard, the lobed rotors perform two functions, (1) to deliver a uniformly metered quantity of paper making stock to the slice region, and (2) to impose a high intensity shear field on the stock to break up the flocculation that normally occurs. | 3 |
This application is a continuation-in-part of application Ser. No. 563,090, filed Dec. 19, 1983, now abandoned.
BACKGROUND OF THE INVENTION
The subject application is a continuation-in-part application of my copending patent application, Ser. No. 563,090, filed on Dec. 19, 1983 entitled COMBINATION VALANCE AND AIR CONDITIONED AIR ADMISSION AND RETURN DUCTS.
Rooms in structures and dwellings are typically heated by the circulation of heated liquids enclosed within piping systems, the admission of forced heated air through diffusers in a room, or by electrical resistance heating units. Additionally, the rooms are cooled by either an individual air conditioning unit or a central forced air system often combined with the forced air heating system. It has been considered good practice to locate the heat emitters or the forced air diffusers along an outside wall of the room and especially below a window in an outside wall where the temperature inside the room is most likely to be affected adversely by the outside temperature.
The method of circulating centrally heated liquids with associated radiation structures in the rooms has been employed to a considerable extent and is reasonably satisfactory where the structure has a basement or crawl space below the ground floor structure affording access to the piping associated with the heating system. However, with the currently widely used concrete slab which supports the dwelling, the piping is typically embedded in the concrete. Similarly, the plumbing for the houses is frequently embedded as well in the concrete. The serious disadvantage of this technique is that repairs to the system are often very costly.
Dwellings or structures constructed on the concrete slab or a flooring with essentially inaccessible crawl space beneath, are not well suited to perimeter heating at the baseboard level using forced air because the concrete slab or foundation will not readily accommodate air delivery ducts. Thus, the forced air diffusers and collection registers are typically placed in the ceiling with the associated ductwork above the ceiling which results in a less efficient method of heating or cooling a room. In the case where the air diffusers have been placed in the wall, it has not been feasible to locate them strategically relative to windows around sidewalls, because of the logistic problem in running ductwork through the walls. Additionally, diffusers located in the walls and the ceilings seriously detract from the aesthetic appearance of the room.
In the case of structures built on concrete slabs utilizing forced air systems, an additional problem arises in providing air return registers and ducts. Typically, one or several common registers are placed in a centrally located area usually in the ceiling and near the air conditioning unit. Locating the return air registers as such decreases the overall efficiency in the heating or cooling system, decreases the efficiency with which the conditioning of the air in the individual rooms can be controlled, and decreases the exchange rate of air in a room, particularly when both the diffusers and the return registers are located in or near the ceiling.
An improvement to the forced air heating and cooling method has been made by the subject applicant, in U.S. Pat. No. 3,779,150, the disclosure of which is expressly incorporated herein by reference, wherein heated or cooled air is supplied to a plenum or chamber located above a ceiling and in close proximity to an outside wall, typically above an outside window. The plenum chamber is triangularly shaped being formed by the sloped roof and horizontal ceiling on two sides and by a closure panel installed on the third side spanning the space between adjacent joists and rafters in the attic. The plenum generally extends the length of the outside wall and is enclosed on its ends by triangular shaped side panels attached to the outer surfaces of the joists and rafters. The heated or cooled air that is delivered to the plenum is then directed into the room through diffusers located in the ceiling. The diffuser is typically an elongate relatively narrow aperture or series of apertures that are parallel to and extend along the exterior wall of the structure. A valance is provided along the apertures toward the center of the room that serve to both conceal the apertures from view from the room and also to assist in directing the air from the diffusers in a downwardly direction from the ceiling. An additional baffle board between the wall or curtains and the apertures assists in directing the air emerging from the apertures in a downwardly direction and serves to block the flow of air over the top of the drapery and into the space been the drapery and the window. This improvement provides a more efficient way of diffusing heated or cooled air into the room, enhances the comfort of the room by establishing a layer of conditioned air along the exterior wall between the room and the window, and further provides an aesthetically acceptable method of concealing the apertures or diffusers located in the ceiling.
SUMMARY OF THE INVENTION
The present invention is an improved apparatus and method of delivering conditioned air to rooms of a structure or dwelling wherein incoming conditioned air is directed into rooms of the structure through diffusers located adjacent the outside walls of the structure while return air is recirculated through plural channels formed under the flooring of the structure via the aid of an auxiliary forced air fan. The present invention improves on the prior art and more particularly, the applicant's previously patented system, by providing a more simplistic construction of the air duct delivery system to the diffusers located adjacent the ceiling of the dwelling, and providing for an air return system under the flooring of the dwelling to collect the air near the floor surface of the room, thereby increasing the effectiveness and efficiency of the heating or cooling system.
Because of the very prevalent custom of providing the windows on outside walls of dwellings with draperies hung on traverse rods, and of an equally prevalent custom or providing such a drapery with a valance at least as long as the span of the drapery for concealing the rod from which the draperies are suspended, the present invention integrates such a valance with a conditioned air diffusers for the purpose of concealing the air diffuser.
In the preferred embodiment of the invention, the diffuser comprises an elongate rectangular-shaped chamber, preferably positioned adjacent each of the window and door openings of the structure extending at least as long as the span of the drapery or door opening. The boundaries of the diffuser are defined by the outside wall of the structure and the valance which form its sides, the ceiling forms its top, while an additional planar member extending between the wall and the valance, and spaced below the ceiling, to which the traverse rod of the draperies may be attached forms the bottom surface of the diffuser. A series of elongate relatively narrow apertures are formed in the bottom planar member of the diffuser, and are provided with means by which the quantity of air flow exiting the diffuser may be adjusted. These apertures thereby permit a metered velocity and or quantity of air to flow into the room, thereby insuring against undesirable drafts to be sensed within the rooms of the structure while at the same time providing an effective conditioned air shield, i.e. a thermal barrier or curtain, along a greater portion of the exterior wall to prevent heat loss to the environment. A conventional air supply duct system is additionally disposed within the attic of the structure and is utilized for supplying conditioned air to the chamber from a conventional forced air heating or air conditioning unit.
The novel air return system of the present invention comprises a series of channels that are formed preferably of concrete and directly in the excavation site in relation to concrete slab floor structures prior to forming the flooring of the structure. This network of channels which preferably extends throughout the house resides beneath each room of the structure and is completely covered by the flooring of the structure except at predetermined locations wherein a square or rectangular opening is formed into which a register may be mounted. These registers are preferably strategically and unobstructively positioned within each room to provide for the most efficient collection of air from any particular room.
The channels are interconnected so as to all be in flow communication with a conventional centralized forced air heating/air conditioner unit having a primary air circulation fan or blower disposed therein for circulating air from the channels through the heat exchanger of the forced air unit and subsequently into the air diffusers. To augment air circulation within the system, the present invention incorporates an auxiliary fan disposed within the channels and positioned adjacent to the intake opening of the forced air unit which serves to draw air through the channels and push the same into the forced air unit. Thus, the auxiliary fan forms a "super-charging" effect which has been found to increase system performance.
In addition, both the registers and the air diffusers are provided with an adjustment means for accurately regulating the circulation of the air within the room. Further, the network of channels in the air return system, because of their relative accessibility, can also be used for other purposes, for example, for utility entrances into the structure such as plumbing, electrical conduit, or sewer pipes.
Thus, in summary, the present invention provides a means by which conditioned air can be delivered to concealed ceiling diffusers which distribute the air in a downward direction along an exterior wall and a network of preformed channels under the flooring of the dwelling or structure and further provides an efficient and effective means by which the air can be collected from a room at floor level and delivered to a central heating or air conditioning system assisted by an auxiliary fan located in the channels.
DESCRIPTION OF THE DRAWINGS
These as well as other features of the present invention will become more apparent upon reference to the drawings, wherein:
FIG. 1 is a perspective view of a typical dwelling structure utilizing the present invention;
FIG. 2 is a floor plan of the dwelling structure showing the air return channels as phantom lines;
FIG. 3 is a perspective view of a manner of forming the air return channels for use with concrete slab construction techniques;
FIG. 4 is a perspective view of a concrete slab for a dwelling structure showing the air return channels as phantom lines and also depicting the central heating and air conditioning unit with the primary and auxiliary fans;
FIG. 5 is a perspective view of the air delivery system of the present invention;
FIG. 6 is a partial cross-sectional view of a portion of a room, attic, floor, and roof of the structure depicting the central air heating and cooling unit;
FIG. 7 is a perspective view taken at generally about line 7 of FIG. 5; and
FIG. 8 is a cut-away view taken generally about the line 8--8 of FIG. 6; and
FIG. 9 depicts an additional embodiment of the valance air vent adjustment means of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring generally to FIGS. 1 through 6, there is shown a typical dwelling 12 as constructed on a concrete slab floor 14. The invention consists generally of a valance/diffuser air system 16, an air delivery system 18, and an air return system 20. Although the dwelling 12 is shown constructed on a concrete slab 14, other types of floorings to which the invention may be applied are contemplated. Additionally, although the dwelling 12 depicted is a residential house, application of the invention is also contemplated in other types of commerical and noncommercial structures. As such, for purposes of this application, the term dwelling shall be defined to include other types of inhabitable structures while the term concrete slab or flooring shall be defined to include other types of conventional flooring.
The air return system 20 of the present invention is comprised of a network of channels formed preferably from concrete, in trenches that are formed in the excavation site prior to forming the concrete slab 14 of the dwelling 12. A typical network of channels 22 comprising the air return system 20 is clearly illustrated in FIG. 3. Once the air return system 20 has been formed, the individual channels 22 are protected by plywood, foam packing, or the like, and the concrete slab 14 is then poured over the air return system 20. As determined by the specific floor plan of the dwelling 12, provisions are made prior to the pouring of the concrete slab 14 to form square or rectangular openings 24 in the concrete slab 14 to communicate with the individual channels 22 of the air return system 20 and into which a register 26 may be mounted. These registers are preferably strategically and unobstructively positioned to provide each room 28, as dictated by the particular floor plan, with at least one register 26. The registers 26 are further provided with conventional adjusting means by which the air flow through the registers 26 into the air return system 20 can be accurately adjusted.
The air return system 20 directly communicates with a system that heats, cools, or otherwise conditions the air, hereinafter termed the conditioning unit 30, as is shown in FIG. 6. As is well known, the conditioning unit 30 typically comprises a forced air unit having a heat exchanging portion 32 through which air is forced by a conventional blower fan 34 and into the air delivery system 18. The present invention includes an auxiliary fan 36 which forces air into the blower 34, thereby providing a more efficient and uniform return of the air to the conditioning unit 30 from the air return system 20. Although the conditioning unit 30 and the auxiliary fan 36 are shown as being located in a central position with respect to the floor plan of the dwelling 12, as can be more readily seen in FIG. 4, it will be understood that the conditioning unit 30 may be located at any appropriate place in the dwelling 12 and that one or more auxiliary fans 36 may be employed and strategically placed in positions in the air return system 20 to improve the efficiency of the air return system 20.
Referring to FIGS. 5 and 6, returned air that has been conditioned by the conditioning unit 30 is then forced by the blower 34 in to the air delivery system 18. The air delivery system 18 consists of a network of ducts 38, preferably constructed of conventional material, such as aluminum, and configured as directed by the floor plan of a particular dwelling 12 to effectively deliver conditioned air to each room 28 of the dwelling 12. The ducts 38 of the air delivery system 18 transport the conditioned air to the air diffusing system 16 through common apertures 40 in the ducts 38 and the ceiling 42.
Referring to FIG. 8, there is shown a cut-away view of a portion of the air diffusion system 16, which consists of an air diffusion chamber 44 located below and in communication with the apertures 40 in the ceiling 42. The chamber 44 is formed on two sides by the wall 46 and the valance 48, on the top by the lower surface of the ceiling 42, and on the bottom by a closure panel 50 disposed between the wall 46 and the valance 48.
The closure panel 50 is provided with one or more elongate apertures 52 through which the conditioned air may pass under pressure provided by the conditioning unit 30. The closure panel 50 is further provided with a slide plate 54 which extends the length of and is in close contact with the closure panel 50. Since it is desirable to be able to control the amount of air entering a room 28, the position of the slide plate 54 is made adjustable over a portion of the width of the closure panel 50 such that the slide plate 54 acts as a variable closure means for the apertures 52. The adjusting means may comprise several screws 56 threaded into the closure panels 50 through elongate slots 58 in the slide plate 54, or a variety of other means by which the slide plate 54 may be positioned over the apertures 52 to adjust the air flow to the desired amount then secured to the closure panel 50 so that the slide plate 54 will remain in the position to which it has been adjusted.
In FIG. 9, an additional means for adjusting the amount of air entering into the room through the aperture 52 in the closure panel 50 is shown. The additional means comprises an elongate panel 90 formed of a pair of elongate segments 92 and 94 which are laterally interconnected by plural web members 96. The web members 96 as well as preferably the elongate segments 92 and 94 are formed of a plastic resilient material whereby the segments 92 and 94 can be hinged relative one another about the plural webs. The segment 92 is rigidly mounted to the closure 50 in a proximal position to the apertures 52 while the segment 94 is releasably mounted in an overlapping orientation to the apertures 52 by way of one or more manually rotatable lever arms 98. As will be recognized, when it is desired to close off the aperture 52 and thereby discontinue air flow into the room, the segment 94 may be hinged upward and locked in position by the lever arms 98 to completely cover the apertures 52. Conversely, when air flow into the room is desired, the lever arms 98 may be manually removed from contact with the segment 94, and the segment may be hinged downwardly to uncover the aperture 52.
The closure panel 50 may also be provided with a traverse rod 60 from which a drapery 62 may be suspended. The valance 48 extends below the closure panel 50 so that the air diffusing apertures 52 and traverse rod 60 are generally concealed from view except from a viewing point directly below the closure panel 50.
With the structure defined, the method of providing conditioned air to a room 28 with increased efficiency and having enhanced aesthetic appearance and operation may be described. Conditioned air forced into the air delivery system 18 by the blower 34 of the conditioning unit 30 is transported through the apertures 40 in the ceiling 42 to the diffusion chamber 44 of the air diffusing system 16. The air is initially distributed lengthwise along the chamber 44 and then distributed through the apertures 52 in a downwardly direction. The extension of the valance 48 below the closure plate 50 assists in directing the air from the diffusing apertures 52 in a downwardly direction along the outside wall as shown in FIG. 6. Since the outside wall 46 or window 64 represents that area of the dwelling 12 where the maximum difference between the inside and outside temperature is observed, it is within this area that the temperature of the air inside the room 28 is most adversely effected by the outside temperature. To address this problem and to provide a more uniform temperature of the air inside the room 28, the air is purposely directed downwardly in front of the wall 46, window 64, or drapery 62, and is presented such that a thermal barrier is formed by this column of air.
The air from this thermal barrier as well as other air in the room 28 is then drawn through the room and subsequently into one of the registers 26 located in the slab 14 and through the channels 22 of the air return system 20. As will be understood, the air is transported through the channels 22 by the fan 34 of the conditioner 30 assisted or supercharged by the auxiliary fan 36 located within the channel 22. The auxiliary fan 36 thus force-feeds the main blower fan 34 to form a push-pull arrangement which forces the air through the conditioning unit 30 across the heat exchanger 32 and back into the air delivery system 18.
The method of creating the thermal barrier along the outside wall by air diffusing downwardly from the ceiling 42 and subsequently being received by registers 26 located on the floor of the room 28 represents a more efficient means by which the temperature in a room 28 can be controlled and, further, minimizes the drafts being created by conventional systems which force the air in a general direction about the room 28. In addition, by having the auxiliary fan 36 located in the channels 22 under the slab 14 and the main blower fan 34 centrally located, the air movement and the mechanisms by which the air is forcibly moved are essentially inaudible in the rooms 28.
It will be understood by those skilled in the art that there are many ways of implementing the combination air diffusing chamber 44 and the valance 48 within the contemplation of the invention. For example, the air diffusion system 16 may be constructed as a unitary structure that communicates with the apertures 40 in the ceiling 42.
In addition, referring to FIG. 7, the channels 22 of the air return system 20 provide relatively accessible channels 22 through which utilities 66, such as plumbing, electrical conduit and sewer piping may be run. As shown, utilities 66 positioned in the channel 22 of the air return system 20 and directed underground near the foundation 68 of the dwelling 12. Once the utilities 66 are in place, a closure plate 70 is secured against the foundation 68 to provide a seal against the intake of outside air into the air return system 20.
Thus, in summary, the present invention provides a significant improvement in the air circulation system for a dwelling 12 constructed on a concrete slab 14 by delivering conditioned air downwardly along an outside wall 46 from an air diffusion chamber 44 located on the ceiling 42 and concealed by a conventional valance 48. Adjustable apertures 52 in the chamber 44 allow the air flow to be controlled. The conditioned air is returned to the central conditioning system 30 through a network of interconnected channels 22. Additionally, an auxiliary fan 36 is placed in the air return system 20 near the conditioning unit 30 to assist in the more efficient recirculation of the conditioned air. Those skilled in the art will recognize that the present invention may be readily adapted to deliver conditioned air above walls other than outside walls and include other air diffusion chamber 44 designs without departing from the spirit of the present invention. | An improved apparatus and method of delivering conditioned air to rooms of a structure or dwelling through ceiling diffusers concealed by a valance and located adjacent the outside walls of the structure is disclosed. Air is delivered to the diffusers by conventional ducting located above the ceiling from a central forced air heating/cooling system and is directed into the room through adjustable apertures in the diffuser in a downwardly direction thereby forming a thermal barrier along the outside wall. Return air is collected at adjustable registers in the floor of the structure which communicate with a network of preformed channels under the flooring and delivered to the central heating or air conditioning system assisted by an auxiliary fan located in the channels. | 5 |
RELATED APPLICATION
[0001] This is a continuation-in-part of my application Ser. No. 10/779,833 filed Feb. 17, 2004 titled “Articulated Football Goal Post,” which in turn claims the full benefit of my Provisional Application 60/449,480 filed Feb. 21, 2003, titled “Hydraulically Actuated Football Goal Post.”
FIELD OF THE INVENTION
[0002] The invention relates to football goals, particularly to a goal that can be adjusted in height and otherwise manipulated for improved safety and security, and readily placed in condition for use according to standard rules. In one embodiment, the crossbar and uprights can be lowered to the field for quick release or disassembly.
BACKGROUND OF THE INVENTION
[0003] Rabid and out-of-control spectators and/or students at many football and other sporting events have frequently surged onto the field to destroy or topple the goal posts, presenting serious threats to human life, physical injuries, damage to and destruction of property, theft, and great expense in repairing and replacing the goal posts. Many presently existing goal posts are not easily removed or damaged, but some spectators have proven determined and innovative in carrying out their objective of destruction, sometimes bringing ropes, ladders and other equipment to aid in their endeavors.
[0004] A football goal is essentially a horizontal pipe or rod important only for extra points and field goals, not necessary for a touchdown. The horizontal rod or crosspiece must, by rule, be in a certain location and has flanking uprights so the officials can readily see whether a kick passes over it. But the support for the structure can be dangerous to the players as it normally is located near the action of the game.
[0005] There is a need for a goal and/or goal post that can safely manipulate the crosspiece to avoid damage by spectators and others, as well as to avoid injury to persons present when a mob is intent on damaging the goal. There is a need also for a goal that can be easily moved from the field for storage, as in the case of a multi-use stadium. And, there is a need for a goal structure that reduces the possibility of players colliding with it and sustaining injuries.
SUMMARY OF THE INVENTION
[0006] My invention provides a cross member for an athletic goal which can be hydraulically elevated to a position well beyond the reach of most vandals and others intent on destruction. The goal can be readily lowered as well, permitting the easy installation and maintenance of television cameras and the like. Manipulation of the goal is accomplished from a remote control panel. The crossbar is supported preferably on a heavy steel upright that can optionally be placed farther back from the field than is commonly the case. The entire assembly can be removed from the field for storage.
[0007] In one embodiment, the structure comprises a vertical column, a main boom, a nose boom, and a goal element including a crossbar and uprights on the ends of the crossbar. The structure is articulated at both ends of the main boom. During raising and lowering, the nose boom is caused to remain horizontal, so that the uprights on the ends of the crossbar remain vertical. In aspect of my invention, the vertical column is bolted or otherwise fixed to a concrete base during use. The bolts may be removed, the wiring disconnected, and the vertical column stored in a safe place, while the concrete substructure is covered with a portable supported playing surface.
[0008] In another embodiment, there need be only one pivot. From a remote location, a hydraulic powered arm is adapted to lower the crossbar to a point near the field; the crossbar and uprights may then, on a remote signal, be detached from the boom, and the boom can be raised again to its normal height. In one variation of the present invention, then, an object of the invention is to reduce the likelihood of spectator injury by providing a sacrificial crossbar assembly. As will be seen, the boom can be quickly lowered to the field and readily released from the boom, and the boom can then be readily lifted out of reach of a crowd.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 a is a side elevational view and FIG. 1 b is a perspective view of one embodiment of my new goal post, in standard position ready for play.
[0010] FIGS. 2 a and 2 b show the goal in the elevated position.
[0011] FIGS. 3 a and 3 b show the goal in the lowered position.
[0012] FIG. 4 is a detailed view of the nose boom assembly.
[0013] FIG. 5 details a hydraulic jack connection to the main boom.
[0014] FIG. 6 is a schematic of the electrical and hydraulic systems.
[0015] FIG. 7 shows an alternate construction in which the main hydraulic cylinder is in the rear of the vertical column.
[0016] FIG. 8 is a further alternate construction, showing a single hydraulic cylinder for operating the main boom, the main boom being held in place by a latch.
[0017] FIG. 9 shows some detail of the hydraulic cylinder and latch assembly.
[0018] In FIG. 10 , the variation of FIG. 8 is shown wherein the latch has been released.
[0019] In FIG. 11 , the boom is lowered to permit removal of the crossbar.
[0020] FIG. 12 is a side elevational view of the sacrificial crossbar hold and release mechanism.
[0021] FIG. 13 a shows the goal in the lowered position. In FIG. 13 b , the crossbar assembly has been released and lies on the field.
[0022] FIG. 14 shows the crossbar neck in a position for inserting into the end of the boom.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring first to FIGS. 1 a and 1 b , the vertical column 1 rests on base plate 2 , which is bolted to a concrete substructure not shown (see item 30 in FIG. 7 ). Vertical column 1 may be fabricated from 4 pieces of ⅜″ mild steel forming the main vertical box structure welded to the base plate 2 . Base plate 2 may have, for example, 8¾ inch holes designed for installation of bolts to provide a mechanical, removable connection between the vertical column 1 and the substructure, permitting complete removal of the apparatus from the field. Main boom 7 (sometimes called an arm herein), which may be made of a lighter metal such as aluminum, is connected to the vertical column 1 at pivot 9 . Nose boom 14 is connected to main boom 7 through a pivot 13 . Beneath nose boom 14 is upper control arm bracket 18 . Upper control arm bracket 18 is fixed to nose boom 14 and connected through pivot 12 to control arm 8 .
[0024] Control arm 8 is adjustable in length by a threaded insert 11 . Adjustment of the length of control arm 8 enables adjustment or correction of the vertical orientation of uprights 17 on the ends of crossbar 16 . Crossbar 16 is fixed to nose boom 14 through removable pin 15 , permitting disassembly of the crossbar from the rest of the structure. Control arm 8 is connected to the vertical column 1 at pivot 10 . Hydraulic jack 6 is pivoted and fixed to the vertical column 1 at lower mount 5 and pivoted and fixed to main boom 7 at upper mount 19 . Vertical column 1 includes an access door 4 for the hydraulic pump, pump motor and other devices for operating the structure, which will be described in more detail with respect to FIG. 6 . Access door 4 has a lockable latch 3 .
[0025] Crossbar 16 may have nipples or vertical extensions, not shown, for insertion into uprights 17 so they may be easily attached or removed. The uprights 17 may be attached to crossbar 16 in any known acceptable manner. Both the crossbar 16 and uprights 17 may be made preferably of a light metal, but any substantially rigid material will suffice. Whether or not the uprights 17 are tubular, they may be adapted for insertion or attachment, at their upper ends, for wind direction indicators or other devices.
[0026] In FIGS. 2 a and 2 b , the goal is in the elevated position. In this depiction of the invention, main boom 7 is at an angle about 60 degrees from the horizontal. A particular feature of the invention is that the nose boom 15 is maintained horizontal, so that uprights 17 are maintained in a vertical orientation. It will be observed that control arm 8 is maintained at a constant length and accordingly pivot 12 moves in a substantially circular arc as main boom 7 is elevated, while control arm 8 is also held substantially parallel to main boom 7 , resulting in nose boom 14 being held substantially horizontal throughout the elevation of main boom 7 from its generally horizontal orientation of FIGS. 1 a and 1 b . A major purpose of elevating the crossbar is to move it far out of the reach of a persons intent on damaging it. Accordingly, the apparatus should be capable of moving the crossbar to a height of at least fifteen feet; I prefer seventeen feet or more.
[0027] Referring now to FIGS. 3 a and 3 b , the apparatus is seen to be in the lowered position, main boom 7 having been lowered from the horizontal about 30 degrees. It should be observed that the hydraulic jack 6 is approximately parallel to vertical column 1 , whereas it is angled slightly away from vertical column 1 in FIGS. 1 a and 1 b . When the apparatus is in the elevated position as shown in FIGS. 2 a and 2 b , hydraulic jack 6 is still slightly angled from vertical column 1 , but not as much as when the apparatus is in the playing mode as in FIGS. 1 a and 1 b . In FIGS. 3 a and 3 b , the uprights remain vertical and nose boom 14 is horizontal, no adjustment being necessary in the length of control arm 8 because of the movement from fully elevated (as in FIGS. 2 a and 2 b ) to completely lowered, as in FIGS. 3 a and 3 b.
[0028] In FIG. 4 , the nose boom 14 and associated parts are shown in detail. Pin 15 can be removed to separate the crossbar 16 from nose boom 14 . Pivot 13 , connecting main boom 7 and nose boom 14 , together with pivot 12 , connecting upper control arm bracket 18 and control arm 8 , assures that nose boom 14 will be held substantially horizontal throughout the manipulation of the apparatus. If there is a slight deviation from the horizontal (which is readily detectable because the uprights 17 will not be vertical), an adjustment in the effective length of control arm 8 can be made by turning threaded insert 11 in one direction or the other. When the length of control arm 8 is coordinated with the effective length of main boom 7 (the distance between pivots 13 and 9 ), it can automatically assure that the nose boom 14 will remain horizontal and the uprights 17 are vertical regardless of the angular position of the main boom 7 .
[0029] Since neither the elevated position nor the lowered position of the apparatus is normally used in the game, it may not be considered essential that the nose beam 7 remain strictly horizontal in those positions nor that the uprights extend exactly vertical; accordingly perhaps the only position for which some users may adjust threaded insert 11 will be the playing position shown in FIGS. 1 a and 1 b . But because of the positioning and close relationship of main boom 7 and control arm 8 , an adjustment of the nose boom 14 to make it horizontal in the playing position will more or less automatically adjust the elevated and lowered positions also so that the nose boom 14 will be horizontal and the uprights 17 vertical.
[0030] The detail of FIG. 5 shows the articulation of main boom 7 in closeup fashion. Hydraulic jack 6 is connected at pivot 20 on upper mount 19 , which is fixed to the main boom 7 . Control arm 8 is situated on pivot 10 in vertical column 1 . Also on vertical column 1 is pivot 9 for the main boom 7 . The main boom 7 is elevated in this view, and accordingly if it were to be lowered to either the play or lowered position, hydraulic jack 6 would be retracted, pivoting on pivot 20 , causing the main boom 7 to be pivoted downwardly on pivot 9 and also causing control arm 8 to be pivoted on pivot 10 . The effective distances between pivots 9 and 10 , and 12 and 13 , are approximately equal, as are the effective distances between pivots 9 and 13 and pivots 12 and 10 . This double pivoting relationship thus forms an approximate parallelogram with the four pivots as corners, which assures that the nose beam remains horizontal throughout any manipulation of the main boom 7 .
[0031] The more or less diagrammatic FIG. 6 shows some power lines 40 , electrical control connections 41 , and hydraulic fluid lines 42 . Hydraulic jack 6 is extended or retracted according to the direction of flow of hydraulic fluid, which in turn is determined by a remotely located hydraulic controller 31 , normally operated by a human being. The reversible hydraulic pump 25 , its associated electric pump motor 26 , and the hydraulic fluid reservoir 27 are all located within the vertical column 1 , designated here as 24 , usually also together with a power junction box 30 , receiving AC power from an external source 32 , a battery backup 28 , and a relay switch 29 for switching from AC to DC in an emergency, i.e. if the external power source is cut or otherwise becomes unavailable. A check valve 21 may be used to guard against sudden interruption of power, or pressure loss. The controller 31 is able to command the pump. Wires connecting controller 31 to the electric motor 26 and three-way solenoid valve 23 should pass underground to the field operator's location remote from the goal. Design and construction of the concrete substructure mentioned in connection with FIGS. 1 a and 1 b should provide a utility channel leading to the desired remote location for power source 32 and controller 31 . Ideally, in this embodiment, the controller will have only three simple options—play, elevated, and lowered. The operator normally needs only to choose one of the three options and the control system will operate the hydraulic jack 6 accordingly. The controller may use a wireless system to communicate with the pump motor and/or other devices within vertical column 1 .
[0032] Persons skilled in the art will recognize that any conventional hydraulic fluid may be used—that is, no special fluid is required, although of course it should have a low freezing point where freezing conditions may be expected. The system may be pneumatic—that is, the fluid may be air. As used herein, the terms “hydraulic” and “hydraulic fluid” means any fluid suitable for use in a positioning cylinder or other actuator such as hydraulic jack 6 . Alternatively, the motion of main boom 7 may be accomplished by mechanical means through gears or other leverage applied directly from an electric motor, such as an electric actuator. Any sutiable device for applying force to cause main boom 7 to pivot on pivot 20 may be satisfactory; such a device—that is, the means for moving the main boom and, sometimes separately, the nose boom or the release mechanism, may be referred to herein broadly as an actuator.
[0033] It also may be observed that the nose boom is not essential if one is not concerned about the orientation of the uprights 17 as the apparatus is moved from the playing mode to the lowered or elevated mode. Also, it is not essential that the vertical column 1 be exactly vertical in orientation—it may “lean” either forward or backward, or may take the form of a pyramid or other support. My use of the term “vertical column” is intended to include any support that is capable of supporting the main boom 7 at a pivot 9 . For example, one might, for whatever reason, wish to support the pivot 9 on a structure having two legs and a horizontal member with a bracket for holding pivot 9 . Such a structure would be functionally and structurally equivalent to the vertical column illustrated herein and accordingly is intended to be included within the meaning of “vertical column.” For my purposes, the pivot 9 will normally be at a height of about the same height as a regulation crossbar, or somewhat lower as is evident in FIG. 1 a ; this may be varied somewhat within the scope of my invention.
[0034] FIG. 7 shows an alternate configuration in which the hydraulic jack 31 is on the side of vertical column 1 opposite that of FIG. 1 a , and pivot 38 on main boom 7 is leveraged somewhat differently from that of FIG. 1 a . Hydraulic jack 31 pivots on pivot 37 and pivot 38 ; main boom 7 pivots on pivots 38 and 39 , which is located on vertical column 1 . In this illustration, it will be seen that there is no control arm 8 , but there is a second hydraulic jack 32 connecting nose boom 35 with main boom 7 . In the variation of FIG. 7 , if one desires to maintain nose boom 35 horizontal at all times, it is necessary to coordinate the action of hydraulic jack 32 with that of hydraulic jack 31 . If main boom 7 is elevated, hydraulic jack 32 will be retracted, and if main boom 7 is lowered, hydraulic jack 32 will be extended to assure that nose boom 35 remains horizontal. The controller in such a system will have somewhat more complexity than those of FIGS. 1-5 , and a separate hydraulic line should be supplied to hydraulic jack 32 .
[0035] The alternate construction of FIGS. 8-14 includes a vertical column 50 , a hydraulic cylinder 51 pivoted at pivot 52 , which is fixed to vertical column 50 and also pivoted at pivot 53 fixed to boom 54 . Boom 54 is pivoted at pivot 55 , which is also fixed to vertical column 50 . Pivots 52 , 53 , and 55 are placed so that actuation of hydraulic cylinder 51 will raise or lower boom 54 depending on whether stem 56 is extended or retracted. Crossbar 57 is shown in side view in FIG. 8 ; the uprights normally attached to the crossbar are omitted from this view.
[0036] As with the variation of FIGS. 1-7 , the variations of FIGS. 8-14 preferably are secured to a concrete substructure 30 such as illustrated in FIG. 7 , having provision for electrical wiring for operating the actuators from a remote location. The goals should be operated independently at each end of the field. Vertical column 50 may contain power connections, pumps, switches and the like including remote control systems, similar to those described with respect to FIG. 6 and elsewhere herein. Alternatively, some or all of the pumps, switches, remote control systems and the like may be located within the concrete substructure 30 .
[0037] Fixed to the boom 54 is a hook latch 58 which is interlocked with a similar hook latch 59 . Hook latch 59 is a part of stabilizing panel 60 . Stabilizing panel 60 is pivoted at pivot 61 . When the hook latches 58 and 59 are joined or interlocked as shown, the boom 54 is held steady, maintaining the crossbar 57 at the correct height for regulation play. Present NCAA (National Collegiate Athletic Association) rules, for example, require a height of ten feet.
[0038] Referring now to FIG. 9 , the portion of FIG. 8 including hydraulic cylinder 51 is seen to be enlarged and the interlocked state of hook latches 58 and 59 may be observed. Spring loaded arm 62 will urge stabilizing panel 60 in an upward and rightward (as depicted) direction when cylinder 51 is actuated to elevate boom 54 , thus disengaging hook latches 58 and 59 as explained further with reference to FIG. 10 .
[0039] In FIG. 10 , actuation of the hydraulic cylinder 51 to extend stem 56 has resulted in the elevation of boom 54 , pivoting on pivot 55 . The movement of boom 54 also causes latch 58 to disengage from hook latch 59 , and arm 62 has moved panel 60 to clear the two latches 58 and 59 ; boom 54 can then be lowered. The hydraulic cylinder 51 can then be retracted, causing boom 54 to pivot downward on pivot 55 . Actuation of hydraulic cylinder 51 thus performs two functions—it not only moves boom 54 , but also disengages latches 58 and 59 , permitting the boom to be turned downward.
[0040] As seen in FIG. 11 , boom 54 is now substantially vertical, and crossbar 57 is very near to the field 63 . The uprights, not depicted here, extend substantially parallel to the field. Also seen in FIG. 11 is the position of crossbar retainer hook 64 within the boom 54 and near its end. This device is described further in FIGS. 12 and 14 .
[0041] Referring now to FIG. 12 , crossbar retainer hook 64 is located more or less centrally within boom 54 . It is seen here to be pivoted at pivot 65 , fixed to boom 54 . Stem 66 extends from a small hydraulic cylinder 70 for attachment to crossbar retainer hook 64 at 71 . Hydraulic cylinder 70 is attached to boom 54 at pivot 67 . Hydraulic cylinder 70 is actuated remotely, preferably by a system which will prevent actuation of cylinder 70 at any time except when boom 54 is in the position of FIG. 11 . Crossbar 57 is attached to crossbar neck 75 , part of which is inserted into boom 54 (seen in detail in FIG. 14 ). Crossbar neck 75 is retained within boom 54 by hook 64 which is engaged with pin 68 . Actuation of hydraulic cylinder 70 will cause crossbar retainer hook 64 to move and disengage from pin 68 .
[0042] FIG. 13 a shows the position of the boom 54 , the crossbar 57 , and uprights 69 prior to the release of the crossbar 57 and uprights 69 . Uprights 69 are seen to be substantially parallel to the field 63 . In FIG. 13 b , the pin 68 has been released from its hold by crossbar retainer hook 64 ; since it is no longer engaged by hook 64 , the crossbar neck 75 has fallen from the end of boom 54 , and the crossbar 57 and uprights 69 are now on the field 63 . If the spectators remove the crossbar assembly, a replacement crossbar assembly is easily inserted into the boom as in FIG. 14 .
[0043] FIG. 14 illustrates in perspective the positioning of neck 75 for connection to boom 54 . Neck 75 is seen to be welded or otherwise attached to crossbar 57 and has a neck extension 72 slightly smaller in dimension than the interior of the end of boom 54 . Neck extension 72 may be slightly tapered to facilitate insertion and removal, preferably on the lower side (as depicted) or the upright sides (as depicted) rather than the upper side in order to help adjust the height of the crossbar 57 to regulation height. The boom 54 may be provided with set screws 73 or other devices to help secure and adjust the position of the crossbar 57 after insertion of the neck extension 72 . Within the neck extension 72 is pin 68 . Pin 68 is positioned for engagement with hook 64 for retention of the neck extension 72 in place in the boom 54 . As described above, hook 64 is manipulated from a remote location by activating cylinder 70 (see FIG. 12 ). Pin 68 and hook 64 may be replaced with any apparatus capable of retaining and releasing the crossbar/neck assembly from the boom from a remote location. Pin 68 may be considered more broadly as providing a stationary retaining surface in or on the neck of the crossbar and upright assembly, and hook 64 , located in a goal holder or support such as, for example, the boom 54 , more broadly provides a movable retaining surface complementary to, and for engagement with, the stationary retaining surface in or on the neck.
[0044] Therefore, it may be understood that my invention includes an articulating goal post for a football field comprising (a) a vertical column, (b) an arm pivoted thereon (c) a crosspiece near the end of the arm, and (d) upright members attached to the ends of the crosspiece. In another aspect, my invention includes a goal post comprising a vertical column having a base, a pivoted arm thereon, a crosspiece near the end of the pivoted arm, and two upright members, the upright members and the crosspiece defining a regulation kicking goal when the goal post is in a playing position, and means for moving the crosspiece and the upright members by the pivoted arm to an elevated position wherein the crosspiece is at least fifteen feet above the base. In yet another aspect, my invention is a football goal post comprising a crossbar, upright members on the ends of the crossbar, a nose boom rigidly connected to the crossbar, a main boom having a forward end and a rear end, the main boom being pivotally connected to the nose boom at the forward end, a vertical column including a pivot connecting the rear end of the main boom to the vertical column, a hydraulic jack pivotally mounted on the vertical column and pivotally connected to the main boom, and a substantially rigid control arm pivotally connecting the nose boom and the vertical column. In another aspect, my invention is a football goal comprising (a) a substantially vertical column, (b) a main boom attached in pivotal relation to the substantially vertical column, (c) an actuator for positioning the boom upwardly or downwardly, and (d) a crossbar and upright assembly including a releasable attachment to the end of the boom.
[0045] In another aspect, my invention includes an articulating football goal comprising a vertical column, a boom movably attached to said vertical column, said boom holding near its end a crossbar and uprights to form a goal when maintained at a height suitable for regulation football, said boom being movable by at least one actuator to lower said crossbar and uprights to near field level, and means for releasing said crossbar from said boom; this aspect may include a movable retaining member in said boom for engagement with said stationary retaining member in said neck, and an actuator in said boom for activating said movable retaining member to release said neck from attachment to said boom. In another aspect, my invention is a crossbar and upright assembly for a football goal comprising (a) a crossbar having uprights on the ends thereof, said crossbar and uprights being of dimensions compliant with football rules, and (b) a neck on said crossbar, said neck being attached substantially centrally on said crossbar and in a plane about 90 degrees from the plane of said uprights, said neck including a retaining surface for releasable engagement with a complementary retaining surface in a holder for said crossbar and upright assembly. My invention also entails an athletic goal comprising (a) a substantially vertical column, (b) a boom including a vertical column end and a remote end, said boom being attached at its vertical column end in pivotal relation to said substantially vertical column, (c) an actuator in said athletic goal for moving said boom, and (d) a crossbar and upright assembly including a releasable attachment member for attachment of said assembly to the end of said boom; as with the other variations, this aspect of the invention may include a remotely operable release actuator within said boom for releasing said releasable attachment. In addition, my invention includes a football field including two goal posts at least 100 yards apart, said goal posts each comprising a vertical column, a boom articulated thereon and operable from a remote location, and a detachable crossbar and upright assembly releasable retained on said boom, whereby said crossbar and upright assembly may be lowered for release thereof onto said football field.
[0046] My invention may be otherwise varied within the scope of the following claims. | An articulated athletic goal can be raised to a high position and/or a low position relative to the game position, for safety and security. The crossbar and uprights are supported on the end of a boom pivoted on a vertical column and powered by a hydraulic actuator, which may be operated remotely. Through either a parallel linkage or a separate hydraulic actuator, the uprights are held in a substantially vertical orientation throughout the pivoting motion. In a preferred embodiment, the boom is mounted on a single pivot and articulation enables the boom to be oriented substantially vertically downward. The boom is provided with a second, smaller, actuator, for releasing the crossbar/upright assembly when it is near the field, completely separating the crossbar/upright assembly from the boom. The sacrificial crossbar/upright assembly may then be removed by spectators without the dangerous and destructive mob action previously associated with after-game celebrations. A replacement crossbar/upright assembly is easily attached and readied for the next use. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/727,791, filed on Nov. 19, 2012.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] This invention was made with government support under DEB 0842230 and DEB 0543398 awarded by the National Science Foundation (NSF). The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to carbon sequestration modeling and, more particularly, to an accurate method for estimating carbon sequestration in tropical grasslands.
[0005] 2. Description of the Related Art
[0006] Soil organic carbon (SOC) in grasslands and savannas represents one of the largest reservoirs of carbon on earth and thus one of the most important potential sinks of carbon dioxide in the effort to mitigate climate change. Understanding the dynamics of SOC is thus of paramount importance for scientists and policy-makers. A major question is what management practices in grasslands, in the form of grazing, fire, fertilization, re-vegetation and restoration, etc., can lead to net sequestration of carbon. Because SOC changes often require years to reach a level detectable against large SOC stocks, models represent key tools for assessing the consequences of management.
[0007] A wealth of field studies in North America, Europe, and increasingly in Asia, have supported modeling of SOC for temperate grasslands. This effort has culminated in large, complex, and mostly successful models such as CENTURY and RothC that require entry of or draw from empirical databases to make default selections of a large number of parameters. Some of the many factors incorporated into these models include precipitation, soil texture, pH, exchangeable bases, temperature, grazing, fire frequency, soil nutrients, plant tissue nutrients, etc. The models typically track two or more SOC pools that differ in their turnover of carbon, and consider changes in parameter values over relatively fine time scales (days, weeks, or months). These models generally predict well changes in SOC related to production and decomposition, but can they can be insensitive to changes related to the management of grasslands, namely fire and grazing.
[0008] Tropical grasslands and savannas occupy nearly 10% of the earth's land surface and have measured SOC stocks from 10-120 metric tons(mt)/ha. However the dynamics of SOC in response to changes in fire, grazing, and other management in tropical systems are virtually unstudied. Tropical grasslands feature several characteristics that may cause them to function differently than temperate systems, and exhibit different SOC dynamics. First, they are almost entirely dominated by warm-season (C4) grasses that invest heavily in rhizomes and other storage organs that allow them to respond quickly to rainfall and to defoliation. In particular, compensatory responses to grazing can involve a reduction in allocation to stem and an increase in specific leaf area, which might sustain ecosystem photosynthetic capacity despite removal of considerable production. Second, these grasses contain higher levels of lignin and cellulose, which are generally recalcitrant to decomposition. Thirdly, high seasonal rainfall can lead to intense periods of production followed by drier periods during which standing biomass is highly vulnerable to and frequently experiences fire. Finally, benign temperatures allow for the prevalence of macro-decomposers, such as termites and dung beetles, which often rapidly incorporate senesced plant material and herbivore dung into soil. These and other features suggest that carbon fixation may be relatively insensitive to grazing and fire, that fixed carbon may be less decomposable, and that combustion and incorporation of dung into soil organic matter may represent important and fates of fixed carbon not prevalent in many temperate systems.
[0009] Although the most successful temperate SOC models have not been tested in tropical ecosystems, the large numbers of parameter inputs they require to make good predictions are virtually unavailable from the less intensively studied tropics. For example, CENTURY will select parameters by default from internal databases, but these data may not represent tropical conditions or functional relationships as discussed in Paustian, K., W. J. Parton, and J. Persson, Modeling soil organic-matter in inorganic-amended and nitrogen-fertilized long-term plots, Soil Science Society of America Journal 56:476-488 (1992), hereby incorporated by reference and referred to herein as Paustian. Thus, a simpler modeling approach with fewer inputs might be necessary at this point to explore SOC dynamics to even a first approximation for tropical habitats.
[0010] For example, one study found that a relatively simple model of nitrogen dynamics, with fine time scales of resolution but consideration of relatively few pools and fluxes, described well the impacts of grazing animals and fire on soil N in the Serengeti, see Holdo, R. M., R. D. Holt, M. B. Coughenour, and M. E. Ritchie, Plant productivity and soil nitrogen as a function of grazing, migration and fire in an African savanna, Journal of Ecology 95:115-128 (2007), hereby incorporated by reference and referred to herein as Holdo. Empirical studies of SOC dynamics in the tropics suggest that relatively few factors may explain the majority of variation in SOC and key processes that affect it, like soil microbial respiration and termite decomposition of plant litter, see Wilsey, B. J., G. Parent, N. T. Roulet, T. R. Moore, and C. Potvin, Tropical pasture carbon cycling: relationships between C source/sink strength, aboveground biomass, and grazing, Ecology Letters 5:367-376 (2002) hereby incorporated by reference and referred to herein as Wilsey. Consequently, there is a need for a process that estimates SOC using a highly simplified model of SOC dynamics to explain the considerable variation in SOC stocks in tropical grasslands.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention provides a method for estimating the sequestration of carbon in grazed grasslands. The present invention considers the major pathways of the fate of fixed carbon (e.g., incorporation in biomass, combustion, consumption, dung deposition, respiration) and the mechanisms that prevalent in and unique to tropical systems, such as compensatory responses to defoliation. More specifically, the method of the present invention is based on a simplified model of SOC dynamics for tropical grassland that operates as a function of five input variables: mean annual rainfall, grazing intensity, fire frequency, aboveground percent cellulose plus lignin, and soil texture (percent sand), along with several key grassland parameters.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0012] The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:
[0013] FIG. 1 is a schematic showing the major fates of carbon in tropical grassland;
[0014] FIGS. 2A through 2F are graphs illustrating the key parameter relationships underlying the method of the present invention;
[0015] FIG. 3A trough 3 D are graphs illustrating the predictions of the present invention as a function of the key input variables of grazing intensity and fire frequency for different combinations of low (RAIN=450) and high (RAIN=800) rainfall and low (SAND %=25, Fine-Textured Soils) and high (SAND %=65, Coarse-Textured) soil sand content, where the lignin and cellulose content (LIGCELL) was set at 0.3;
[0016] FIG. 4 is a graph comparing the estimates provided by the method of the present invention with actual measurements taken at eight test locations.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring now to the drawings, wherein like reference numerals refer to like parts throughout, there is seen in FIG. 1 a model of the major fates of carbon in tropical grassland considered by the present invention as part of a practical soil carbon dynamic model to allow for the estimation of soil organic carbon over time. Net fixed carbon becomes resident soil organic carbon (SOC) through two major pathways: plant-derived SOC not consumed by microbes (in soil or the guts of macro-decomposers like termites) (heavy solid arrows), and dung-derived SOC (heavy short-dashed arrows) not assimilated by grazers and gut or soil microbes. All other carbon is combusted through fire (black arrow), or respired by grazers and microbes in soil or the guts of macro-decomposers (long dashed arrows).
[0018] The method of the present invention is based on a number of observations about the SOC dynamics of tropical grasslands. First, tropical grasses exhibit compensatory responses to defoliation that maintain similar leaf area, and thus photosynthetic capacity, across a broad range of grazing intensities. Second, the largest carbon inputs to the soil organic matter pool occur through decomposition of aboveground and belowground biomass and through incorporation of herbivore dung into soil. Third, the major losses of SOC derive from combustion (fire), herbivore respiration, and soil microbial respiration. Finally, all plant tissue, other than lignin and cellulose, is assumed to be respired through by herbivores and by microbes in soil or the guts of macro-decomposers.
[0019] Using these observations, the present invention provides a simplified method for analyzing SOC dynamics for tropical grassland as a function of five input variables, i.e., mean annual rainfall, grazing intensity, fire frequency, lignin and cellulose content, and soil texture (percent sand), as well as a few standard parameters. Using these input variables and parameters, the method of the present invention can be used to estimate the SOC for a particular location and to provide an estimate of the change in SOC over time.
[0020] Referring to FIG. 2A , the method of the present invention considers the proportion of leaves (P L ) in a given location. As seen in FIG. 2B , a leaf area index (LAI, cm 2 /cm 2 ) of grazed and ungrazed plants as a function of grazing intensity (GI) may also also considered. As seen in FIG. 2C , the number of moist soil days (WETDAYS) as a function of annual rainfall (RAIN) is also considered. Other parameters taken into consideration by the method of the present invention are known in the art. For example, as seen in FIG. 2C , the decline in water-holding capacity of soils with increasing sand content, see Ruess, R. W. and S. W. Seagle, Landscape patterns in soil microbial processes in the Serengeti National Park. Ecology 75:892-904 (1994), hereby incorporated by reference and referred to herein as Ruess, is one parameter considered in the present invention. In addition, as seen in FIG. 2D , the annual belowground production as a function of rainfall, as described in McNaughton, S. J., F. F. Banyikwa, and M. M. McNaughton, Root biomass and productivity in a grazing ecosystem: the Serengeti. Ecology 79:582-592 (1998) hereby incorporated by reference and referred to herein as McNaughton (1998), is taken into consideration. Finally, as seen in FIG. 2E , the microbial maximum respiration rates as a function of soil carbon stocks ((SOC) as discussed in Ruess), were also used in the method of the present invention.
[0021] The first step in the method of the present invention is to calculate the maximum aboveground net primary productivity (ANPP t max ) using annual rainfall in millimeters (RAIN). The equation for calculating the maximum aboveground net primary productivity (ANPP t max ) according to McNaughton, S. J., Ecology of a grazing ecosystem: The Serengeti. Ecological Monographs 55 259-294 (1985) hereby incorporated by reference and referred to herein as McNaughton (1985), weighted by the water holding capacity (WHC) that, according to Ruess, is negatively related to the sand content (SAND %) of the soil:
[0000] ANPP t max =(0.84*RAIN−27.5)*(1.315−0.007*SAND %)
[0000] Using the aboveground net primary productivity (ANPP t max ) determined above, it is then possible to calculate the estimated aboveground net primary productivity (ANPP t est ) based on the leaf area index, LAI as follows:
[0000] ANPP t est =LAI*ANPP t max
[0022] The next step in the process is to determine a leaf area index (LAI). The leaf area index (LAI) is based upon the proportion of leaves (P L ), which is in turn a function of the grazing intensity (GI). Grazing intensity (GI) is the second variable input of the present invention and comprises the fractional difference between standing aboveground biomass (AGB) outside a grazing enclosure verses inside a grazing enclosure. Grazing intensity (GI) is not a direct measure of the fraction of annual production consumed by grazing animals, but instead reflects the degree to which grazing reduces standing fuel for fires and provides a lower bound on an estimate of the fraction of aboveground production that is converted into dung. Grazing intensity (GI) may be calculated, as discussed in McNaughton (1985), from the difference in aboveground biomass under ungrazed conditions (ABG ug ) and aboveground biomass under grazed conditions (ABG g ):
[0000] GI=1−AGB g /ABG g
[0023] The proportion of leaves (P L ) may be calculated from the grazing intensity (GI) according to the following:
[0000] P L =0.6+0.24*GI
[0024] Using the proportion of leaves (P L ), as well as the maximum aboveground net primary productivity (ANPP t max ) and annual rainfall (RAIN), the leaf area index (LAI) may be calculated as follows:
[0000] LAI=(P I /0.6)−0.015(ANPP t max /RAIN)exp(4.6*GI)
[0025] Once the leaf area index (LAI) is determined, an estimated aboveground net primary productivity (ANPP t est ) may be calculated as follows:
[0000] ANPP t est =ANPP t max *LAI
[0000] Thus, using the maximum amount of productivity possible and factoring in the proportion of leaves and the leaf area index, the method of the present invention can estimate the actual amount of productivity of the grassland at issue.
[0026] In addition to an estimated aboveground net primary productivity (ANPP t est ), the method of the present invention considers the estimated belowground net primary production (BNPP t est ) for the given location. According to McNaughton, (1998) and McNaugton, (1985), the estimated belowground net primary production (BNPP t est ) for a grassland may be calculated based on the annual rainfall using the following formula:
[0000] BNPP t est =917.4 −0.763*RAIN
[0027] Once the estimated aboveground net primary productivity (ANPPt est ) and estimated belowground net primary production (BNPP t est ) are determined, the plant derived SOC (PDSOC) may be calculated from the fire frequency (FIRE) and the lignin and cellulose content (LIGCELL). The fire frequency (FIRE) represents the number of fires every ten years or, alternatively, the fraction of landscape burned each year on average. The fire frequency may be measured based on the burned and unburned areas during the late dry season using satellite images, such as MODIS' Burned Area Product, or similar validated technique. An acceptable method for measuring fire frequency based on satellite image is explained in Dempewolf et al., I.E.E.E. Geoscience and Remote Sensing Letters 4(2): 312-316 (2007), hereby incorporated by reference.
[0028] The lignin and cellulose content (LIGCELL) is determined based on the lignin and cellulose fraction of aboveground tissue. If the lignin and cellulose content of the aboveground plant tissue is not known, it may be measured by sequential digestion of tissue material. For example, all plant material from a given plot, such as 15 by 15 centimeter square, may be clipped and dried. The clipped and dried material may then be digested in an acid detergent to remove the non-lignin, non-cellulose portions, digested in concentrated sulfuric acid, to remove the cellulose, and then subject to ashing at 400 degrees C. for 24 hours to remove lignin, leaving behind only minerals.
[0029] The plant derived SOC (PDSOC) may then be calculated from fire frequency (FIRE) and the lignin and cellulose content (LIGCELL) as follows, where 0.45 represents the carbon content of plant material, as discussed in Tao, G. C., T. A. Lestander, P. Geladi, and S. J. Xiong, Biomass properties in association with plant species and assortments I: A synthesis based on literature data of energy properties, Renewable & Sustainable Energy Reviews 16:3481-3506 (2012), hereby incorporated by reference in its entirety, as follows:
[0000] PDSOC t =LIGCELL*0.45*[ANPP t est *(1−GI)*(1−FIRE)+BNPP t est ]
[0000] In this manner, the method of the present invention accounts for carbon losses as a result of the digested portion of the plant material as a well as losses attributable to fire.
[0030] In addition to the plant derived SOC (PDSOC), the present invention further considers the amount of dung derived SOC (DDSOC) that is placed in the soil based on the lignin and cellulose content (LIGCELL) of the plant material, the carbon content of plant material, the grazing intensity (GI) calculated above, and the aboveground net primary productivity (ANPP t est ) calculated above, as follows:
[0000] DDSOC t =LIGCELL*0.45*GI*ANPP t est
[0031] In calculating total SOC, it is also necessary to account for carbon losses associated with maintenance respiration (MRESP t ). Maintenance respiration (MRESP t ) is a function of the number of wet days (WETDAYS) which is, in turn, determined based on the average annual rain fall as follows as derived from additional data collected by the inventor:
[0000] WETDAYS=(0.00044*RAIN−0.025)*240
[0032] Once the wet days are calculated, the microbial maintenance respiration (MRESP t ) may be calculated based on the number of wet days (WETDAYS) and the soil carbon stocks (SOC t ), adjusted for soil sand content (SAND %) using the formula derived with data from Ruess and Seagle (1994), hereby incorporated by reference:
[0000] MRESP t =WETDAYS*(0.7+0.3*SAND %/100)*(0.00044*SOC t −0.579)
[0033] Finally, the change in sequestered carbon (ΔSOCt) can be estimated by adding the plant derived SOC (PDSOC t ) to the dung derived SOC (DDSOC t ) and then subtracting the carbon lost through microbial maintenance respiration (MRESP t ) as follows:
[0000] ΔSOCt=PDSOCt+DDSOCt−MRESPt
[0034] By setting ΔSOCt=0, the above equation can be solved for the SOCt term in MRESPt to yield an equilibrium SOC eq .
[0000] SOC eq =[PDSOCt+DDSOCt+WETDAYS*(0.579)*(0.7+0.3*SAND %/100)]/[(0.00044*WETDAYS*(0.7+0.3*SAND %/100)]
[0035] Referring to FIG. 3A through 3D , the estimates provided by the method of the present invention are a function of the key input variables of grazing intensity and fire frequency for different combinations (of low (RAIN=450) and high (RAIN=800) rainfall and low (SAND %=25, Fine-Textured Soils) and high (SAND %=65, Coarse-Textured) soil sand content, where the lignin and cellulose content (LIGCELL) was set at 0.3.
[0036] The accuracy of the estimated SOC provided by the method of the present invention with respect to eight discrete grassland locations was evaluated against actual samples collected at those sites. The eight sites varied widely in rainfall, grazing intensity, fire frequency, and soil texture. The method of the present invention fit the observed data extremely well (R 2 =0.95), establishing that the present invention captures important pathways of carbon transfer and, in particular, the importance of plant compensation to grazing and the importance of dung inputs to SOC.
[0037] Table 3 below sets forth the actual measured characteristics for the eight grazed grassland sited used to evaluate the accuracy of the method of the present invention. At the sites, the grazing intensity, soil sand content, and aboveground tissue lignin and cellulose were measured, and the mean annual rainfall and fire frequency over the previous nine years were known.
[0000]
TABLE 3
Mean (±SE) characteristics of the eight study sites in the grazing experiment.
Grazing
Ungrazed
Lignin +
Rainfall
Intensity
Biomass
Cellulose
1999-2008
Soil N
Soil C
(%)
(g/m 2 ,
(%)
(mm/y,
Fires,
(%,
(%,
Site
(N = 3)
N = 3)
(N = 3)
N = 9)
2000-2008
N = 6)
N = 6)
Balanites
32 ± 14
847 ± 133
34.1 ± 2.3
721 ± 86
4
0.19 ± 0.05
1.84 ± 0.13
Barafu
65 ± 4
605 ± 66
34.5 ± 1.9
472 ± 31
2
0.26 ± 0.07
3.14 ± 0.06
Klein's
56 ± 9
691 ± 71
36.3 ± 2.4
771 ± 61
5
0.22 ± 0.03
1.77 ± 0.09
Camp
West
Kemaris
66 ± 3
643 ± 27
31.6 ± 3.1
832 ± 87
4
0.25 ± 0.06
2.67 ± 0.08
che Hills
Kuka
49 ± 4
623 ± 20
37.7 ± 2.4
784 ± 41
5
0.13 ± 0.04
2.13 ± 0.03
Hills
Musabi
28 ± 13
827 ± 251
37.6 ± 1.9
885 ± 63
7
0.14 ± 0.07
2.20 ± 0.21
Plains
Soit
54 ± 13
292 ± 53
35.6 ± 2.1
499 ± 39
4
0.11 ± 0.02
1.91 ± 0.14
Olowotonyi
Tagora
69 ± 12
744 ± 27
31.8 ± 2.8
654 ± 87
5
0.15 ± 0.06
1.85 ± 0.07
Plains
Bulk
Sand
Silt
Clay
Density
Soil P
(%,
(%,
(%, N =
(g/cm 3 ,
Site
(%, N = 6)
N = 6)
N = 6)
6)
N = 6)
Balanites
0.0325 ± 0.0030
51.0 ± 2.5
38.3 ± 4.2
10.7 ± 2.2
1.31 ± 0.14
Barafu
0.1132 ± 0.0038
27.6 ± 2.2
60.6 ± 4.1
11.7 ± 2.0
0.85 ± 0.12
Klein's
0.0059 ± 0.0008
40.6 ± 3.1
35.5 ± 3.3
23.9 ± 2.4
1.07 ± 0.17
Camp
West
Kemaris
0.0500 ± 0.0086
35.5 ± 2.7
52.0 ± 1.8
12.5 ± 2.8
0.96 ± 0.04
che Hills
Kuka
0.0075 ± 0.0005
45.4 ± 1.2
46.2 ± 2.8
8.40 ± 1.3
1.15 ± 0.12
Hills
Musabi
0.0692 ± 0.0063
32.9 ± 4.6
31.2 ± 3.6
35.9 ± 2.9
0.90 ± 0.10
Plains
Soit
0.1240 ± 0.0052
32.1 ± 4.1
55.4 ± 4.1
12.5 ± 2.4
0.84 ± 0.08
Olowotonyi
Tagora
0.0612 ± 0.0030
65.8 ± 3.7
28.0 ± 1.5
6.21 ± 1.3
1.22 ± 0.17
Plains
[0038] As seen in FIG. 4 , the predicted equilibrium soil organic carbon stocks (g/m 2 to 40 cm depth) SOC eq were obtained using the present invention by solving for SOC when ΔSOCt=0. Calculations of SOC eq were accurate when compared to mean observed soil carbon stocks (N=8), thereby demonstrating the accuracy of the present invention. The slope 1.088±0.056 (SE) is not significantly different from 1 (P=0) and the intercept −192.8±567 (SE) is not significantly different from zero (P=0.91), indicating that the model is unbiased. It should be recognized by those of skill in the art that the present invention may be implemented via a computer spreadsheet or by a dedicated computer program or application that is programmed to accept entry of the information and perform the appropriate calculations.
[0039] The method of the present invention may be used to estimate soil organic carbon stocks for the purposes of obtaining certification for a particular carbon credit project and for calculating the appropriate number of carbon credits generated by the project. Using the present invention, a carbon project developer that wants to start a carbon credit projects in a tropical grassland where cattle grazing or fire occurs can perform accurate modeling of soil carbon changes in order to claim carbon credits on a periodic basis, thereby avoiding the need to wait years for the soil carbon changes to be detectable.
[0040] To be used in a carbon credit project, the present invention must be validated for the project area by showing its ability to predict initial carbon stocks as a consequence of past management actions and conditions, such as rainfall, plant species composition, grazing intensity, fire history, etc., in different subareas (strata) within the project area that differ strongly in past conditions or in management activities. The project area-validated model is used first to back-cast soil carbon dynamics to assess the maximum SOC that likely occurred in the previous 10 years as the baseline SOC, as required by the Verified Carbon Standard as an uncertainty deduction for activity-based projects. The same model is then used to calculate an expected future equilibrium SOC under proposed project activities, the time in years to reach this equilibrium, and the average annual increment in SOC sequestration expected under the proposed project activities.
[0041] Typically, the user would define a project area and identify or measure the key input parameters of the present invention, namely, mean annual rainfall (RAIN), mean grazing intensity that has been in effect for the previous 10-30 years (GI), aboveground plant lignin and cellulose content (LIGCELL), fire frequency (FIRE), and soil texture (SAND %) that apply to that area. The user would then calculate, with the present invention, the equilibrium SOC under these historical conditions SOC eq and then calculate SOC that occurred 10 years earlier as the maximum SOC that occurred in the past 10 years as a conservative starting point for the carbon project, SOC 0 . Then, the SOC at equilibrium under a proposed carbon project activities in the project area can be calculated (SOC act ). These two calculations from the present invention would then be used to calculate the average annual change in soil carbon that would result from the project activities, which is then used to determine the number of carbon credits that can be claimed from the project. | A method of estimating the soil organic carbon (SOC) stocks for a grassland based on the plant-derived SOC plus the dung-derived SOC minus the carbon lost through microbial maintenance respiration. The plant-derived SOC, dung-derived SOC, and microbial maintenance respiration are estimated by considering the effect of one or more of the lignin and cellulose content of the plant material, the estimated annual aboveground and belowground plant production, the grazing intensity, the number of fires per year, the mean annual rainfall, the belowground net primary production, and the soil texture. The method thus provides an allowance of plants to compensate for grazing without losing leaf area, and the diversion of carbon through grazing animals and into soil through the deposit of dung. | 8 |
This application is a divisional of U.S. application Ser. No. 09/641,693, filed Aug. 18, 2000 now U.S. Pat. No. 6,601,191 which is a continuation of U.S. patent application Ser. No. 09/031,391, filed Feb. 26, 1998, now U.S. Pat. No. 6,112,314 which is a continuation of U.S. patent application Ser. No. 08/736,195 filed Oct. 24, 1996, now U.S. Pat. No. 5,771,346 all of which are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to multistate memory devices, and more specifically, to an apparatus and method for detecting and correcting an over-programming condition in a memory cell of such a device.
BACKGROUND OF THE INVENTION
In conventional single-bit per cell memory devices, the memory cell assumes one of two information storage states, either an “on” state or an “off” state. The binary condition of “on” or “off” defines one bit of information. As a result, a memory device capable of storing n-bits of data requires (n) separate memory cells.
Increasing the number of bits which can be stored using single-bit per cell memory devices depends upon increasing the number of memory cells on a one-for-one basis with the number of bits of data to be stored. Methods for increasing the number of memory bits stored in a memory device composed of single-bit capacity cells have relied upon techniques such as manufacturing larger die which contain more memory cells, or using improved photolithography techniques to build smaller memory cells. Reducing the size of a memory cell allows more cells to be placed on a given area of a single chip.
An alternative to single-bit per cell designs is the storage of multiple-bits of data in a single memory cell. One type of memory in which this approach has been followed is an electrically erasable and programmable device known as a flash memory cell. In flash cells, programming is carried out by applying appropriate voltages to the source, drain, and control gate of the device for an appropriate time period. This causes electrons to tunnel or be injected from a channel region to floating gate. The amount of charge residing on the floating gate determines the voltage required on the control gate in order to cause the device to conduct current between the source and drain regions. This voltage is termed the threshold voltage, V th , of the cell. Conduction represents an “on” or erased state of the device and corresponds to a logic value of one. An “off” or programmed state is one in which current is not conducted between the source and drain regions and corresponds to a logic value of zero. By setting the threshold voltage of the cell to an appropriate value, the cell can be made to either conduct or not conduct current for a given set of applied voltages. Thus, by determining whether a cell conducts current at a given set of applied voltages, the state of the cell (programmed or erased) can be found.
A multi-bit or multistate flash memory cell is produced by creating multiple, distinct threshold voltage levels within the device. Each distinct threshold voltage corresponds to a set of data bits. This allows multiple bits of binary data to be stored within the same memory cell. When reading the state of the memory cell, each bit set has a corresponding decode value of ones and zeros depending upon the conduction of the device at the threshold voltage level detected. The threshold voltage level for which the cell does not conduct current indicates the bit set representing the data programmed into the cell. Proper data storage requires that the multiple threshold voltage levels of a memory cell be separated from each other by a sufficient amount so that a level of a cell can be programmed or erased in an unambiguous manner. The relationship between the data programmed into the memory cell and the threshold voltage levels of the cell depends upon the data encoding scheme adopted for the cells.
In programming a multistate memory cell, the objective is to apply a programming voltage over a proper time period to store enough charge in the floating gate to move the threshold voltage to a desired level. This level represents a state of the cell corresponding to an encoding of the data which is to be programmed into the cell. It is necessary to be able to program multiple bits (and as a result, multiple memory cells) at the same time in order to produce a commercially desirable memory system which can be programmed within a reasonable amount of time. However, a problem arises when a number of bits are to be programmed at the same time. This is because the characteristics of each bit are different (due to minor variations in the structure and operation of the semiconductor devices which comprise the memory cells), so that variations in the programming speed of different cells will typically occur. This results in bits that become programmed faster than others, and the possibility that some bits will be programmed to a different state (the cell will programmed to a different threshold voltage level) than intended.
As noted, fast programming of multiple memory cells can result in overshooting the desired threshold voltage state of some cells, producing an error in the data being stored. In some flash memory systems, this problem can remain unknown and result in a long (and unproductive) programming cycle. This can occur because the memory system is controlled to carry out the programming operation until the programming data compares with the data applied or a maximum pulse number, voltage, and programming time occur before it aborts and sets an error flag or performs the programming operation at an alternate storage location. In mass storage systems where programming speed is a key performance criteria and lengthy re-programming and erase operations are not desirable, a method for detecting and handling over-programming of bits during programming operations would be more efficient.
In discussing the problem of over-programming of a multistate memory cell, two primary issues need to be addressed: 1) Overshoot in the threshold voltage level of the cell state (programming a cell to a level corresponding to incorrect data) needs to be detected early in the programming operation in order to stop the programming cycle. This eliminates the time wasted in trying to get the memory cells to achieve a verified threshold voltage level; and 2) An over-programmed cell would normally result in a file being marked as bad or obsolete and written elsewhere in the memory array. A procedure that allows recovery (correction) of the bad cells in a multistate device will save the reprogramming effort and boost performance, allowing for more efficient use of the programming time and storage capacity.
The first issue is not a problem when dealing with conventional two-state memory cells. When detecting an erased state compared to a programmed state, the only requirement is to detect that the programming operation progressed far enough that a programmed charge reference level was exceeded, so that the cell would indicate a programmed state when read. For the two-state memory cell, a program verify sequence consists of carrying out a program operation on the memory cell, then reading the programmed data and comparing it with the desired state (original) of the data being written. If this compare step fails, the cell is given another programming pulse and a compare operation is again performed to see how the programmed data compares with the original data. This sequence is repeated for two-state memory systems until all cells compare, at which time a programming operation is considered successful, or until the number of programming attempts reaches a pre-set limit and the programming operation is aborted.
In multistate memory devices, there are intermediate states that are programmed by setting specific threshold voltage levels within small variations. If the conventional approach to programming is used (a read and compare is performed), a cell that is over-programmed beyond the desired threshold voltage level will never compare properly. The failure of the compare operation will cause the memory cell to be repeatedly programmed, in an attempt to get the error bit to agree to the desired data. The bit failing the compare operation will cause a continuation of the program and compare cycles until the maximum number of programming attempts is reached. This wastes precious time and is an inefficient way of using the memory system.
There is another possible scenario where a memory cell would compare properly during the program verify sequence, but would fail a subsequent read operation because the cell threshold voltage was too high. To account for this possibility, a second verify operation should be performed to check for the upper margin of the cell threshold voltage (note that the standard verify operation checks for the lower margin of the threshold voltage). Circuitry and a method for performing the desired analog verification operations are described in the commonly assigned U.S. Patent Applications entitled “Apparatus for Reading State of Multistate Non-volatile Memory Cells”, Ser. No. 08/736,194, and “Method for Performing Analog Over-program and Under-program Detection for a Multistate Memory Cell”, Ser. No. 08/736,568, both filed the same day as this application and the contents of which are hereby incorporated by reference. The above-referenced applications discuss how the data required by the circuitry described in the present application is generated.
What is desired is a means for detecting an over-programming condition in a multistate memory cell. It is also desired to have a means for identifying over-programmed cells and correcting the data programmed in the cell to its intended value.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus and method for detecting an over-programming condition in a multistate memory cell. The invention is also directed to a means for identifying the over-programmed cells and providing an alternate location at which to write the data intended for the over-programmed cell.
These goals are achieved by use of a over-programmed state detection circuit which generates an error signal when the data contained in a multistate memory cell is found to be over-programmed relative to its intended programming (threshold voltage level) state. Upon detection of an over-programmed cell, the programming operation of the memory system is modified to discontinue further programming attempts on the cell. The over-programmed state detection circuit is also used to assist in correcting for the over-programming state, permitting the programming error to be compensated for by the memory system.
The over-programming circuit operates by comparing the desired state (intended data) of the memory cells with the state read from the cell after a programming operation. If a cell has been programmed beyond its desired state (i.e., entered program state 2 when trying to program it to program state 1), the over-program detection circuit prevents continual programming attempts which would normally occur until the programming algorithm fails and the programming operation is aborted. This saves wasted programming time, and allows a memory system controller to save the bit which failed the programming operation and write it at an alternate location. Saving the error data in this manner and substituting the correct data value back at a later time prevents the block being programmed from being identified as faulty. This saves memory capacity and the time required to move the entire file containing the faulty bit to a new memory location.
Further objects and advantages of the present invention will become apparent from the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a non-volatile memory system which includes the over-program detection circuit of the present invention.
FIG. 2 is a block diagram of the control logic circuitry contained in the non-volatile memory system of FIG. 1 , which is used for detecting the over-programming of a memory cell.
FIG. 3 is a schematic diagram of the over-program detection circuit of the present invention.
FIG. 4 is a block diagram of a circuit which incorporates the over-program detection circuitry of FIG. 3 and which can be used to check each byte of data for the existence of an over-programming error.
FIGS. 5A and 5B show two possible formats in which the information regarding the over-programmed bits can be appended to the data contained in a data field of the memory device.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, FIG. 1 is a block diagram of a non-volatile memory system 10 which includes the over-program detection circuit of the present invention. Memory system 10 includes non-volatile memory device 12 , which is typically in the form of an array of memory cells. The operations of the system, such as the reading, programming, and erasing of the memory cells contained in memory device 12 are controlled by control logic module 14 . Control logic module 14 contains, among other circuitry, an internal state machine (ISM) used to sequence the operations performed on the memory cells and high voltage pulse generators used for programming and erasing the cells. In some configurations, control module 14 may also contain sense amplifiers used to read the contents of a cell. Control module 14 receives instructions from micro-controller 16 and communicates with a host processor (not shown) via host interface bus 18 .
Static random access memory (SRAM) module 20 contains the program implemented by micro-controller 16 for use in controlling the operations of controller 14 and memory system 10 . This program is typically loaded into SRAM module 20 when system 10 is powered up. SRAM module 20 can also contain look up tables used in managing the files of data stored in memory device 12 . Memory device bus 22 is used to send control commands from control logic module 14 to memory device 12 , and to exchange the data read from or written to memory device 12 with control logic module 14 and the host processor. Power supply module 24 acts to condition operating voltage 28 to provide the source of the low voltages (approximately 3 volts) used for operating memory system 10 . Power supply module 26 similarly conditions voltage source 28 to provide the source of the high voltages (approximately 12 volts) used for programming or erasing the memory cells contained in memory device 12 . It is noted that power supply module 26 may be implemented in the form of a charge pump or a dc-to-dc converter whose design is based on inductive principles.
FIG. 2 is a block diagram of the circuitry contained in control logic module 14 of the nonvolatile memory system 10 of FIG. 1 which is used for detecting the over-programming of a memory cell. In the figure, control logic module 14 is shown connected to memory device 12 (shown in FIG. 1 ) via bus 22 . Data buffer 100 contains the original data which is intended to be programmed into the memory cells of memory device 12 . As the data in each memory cell is read during a programming verify operation (which includes the over-programming condition check), the corresponding data contained in data buffer 100 is also accessed. The two sets of data are compared, a byte at a time, using over-program detection circuitry 106 .
As the data programmed into a memory cell is read from memory device 12 , and the intended data is read from buffer memory 100 , over-program detection circuitry 106 acts on a byte wide data stream in tandem with the programming operations being performed by programming module 102 . Programming module 102 executes the data processing operations involved in programming the multistate memory cells. These operations may include, for example, repeated programming cycles followed by comparisons between the programmed data and the desired state of the cells. In this case programming module 102 would access the contents of the memory cells and the data from buffer 100 and then perform comparison and data modification operations using an arithmetic logic unit (ALU) and control elements. During an iterative programming operation, the data would be loaded into a data out register contained in module 102 and sent to memory device 12 via buffers 122 . Thus, while programming module 102 is performing the data comparison and modify operations in order to correctly program a cell, over-program detection module 106 is checking to see if the cell has been over-programmed during the cycle.
A multistate byte that contains an over-programmed bit will cause an over-program error flag to be set. This error signal 124 indicates to controller processor 16 that an over-program error has occurred, and causes the byte containing the data to be stored in holding latch 108 . As will be described, processor 16 later appends this data to the end of the data stream with a flag indicating its presence. When an error is detected and the byte is no longer valid, processor 16 will force the contents of a data out register contained in programming module 102 to be all ones. This will stop further programming attempts and remove the over-programmed byte from the data checking operations. This has the effect of speeding up the programming operation within the memory device and the system.
Data is gated from buffer 100 starting at the beginning of a sector of memory. Direct memory access (DMA) address generator 110 is responsible for accessing the appropriate data from buffer 100 and works in conjunction with data pipeline 112 to send the data to over-program detection circuitry 106 and programming module 102 . As noted, programming module 102 performs data modify and compare operations which are designed to program a memory cell to a desired state.
As noted, data is sent through the ALU contained in programming module 102 and loaded into a data out register. The data is enabled onto flash memory bus 22 via buffers 122 (which are also used in loading data from memory device 12 into over-program detection circuitry 106 and programming module 102 ), and loaded into flash memory device 12 by means of a strobe pulse on the memory device-controller interface.
A read operation for retrieving data from memory device 12 for purposes of verifying a programming operation or for an over-program detection operation consists of sending the starting address of the desired data from processor 16 to memory device 12 and then strobing the read data into controller 14 . As data is brought into controller 14 it is sent through programming module 102 and is then loaded into read pipeline circuitry. The read data is then transferred to data buffer 100 by means of DMA control. The data is checked for errors by error correcting code (ECC) hardware (not shown), allowing controller 14 to correct the data.
As noted, over-program detection module 106 contains the circuitry which implements the over-programming detection operations of the present invention. There are two basic possible approaches to designing an over-program detection circuit. The first is a logic gate implementation for each cell. For a multistate memory cell having four states, the memory system takes two bits of input data and stores these two bits in a memory cell by encoding them in a binary state. One way of encoding the four possible states is shown below:
Bit 1 Value (I B ) Bit 0 Value (I A ) State 1 1 Erased State 1 0 First State 0 0 Second State 0 1 Third State
Note that bit zero is labeled input bit A (I A ) and bit one is labeled input bit B (I B ) in the following discussion.
This is one example of a possible encoding scheme for a four state cell. Other encoding methods could be used with adjustments in the circuits to reflect these changes. The above code is used because it assists with error correction (ECC). A state that is in error by one binary value when being read would result in a single bit error instead 2 bit error which would result using a non gray scheme. By adjusting the encoding scheme to reflect the most likely over-programming errors, errors in which the programmed state is one state off on reads will result in a 1 bit error instead of two. The goal of over-programming detection circuit 106 is to detect data read back from the memory device at a higher state than the intended programming data. For example, a value of (1) (0) being programmed into a memory cell would result in an error if states (0) (0) or (0) (1) were detected upon reading back the programmed data. A state of (0) (0) would report an error if a programmed value of (0) (1) was read.
FIG. 3 is a schematic diagram of the over-program detection circuit 106 of the present invention. As noted, the erased state is set to have the 2 bit value of (1) (1). The first state checked for by circuit 106 is the erased state. If the original data that was to be contained in the memory cell was indicative of an erased state, then no programming of the cell was required. An over-programming error would result if the cell indicated a state other than an erased state upon reading back its contents. AND gate 200 is used to detect the presence of an erased state in the original data. Initial data bits I A and I B corresponding to the original data are obtained from data buffer 100 of FIG. 2 and provided to circuit 106 , where they form the inputs for gate 200 . With input bits I A and I B both high, the output of gate 200 is high. The output of gate 200 is provided as one of the inputs to AND gate 202 .
NAND gate 204 is used to detect the presence of a zero in signals R A and R B , which are the data read back from memory device 12 . Note that read back bit zero is labeled bit A (R A ) and read back bit one is labeled bit B (R B ) in the following discussion.
If either R A or R B is a zero, then the data in memory device 12 does not correspond to an erased state, and an error has occurred during the programming operation. With either R A or R B zero , the output of NAND gate 204 goes high. This output is provided as one of the inputs to gate 202 , in addition to the previously mentioned output of gate 200 . A third input to gate 202 is a global enable signal 205 . The combination of an erase state (1) (1) being detected by gate 200 and gate 204 detecting a data read back state other than an erased state, along with enable signal 205 , results in the output of gate 202 going high. This indicates an erase state over-programming error. The output of gate 202 is provided as an input to OR gate 208 . Thus, if the output of gate 202 is high, the output 218 of gate 208 will be high, indicating an over-programming error.
The next over-programming error checked for is the first programming state, represented by the two bit values (1) (0). AND gate 210 is used to detect the presence of the first state in the initial data. Initial data bits I A and I B are again obtained from data buffer 100 of FIG. 2 and provided to circuit 106 , where they form the inputs for gate 210 . Note that I A is inverted prior to being input to gate 210 . A low logic value for input bit I A and a high value for bit I B (corresponding to a (1) (0) state) causes the output of gate 210 to be high. The output of gate 210 is provided as one of the inputs to AND gate 212 .
Since the program states above the first state are (0) (0) and (0) (1), an over-programming error is present if the value of read back bit R B is zero. As indicated by the figure, the inverted value of R B is also provided as an input to gate 212 . A third input to gate 212 is global enable signal 205 . With R B being low (corresponding to a value of zero), a high output from gate 210 (indicating a first programming state), and the presence of enable signal 205 , the output of gate 212 will be high, indicating the presence of a first programming state over-programming error. The output of gate 212 is provided as an input to OR gate 208 . Thus, if the output of gate 212 is high, the output 218 of gate 208 will be high, indicating an over-programming error.
The next over-programming error checked for is the second programming state, represented by the two bit values (0) (0). AND gate 214 is used to detect the presence of the second state in the initial data. Initial data bits I A and I B are again obtained from data buffer 100 of FIG. 2 and provided to circuit 106 , where they are inverted to form the inputs for gate 214 . A low logic value for input bits I A and I B causes the output of gate 214 to be high. The output of gate 214 is provided as one of the inputs to AND gate 216 .
Since the only program state above the second state is (0) (1), an over-programming error is present if the value of read back bit R A is one and the value of read back bit R B is zero. As indicated by the figure, the values of R A and R B are also provided as inputs to gate 216 . A fourth input to gate 216 is global enable signal 205 . With R A being high (corresponding to a value of one), R B being low (corresponding to a value of zero), a high output from gate 214 , and the presence of enable signal 205 , the output of gate 216 will be high, indicating the presence of a second programming state over-programming error. The output of gate 216 is provided as an input to OR gate 208 . Thus, if the output of gate 216 is high, the output 218 of gate 208 will be high, indicating an over-programming error.
Over-programming of the third program state (represented by the bit values (0) (1)) is not possible because there are no states having higher threshold voltage values. Thus, no checking for over-programming of this state is required.
The over-program detection circuit of FIG. 3 can be extended to work with memory cells having greater than four programming states. For example, if each memory cell has eight programmable states, then three bits of the data from buffer 100 would be examined, along with three bits of data read back from a cell contained in memory device 12 . This process can be extended to other binary based data encoding methods for an increasing number of states. It is noted that one skilled in the art would be capable of designing a logic circuit similar to that of FIG. 3 for use with a multistate memory cell having more than four programming states.
As the number of states which can be programmed into each memory cell increases, the amount of decode logic (such as that shown in FIG. 3 ) continues to increase. At some point it may become more economical to implement the over-program detection function in the form of a RAM, ROM, EPROM or EEPROM small memory look up table. In this design, data R A , R B , I A , and I B would be input to a memory element containing the look up table. The look up table would perform the operation of comparing the data intended to be programmed (I A and I B ) with the data read back from the memory device (R A and R B ), with an error signal being produced to indicate an over-programming condition.
While the use of a look up table is straight forward and easy to implement, it may be too costly for some designs. Small memory look up table elements require a lot of die area and are not practical if a large number of bits are being examined. However, this approach could be very attractive for a serial memory with only a few bits being programmed at one time. This look up table approach also offers design flexibility if several different data encoding methods are implemented in a memory, or are required to be supported by a controller which interacts with differing types of memory.
Whichever implementation of the over-program detection circuitry is used, a number of the circuits or look up tables would be required to check more than one memory cell at a time for the presence of an over-programming condition. For example, in order to check each byte of data in parallel, four of the over-program detection circuits shown in FIG. 3 (or a memory containing a corresponding look up table) would be used for a four state memory cell (a sixteen state cell would typically use two over-program detection circuits per byte). Such an implementation would utilize an eight bit data bus. Other configurations in which a greater number of bits are checked in parallel are also possible, subject to the capacity of the data bus. It is noted that the over-programming detection circuitry can be built into the memory devices themselves (placed on the same chip as the memory cells) or can be placed in an off-chip controller for use in performing over-program detection for multiple memory devices. One benefit of placing the detection circuitry in an off-chip controller is that it allows the cost of the circuitry to be amortized over multiple memory devices, instead of duplicating the function in each memory device.
In the configuration to be discussed, an eight bit bus is used and eight bits (one byte) of data is checked for an over-programming condition at a time. Thus, the over-program detection circuitry or look up table is duplicated four times. FIG. 4 is a block diagram of a circuit 300 which incorporates the over-program detection circuitry 106 of FIG. 3 and which can be used to check each byte of data for an over-programming error.
In FIG. 4 the data programmed into each byte of memory device 12 is provided to circuit 300 by means of data inputs 302 (labeled as pins D 0 through D 7 in the figure). The eight bits of data 302 represents the data contained in four memory cells, with the data from each cell being represented as two bits, R A and R B . Data buffers 304 are used to load the data into circuit 300 . Each pair of bits R A and R B serve as an input to one of the four over-program detection circuits 106 . A second input to each over-program detection circuit 106 is the data which is intended to be programmed into the memory cells. This data is represented as four pairs of bits I A and I B in the figure. The output of each over-program detection circuit 106 is an error signal 218 which indicates if an over-programming error is present in the data being checked.
The design of circuit 300 allows eight bits of data from memory device 12 to be checked for over-programming at the same time. As a byte of data (consisting of bit pairs R A and R B for each cell) is read from memory via inputs 302 , the original data intended to be programmed into the memory device (bit pairs I A and I B ) is read from data buffer 100 , allowing for a direct byte by byte compare. The output 218 of each over-program detection circuit 106 is input to OR gate 306 . In the event that one of the memory cells in the byte being checked has been over-programmed, one of the error signals 218 will become active. This will cause the output of gate 306 to be high.
The output of gate 306 is provided as an input to AND gate 308 . A second input to gate 308 is a clock signal 310 , whose function will be discussed. The third input to gate 308 is a over-program detection enable signal 312 . When the output of gate 306 is high (indicating an over-programming error) and clock signal 310 and enable signal 312 are high, the output of gate 308 is high. The over-program error signal (the output of gate 306 ) is strobed by clock signal 310 . The strobed clock signal has two functions. Firstly, it is used to indicate the occurrence of an over-programming error by setting error register 318 . This causes a signal to be sent to direct memory access (DMA) address generator 110 , interrupting its operation. DMA address generator 110 is responsible for providing the addresses used for accessing the appropriate data from buffer 100 . The interruption prevents further checking of the data in the memory device. In addition, the strobed clock signal sets register 314 which contains the address of the byte containing the over-programmed data. The signal from register 318 is sent to the host microprocessor as a status bit and/or interrupt bit by means of data line 315 . This notifies the processor of an over-programming error. The processor then executes an operation to read the address of the data containing the over-programming error contained in register 314 . The processor then reads buffer 316 which transfers the over-program error signals to the processor, allowing the processor to determine which of the checked bits was over-programmed.
The processor reads the data byte of the original data in memory (using the address supplied by DMA address generator 110 ) and saves the correct data for the bit pair in the byte that corresponds to the over-programmed bit pair. The processor saves the contents of the two registers for later use. When these two registers have been saved, the processor clears (resets) error register 318 , causing the control signal supplied to DMA address generator 110 to go low, which allows the over-programming detection process to continue. The group of bits found to have an error are skipped, as continued processing would be a waste of time. Controller 14 continues to verify the rest of the data for that sector of memory. If other over-program errors are detected, the same halt and save sequence is repeated. At the end of the sector of data, controller 14 appends the saved information to the sector data. As will be discussed, the appended data will be used on future reads of the sector to recover the original data written to the memory cells found to be over-programmed.
FIGS. 5A and 5B show two possible formats in which the information regarding the over-programmed bits can be appended to the data 400 contained in a sector of the memory device. If there is a minimal number of errors the processor stores a marker 402 indicating that over-program replacement bits 404 are stored. In this format the error replacement bits 404 (the correct data) are stored along with the address and bit location 406 indicating where the replacement bits are to be inserted when reading the data.
If more over-programming errors exist than the row has bits for storing the information in the format shown in FIG. 5A , the system switches to the format of FIG. 5B . In this format, the value of flag 402 indicates that the over-program error data is stored in the alternative data format. Flag 402 is followed by the number of over-programming errors detected 408 , and the address 410 of an alternate memory location. Address 410 is a pointer to another location in memory where the replacement bits and associated addresses are stored.
Thus, when over-program errors are detected the present invention compensates for the over-programmed bit locations by storing the correct data bits at alternate locations with address pointers indicating where the correct data is to be inserted. The correct data is then recaptured by the following process.
During a read operation of a sector of memory, the controller first reads the footer area (that section which contains the over-program detection marker, correct data bits, and addresses for replacing the incorrect bits). The controller checks to see if the special overshoot (over-programming error) flags are set, indicating that over-programming error bits are stored and need to be recovered. The overshoot flags are data patterns that describe the format of the stored data. If the flags are not set, a standard read operation is initiated. However, if either of the flags are set a special read recovery sequence is initiated. The controller will read the sector data into a buffer memory. The bad overshoot bits will also be loaded into buffer memory as part of the sector read. After this data is loaded, the controller will replace the detected over-programmed bits with the saved bits, read back at the start of the operation. Once these bits have been substituted in buffer memory, the data in the sector buffer should be correct. These processing operations are similar to those referred to when discussing the operations of programming module 102 . The correct data is verified by taking the data from buffer memory and inputting it to the ECC circuitry. After the data has been input to this circuitry, the ECC bits from the memory device are read in and clocked into the ECC circuitry. At the end of this clocking sequence, any errors should be seen by the error detection bits in hardware. If no error is detected, then the data is good and can be sent to the host processor. If an error is detected, then ECC correction will be invoked before sending the data to the host.
In the above read recovery procedure, if the second format of FIG. 5B was detected, an additional step would be required before starting the read data operation. The controller would read the pointer indicating where the over-program information is stored. It will then take this data and have the controller read this location, gathering the replacement bits (the correct data) and the bit address pointers. Once these bits are input and saved in the controller the read recovery operation proceeds as described.
The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described, or portions thereof, it being recognized that various modifications are possible within the scope of the invention claimed. | An apparatus and method for detecting an over-programming condition in a multistate memory cell. The invention is also directed to identifying the over-programmed cells and providing an alternate location at which to write the data intended for the over-programmed cell. An over-programmed state detection circuit generates an error signal when the data contained in a multistate memory cell is found to be over-programmed relative to its intended programming (threshold voltage level) state. Upon detection of an over-programmed cell, the programming operation of the memory system is modified to discontinue further programming attempts on the cell. The over-programmed state detection circuit is also used to assist in correcting for the over-programming state, permitting the programming error to be compensated for by the memory system. | 6 |
[0001] The present U.S. patent application is a Division of U.S. patent application Ser. No. 11/103,785, filed on Apr. 12, 2005, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to printing, scanning and document authentication technology, and in particular to a method and system for generating and authenticating documents using stored electrostatic patterns.
[0004] 2. Description of Related Art
[0005] Document authentication technologies are increasingly in-demand as technologies for counterfeiting improve. Further, due to the ease of document alteration possible with today's computer document processing tools, needs for verification that a document is an unaltered original are also continuously increasing.
[0006] Existing technologies for verification include microscopic watermarks and magnetic ink patterns such as those used on currency and bank notes. A pattern that is not visible to the human eye or not visible without proper detection devices is more difficult to duplicate and/or alter. Technologies to thwart the security measures afforded by existing technologies emerge as those technologies are implemented or improved upon.
[0007] Applications of the above-mentioned security patterns are generally provided in automated printing process, but it would be useful to provide for such processes with respect to handwritten instruments. However, the technology required to implement “hidden” patterns within a document typically has a high cost that makes it prohibitive to incorporate watermarking or magnetic marking techniques within a handheld device such as a pen.
[0008] Similarly, it is typically not cost-effective to incorporate the above-described security marking techniques within a low-cost printer, as to be effective, a microscopic watermark must not be renderable by a typical photo-copier or printer and a magnetic marking process typically requires a second pass with a special device that magnetizes domains within the magnetic ink.
[0009] U.S. Pat. No. 6,530,602 discloses including machine-readable patterns of an invisible substance including binary patterns or bar codes that are printed on a document and later used to verify authenticity. The substance has physical properties that are detectable via machine, such as luminescent, magnetic, electroconductive or other mechanical properties. However, the above-referenced patent discloses only the presence or absence of an applied substance and does not contemplate application of electrostatically-detectable substance, nor a system for the production and verification of handwritten documents.
[0010] It is therefore always desirable to provide new methods and systems for document authentication. It is further desirable to provide such methods and systems having a low associated cost. It is also desirable to provide such methods and systems that can be applied to handwritten documents.
BRIEF SUMMARY OF THE INVENTION
[0011] The objective of providing new low-cost techniques for document authentication is provided in methods and systems for generating and reading a document having embedded electrostatic pattern information.
[0012] Paper is printed or hand-written with an ink that includes a plurality of permanently charged electric monopole elements, which may be two pluralities of electric monopole elements having opposite charge. The electric monopole elements are suspended in a liquid binder that is either cured by drying, exposure to air or via another curing process. The paper can be exposed to an electrostatic field that generates a pattern in the document while the ink cures or the ink may be jetted through a print head such as those found in inkjet printers, or written by a pen having an intermittently selectable ink source or additive source that provides for addition of the monopole elements to the ink. When the ink has cured, a permanent charge pattern is available for detection at the surface of the document, which can be used to verify the authenticity of the document by reading the charge pattern with an electrostatic scanner.
[0013] The charge pattern may be tied to visible properties in that the polarity of the dipole elements may be associated with a white or black dye or dyes of differing color. Alternatively, or in combination, “invisible” ink may be printed by using dipole elements of a transparent or neutral color (e.g. white dyed dipole elements on a white background) and another non-charged ink can be used to produce the image of the document. Also, alternatively or in concert, a watermark may be printed using the charged-dipole ink or the ink may be used for the actual document image/text. The pattern of the charged-dipole ink may be a graphical pattern or may contain data such as a security certificate, information associated with the document itself or other data that is to be provided invisibly in the document.
[0014] The foregoing and other objectives, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiment of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0015] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein like reference numerals indicate like components, and:
[0016] FIGS. 1A-1D are exemplary patterns as produced in a document in accordance with embodiments of the present invention.
[0017] FIGS. 2A and 2B are diagrams depicting document generating devices in accordance with an embodiment of the invention.
[0018] FIG. 3 is a diagram depicting a document verifier in accordance with an embodiment of the present invention.
[0019] FIG. 4 is a flowchart depicting a method in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] With reference now to the figures, and in particular with reference to FIGS. 1A-1D , techniques of the present invention are illustrated by pictorial diagrams that show surfaces of documents in accordance with an embodiment of the present invention are produced and readable by systems in accordance with embodiments of the present invention. Each of the surfaces contains regions printed or written with a liquid medium containing electrostatic monopoles that are subsequently adhered in place by drying or curing of a binder in the ink within which the monopoles are suspended.
[0021] The monopoles employed in the present invention are permanently charged, generally in the form of a dielectric sphere that is commercially available for use in sub-elements of larger spheres used in electronic ink displays. U.S. Pat. No. 6,842,165 describes such displays and “electrophoretic” inks and is incorporated herein by reference. An electrophoretic ink is defined by the above-incorporated application as a visible ink containing charged particles. The present invention does not require that pigment be provided in the ink, only that the ink contain the charged particles. The above-incorporated patent application is directed toward new electronic ink displays that contain the sub-element (monopole) spheres within a larger sphere (microcapsule) and permit the sub-element spheres to move only within the larger spheres, which provide an improvement in the “electronic paper” technology described. Prior to the use of the microcapsules, electronic paper based on electrphoretic ink had poorer persistence characteristics.
[0022] In the present invention, the monopoles are used without the enclosing spheres and are permanently affixed at creation of a document, thus the persistence of the electrophoretic ink is not at issue. The document blank form is generally paper, but electrostatic patterns may also be generated on cardboard boxes, plastic, or any other surface to be printed with an image or information for which it is desirable to later authenticate the image or information. As such, it should be understood that the term “document” as used herein applies to the above-listed media and articles such as mailing labels, computer optical media labels (either direct-printed or applied), and so forth.
[0023] Referring now to FIGS. 1A-1D various document surfaces as may be generated and verified by methods and systems according to embodiments of the invention are shown. FIG. 1A illustrates a document containing a printed image 10 that has electrostatic monopoles embedded in patterns within the ink forming the characters. The patterns may be made very small and may be repetitive or unique. The whitespace can also be marked with patterns, as the electrostatic ink can be made invisible or with a neutral color (generally white) matching the document background. An authentication mark 12 , which may also be made visible or invisible can be formed with “electrostatic” ink and used to verify the authenticity of the document, either by pattern-matching the shape, reading binary data encoded within the mark and/or by comparing the visual features of the mark with hidden electrostatic features.
[0024] FIG. 1B illustrates a document having a watermark 16 , which can also be made visible or invisible and can be provided on stock paper, serving as an electronic “letterhead” that is restricted for use to certain personnel, or may be printed at the time of adding text or image information 14 to the document. Letterheads themselves may also serve as the watermark 16 pattern, providing a visible and verifiable form to which content is added later.
[0025] FIG. 1C illustrates the use of the invention in handwriting. Embodiment of the inventions include pens for handwriting that can write an ink containing permanent electrostatic monopoles and may have selectable ink vessels and/or tips that dispense electrostatic inks of either charge polarity and optionally a regular ink. If a regular ink is employed, the electrostatic ink(s) may be invisible. For illustration, if the author of the document in FIG. 1C selects a visible positively charged ink for heading 18 A, a non-charged ink for body text 18 B and a negatively charged ink for signature 18 C, such a pattern can be recalled by the author to verify the authenticity of the document.
[0026] FIG. 1D illustrates a detail that may be embedded in any of FIG. 1A or 1 B, as described above or used alone in visible or invisible form to encode data. The detail is a 2-Dimensional bar code 19 as in common use in visible form for labeling. However, if a visible form of bar code 19 is used, an electrostatic code that may or may not match the visible code may be embedded in bar code 19 . In any form of binary data (or other numeric symbol representation of data) that is embedded in the documents produced by a method and apparatus in accordance with embodiments of the present invention, decryption keys may be embedded in the document for decoding other data in the page or relating amongst pages of a document by decoding other data in other pages, or for verification against a database. Database verification is not limited to encryption/decryption keys, but may also include unencrypted storage of patterns that are embedded in documents or storage of encrypted certificates that can be verified by electrostatically encoded information read from the document to be authenticated.
[0027] Referring now to FIG. 2A , an apparatus in accordance with an embodiment of the invention is depicted in the form of a pen 20 . Within pen 20 , multiple ink barrels (vessels) 21 are selected by buttons 22 to cause tip 23 to protrude for writing. Pen 20 may contain one such barrel having electrostatic ink of one polarity, or may have multiple selectable barrels with two or more of: electrostatic ink of negative polarity, electrostatic ink of positive polarity and visible non-electrostatic ink. While a single electrostatic ink barrel can provide verification either by use in concert with another writing instrument, a selectable barrel pen provides more flexibility in generating hidden authentication information, and can provide for an instrument that can write visibly with no electrostatic feature or alternatively with visible or invisible electrostatic marking.
[0028] Referring now to FIG. 2B , another apparatus in accordance with another embodiment of the present invention is shown in the form of an ink-jet printer. An ink-jet head 25 has multiple nozzles 24 coupled to one or more vessels 27 , at least one of which contains an electrostatic ink containing the above-described monopoles. A printer control 26 provides for interface and operation of the printer and generally comprises a processor, memory and interface circuits. Printer control 26 is electrically coupled to a platen 28 for moving paper 29 and also for providing an electrostatic potential to platen 28 . In standard electrostatic printers that print non-permanently charged ink, the electrostatic potential is typically of one polarity. However, in the present invention, selectable polarity may be employed to attract a particular polarity of ink to paper 29 , and optionally repel another polarity of ink, retaining it in nozzle or directing stray ink of undesired polarity away from paper 29 . Printer control 26 controls ink-jet head 25 to select the desired ink (or combination of inks) for a given pixel. Printer control 26 also may be coupled to vessels 27 to control the ink. It should be noted that platen 28 is not required to be charged, and vessels are not required to be controlled in order to print electrostatic ink, as ink-jet head 25 can release ink that is permanently charged and it can be ejected under the ink's own internal (monopole repulsion) pressure. Alternatively, ink-jet head can be set to a selectable polarity potential and used to accelerate the ink toward the paper and ink-jet head 25 may include stages of alternating potential used to prevent directing the ink toward ink-jet head 25 itself.
[0029] In all of the above-described embodiments, it should be understood that appropriate measures may be required to insulate the ink-containing vessels from each other and from the user if the concentration of the monopoles and the volume of the ink vessels causes sufficient potential to pose a hazard or cause failure of the apparatus. During installation of the ink into a vessel, a potential may be required or sufficient pressure applied to overcome the internal repulsive forces between the monopoles.
[0030] As an alternative embodiment of the ink-jet printer described above, an ink vessel containing both polarities of monopoles may be used that reduces the external field and eases the task of charging the vessels. Selection of a particular ink can then be made by the polarity of platen 28 and/or ink-jet head 25 .
[0031] Referring now to FIG. 3 , a verification system is shown in accordance with another embodiment of the invention. A sensing head 32 contains a matrix of electrostatic sensors 33 , which may be active devices, or may be metal plates. Sensors 33 are connected to sensor circuits 34 that convert the electrostatic information detected by sensor head 32 to pattern information that can be stored in memory of processor 37 and provided to external systems by an interface in processor 37 . A scan control 36 is commanded by processor 37 to move mechanical scan unit 35 over a document, so that sensor 32 can detect the electrostatic pattern embedded in the document.
[0032] Referring now to FIG. 4 an authentication method in accordance with an embodiment of the invention is shown. After the electrostatic embedded information is detected, it is translated into binary information and stored (step 40 ). It should be noted that either polarity or presence of electrostatic information can be detected, i.e., for a single ink the detection criteria is not the positive or negative charge state of the ink, but rather the amplitude of the electrostatic potential detected by sensors 32 over ambient.
[0033] Next, the stored information is compared to known patterns and/or decrypted using a key (step 42 ). If a match is found (decision 44 ) then the pattern is compared to stored database information (step 48 ) and if the information shows a match (decision 49 ) the document is authenticated (step 50 ). While no pattern match is found in decision 44 , the method continues to match other patterns until the pattern database is exhausted (decision 46 ) and the authentication fails (step 47 ). If no match is found in step 49 , the authentication likewise fails (step 47 ).
[0034] While the invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that the foregoing and other changes in form, and details may be made therein without departing from the spirit and scope of the invention. | A method and apparatus for generating documents having stored electrostatic pattern information provides security with respect to the authenticity of documents. A liquid medium including a plurality of electrostatic monopoles is applied to the surface of a document, which embeds a permanent electrostatic pattern in the document. The pattern is then readable by an electrostatic scanner. The monopoles may be associated with differing colors, including black and white, may be transparent or have a neutral color. The patterns may embed data, certificates or shapes. The monopoles may provide a watermark or visible image. The apparatus may be a pen or printer, and may include multiple selectable vessels containing ink and/or electrostatic liquid medium of one or both charge states. Visible features of the document can be compared with the detected pattern, or the pattern may be compared to a database or decrypted with a key. | 1 |
This is a division of application Ser. No. 566,582 filed Dec. 29, 1983, now, U.S. Pat. No. 4,574,025.
BACKGROUND OF THE INVENTION
1. Field of the invention
This invention relates to an improved method of forming a building panel, and particularly in forming the building panel including the door and access opening and, in one aspcct, to a completed door panel unit including the wall members, the door frame, door, closure, and lock unit.
2. Description of the Art
The present invention relates to an improvement in the method of forming a building panel or wall unit for a portable building and to provide the wall unit and door with sufficient rigidity to form a serviceable longer-lifed unit. While vacuum molding has been utilized for the forming of large molded plastic or polymeric parts and that twin sheet forming of parts is known in the industry, the formation of a large twin sheet part to form a wall unit for a portable building structure and to form the unit having the access opening such that the part may be cut to form the opening and assembled to form a frame to utilize the cut piece as the door for the access opening is not known in the art and provides a very economical process for the manufacture of such wall panels.
In this invention the two sheet molding process is utilized to provide, a single molded panel from which cooperating parts are formed which, in combination, provide the wall unit and door with continuity in color and texture and will allow the inside to be of a different color and thickness from the outside.
The wall unit of the present invention provides its own rigidity to remove the need for supporting braces which were added to previously known polymeric wall panels formed by vacuum forming processes. Further, the shape of the outer and inner walls may be dedicated to their individual end use without compromising the shape of the other.
SUMMARY OF THE INVENTION
This invention relates to a new process for the formation of a building panel or wall unit comprising the steps of heating and vacuum forming a pair of mating sheets of polymeric material, bringing the sheets in their molds while still heated into pressure contact to secure the sheets together in their contacting areas, separating the molds and removing the panel, cutting from the panel a door unit and cutting the remaining panel, preferably into two generally equal portions, moving the portions toward one another to place portions thereof in overlapping contact position, securing the same in the overlapped areas, and replacing the door unit in the area from which it was cut where it will now contact the repositioned portions which form a frame for the door. Hinges are secured to the door and one of the panel portions and a door closure and a lock unit for the door can be affixed thereto. The closure comprises a long life return member which will urge the door to the closed position and the lock unit affords a rotary lock and lock position indicating device which is visible from the outside.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail with reference to the accompanying drawing wherein:
FIG. 1 is a schematic diagram of the steps for the production of the building panel according to the present invention;
FIG. 2 is a front elevational view of a panel unit as it is removed from the production line illustrated in FIG. 1;
FIG. 3 is an exploded view of the parts upon cutting the panel;
FIG. 4 is a horizontal sectional view taken on line 4--4 of FIG. 2;
FIG. 5 is a front view of the panel unit with the door fixed by hinges in position in the panel unit and with the closure member in place and the lock unit on the door;
FIG. 6 is a horizontal sectional detail view of the door lock unit;
FIG. 7 is a rear view of the panel unit with the door in place and illustrating the closure unit; and
FIG. 8 is a detail sectional view of the closure unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a fast economical process for the production of a building panel unit having built-in reinforcement to make the panel substantially self supporting. The process comprises the use of a pair of large 5'×9' vacuum form molds which are each provided with a molding face to receive one sheet of polymeric material which may be drawn against the molding face to form the shape desired in the presence of heat. A first mold forms the sheet defining the outer skin for the panel unit and a second mold forms a sheet defining the inner skin of the panel unit. The two sheets are formed in the molds and are then placed, when still in the heated condition, in contact with each other to bond, in the areas of contact, the two sheets together rigidly.
Referring now to FIG. 1 it will be seen that sheets are first moved successively, as by a conveyor frame, not shown, which conventionally grasps the sheets 10 and 11 by clamps positioned along opposite edges to advance the sheets, through an oven 15 where the sheets are heated. The sheets are then moved to a position against a mold 17 or a mold 19, respectively, which molds are formed to draw the heated sheets against the face of the mold under the force of subatmospheric pressure on one side with the atmospheric pressure against the other to make it conform to the mold face. The molds are then moved into contact with each other, as illustrated on the right side of FIG. 1, to place portions of each of said sheets into contact with each other while still in the heated condition. Placing the sheets in contact while heated sufficiently to permit a flow of the polymeric material under pressure causes the contacting areas of the two sheets to be firmly bonded together to thus form the panel generally designated 20, illustrated in FIG. 2.
The sheets 10 and 11, as they move into the oven 15, are 5' by 9' in size and are preferably formed of a polyethylene material.
The panel 20 is formed as hereinabove described with a series of raised ribs 21, arcuate surfaces 22 and transverse rib members 23, as illustrated. The panel is then cut along the line indicated by dots at 30 to remove from the panel a central section 31, as shown in FIG. 3. The removal of the central section then leaves a generally inverted U-shaped portion. The U-shaped portion may be cut at 32 between the cut line 30 of the central section and one marginal edge to form two additional sections 34 and 35. The sections or portions 34 and 35 are moved to bring opposite edges of said sections, remaining upon the cutting of said central section, toward one another such as to reduce the width of the cutout area to define a frame for the section 31. This cut along the dotted line 32 separates the portions 34 and 35 along offset areas of the panel formed with sheets 10 and 11 in contact.
As shown in FIG. 2, support pads 24 and 25 of each pair are vertically offset from one another but, upon reassembly of the portions 34 and 35, and section 31, after making the cuts described above, the pads 25 are aligned with the pads 24 such that the opposite plates of each hinge 40 may be readily mounted in opposed position, see FIG. 5. In FIG. 4 the panel is shown in cross section and the section is taken to illustrate a recessed area 28 defining a hand hold for pulling the door unit open and the bonding of the sheets at 29 where the cut 30 is made.
As shown more clearly in FIG. 5, the portion 34 and the portion 35 are moved into overlapping position adjacent the cut line 32 of each of the panel portions and are then secured together again by suitable fastening means such as bolts or pop rivets. The overlapping amounts to movement of one portion approximately 11/2 inches to move the opposed edges of the two panels closer together such that an edge 41 on the panel portion 34 and an edge 42 on the panel portion 35 form the edges of the frame for the door unit 31. The door is moved upward into the frame approximately 1 inch such that the bottom portion of the overlapping portions adjacent the cut 32 define the frame for the upper portion of the door.
The door is then mounted by hinges 40 supported on the pads 24 and 25 to the panel 34, and the building of the door panel unit continues.
The door is then fitted with a lock unit which is mounted in a recessed portion 45 on the front or outer face of the panel 31 and has the latching handle 51 at the rear or adjacent the inner panel. The lock unit comprises a rotary disc 48 which is positioned in the recess 45 and which is placed beneath a cover plate 49. The disc 48 has a hub with a central opening to receive a spindle 50 fixed to the latch handle 51. On the back side of the panel 31 is mounted a latch plate 52 rotatably supporting the latch handle 51 and having a pair of ears 53 which limit the rotation of the latch handle 51 and the disc 48. The latch handle 51 comprises a handle portion extending radially from the central axis or stub shaft thereof, and a weighted bar forms a counterweight 65 which extends radially from the handle portion to position the handle freely in an unlatched position. The handle can be rotated from the unlatched position to the latched position wherein it is frictionally held against a keeper 54 which is bolted or riveted to the back side of the panel 35 adjacent the frame portion 42. The keeper 54 has a stepped portion to position the handle in a closed frictional latched position. The disc 48 is provided on its front face with indicia and color image areas such that when the unit is unoccupied the disc will display "open" being the open sign and a green surface, and when the unit is occupied with the latch handle 51 in the latched position, the disc will display the words "in use" and a red color, through the window or transparent area 55 in the upper portion of the covering panel 49, see FIG. 5. The red and green colors are selected from fluorescent colors to be visible from over 200 feet.
To maintain the door in a closed position against the door frame formed by the areas 41 and 42, the unit is provided with a spring closure. This closure is illustrated in FIGS. 7 and 8 and comprises a housing 56 which is formed with a cylindrical portion 57 joined by two oppositely extending flange portions 58 which are secured to the back side of the central section or door 31. In the cylindrical portion 57 is a bore in which is positioned a helical spring 59 which is anchored at the left end as illustrated to the housing 56. A cable is threaded through the center of the helical spring. The cable 60 is formed at one end with a ball or keeper 61 having a diameter larger than the end of the tapered end of the spring 59. The opposite end of the cable 58 is provided with a anchoring member 62 to connect or anchor the cable into a plate 64 which is secured to the panel 34 of the unit. The plate 64 is formed with a smooth bend intermediate its ends to carry and contact the cable as the door is opened, but which, because there is no relative sliding movement, protects the cable and provides a fulcrum point for the closing of the door. The closing unit as described is substantially free from vandalism as the portions of the spring and cable are well protected.
Having thus described the present invention it is to be understood that changes may be made without departing from the scope or spirit of the present invention. It is envisioned that the panel unit, prior to the cutting steps, could be formed by blow molding the panel because the technology is now such that large pieces of this type can be used. In such a blow molding operation a parison is first extruded which is a cylindrical shape of material which goes down between the mold halves forming the mold panel and then the cylinder is blown against the opposing mold faces with internal air pressure. The mold faces are brought together to form the completed product wherein one layer of material forms the outer skin of the panel and another layer forms the inner skin of the panel with the panels joined tightly together.
Other modifications might be made in the present invention without departing from the claims as appended hereto. | A wall panel for a building may be formed by twin sheet vacuum form molding an entire end panel which may then be cut to form an access opening which may be closed with the removed portion forming the door with the cut panel reassembled to form the building wall and door frame. A novel closure and lock secures the door. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally pertains to coin telephone (paystation) housings and more particularly to a liner which acts as a spacer to apply a positive upward force on the coin receptacle usually found inside of the lower paystation housing or vault portion.
2. Background of the Invention
Many paystation housings, particularly those manufactured by AT&T, Northern Telecom, and Palco Telecom Inc., require a vault liner, spring or combination which acts as a spacer to apply a positive upward force to operatively position the included coin receptacle in its proper location. Without such a device the coin receptacle self-locking lid arm would not properly engage the rail at the top of the vault and would not properly open. Furthermore, it would not be properly positioned to accept coins and thus may not self-lock as intended upon removal thereby creating a concern for security.
In the past, typically vault liners have been concave metal formed pieces shaped to fit the floor of the vault area with an associated spring eyeleted to the liner or vault floor. This spring provides the spacer with the necessary upward force required to properly position the coin receptacle. The liner itself was as a carrier for the spring and/or to prevent overflow coins from getting into cracks and crevices of the vault portion of the lower paystation housing. In the past, such liners were not user friendly inasmuch as they had sharp metal corners often cutting the fingers of coin collectors or servicemen. The included spring also presented an obstacle to access. The early design springs flattened out making the coin receptacle positioning extremely unreliable. Probably in response to the objection to finger cuts, etc., some later designs eliminated the metal liner altogether and merely eyeleted the spring directly to the bottom of the vault floor.
In recent times, a new problem has surfaced relating to vault security. Burglars have been drilling a large hole through the bottom of the paystation directly into the coin receptacle with a battery powered drill and removing the coins. In existing vault construction in most telephone paystations, the liners and springs provide an excellent pilot hole. These holes are intended to be used in eyeleting the coin receptacle spring to the vault base or liner. Thus providing a natural location for the burglar to start the hole through which the coin receptacle is accessed.
SUMMARY OF THE INVENTION
The present invention is a molded plastic piece generally square or rectangular in configuration and about 1/2 inch thick, properly sized to fit snugly into the paystation vault. The unit actually acts as a platform where the coin receptacle sits. The platform in accordance with the present invention has a slightly convex shaped top to act as a bevel spring. Included beneath the upper surface are internal ribs to keep the top from collapsing under high forces. The smooth top surface makes excess coin removal simple and the liner keeps coins from getting into cracks and crevices of the vault. The liner as designed provides for easy entrance and exit of the coin receptacle providing the other outlined advantages.
If desired, some of the material on the bottom side of the liner (the highest of the internal ribs) may be reduced in size to allow a flat metal plate to be attached to the underside of the liner. If the plate is made of stainless steel of heavy enough gauge, it would deter battery powered drills from drilling holes into the bottom of the coin receptacle, thus providing the necessary protection against burglary that has been found desirable in paystations installed in public areas where little or no security is present.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the lower housing or vault section of a telephone paystation with a coin receptacle shown in place over a vault liner (shown partially in phantom) in accordance with the present invention.
FIG. 2 is a cross-sectional view taken along lines 2--2 of FIG. 1 of the lower housing or vault portion of a telephone paystation showing a coin receptacle placed therein, on top of a plastic vault liner in accordance with the present invention and also showing a protective steel plate positioned below the vault liner.
FIG. 3 is a top view of a vault liner in accordance with the present invention.
FIG. 4 is a cross-sectional view taken along lines 4--4 of FIG. 3 of a vault liner in accordance with the present invention.
FIG. 5 is a bottom view of a vault liner in accordance with the present invention.
FIG. 6 is a bottom view of a steel security plate for placement below a vault liner in accordance with the terms of the present invention.
FIG. 7 is a partial cross-sectional view of a part of the steel plate of FIG. 6 taken along lines 7--7 showing embossed features or bosses that act as spacers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIGS. 1 and 2, and the lower portion or vault section 1 of a telephone paystation is shown with a coin receptacle 2 positioned therein. The details of the coin enclosure 2 are not important inasmuch as they may vary from paystation to paystation (and do not form a part of the invention), therefore the specific details of the vault are not spelled out, it only being required that a top portion of the coin receptacle is forced up against the upper portion of the vault section and the bottom portion rests against some kind of a liner such as vault liner 4 that provides enough spring action to force the coin enclosure up against the top of the vault section. The top of the vault liner 4 must also be smooth to facilitate putting the coin enclosure into and out of the vault portion. As may be seen in both FIGS. 1 and 2, the vault liner 4 is placed over the lower or vault tray portion 3 which retains it in proper position.
As may be seen in FIG. 2, a steel plate 12 has been positioned below the vault liner 4 to discourage the drilling of holes directly into the coin enclosure from the bottom as is frequently attempted by burglars. The steel plate 12, usually constructed of heavy stainless steel, includes two features 13 and 14 or bosses (as well as features 15 and 16) which act as additional spacers to properly position the vault liner between the vault bottom and the coin enclosure bottom.
As may be seen in FIGS. 3, 4, and 5, the vault liner 4 has an upper or convex surface 5 which is smooth and characteristic to facilitate access and egress of the coin enclosure into the vault portion of the paystation telephone. Referring to the sectional drawing of FIG. 4 of the vault liner and also the bottom view FIG. 5, the upper surface of the platform of which the vault liner 4 consists has supporting it four edges 4, 7, 21, and 24. Also providing support for the upper surface or top portion of the vault liner are a number of ribs. The first group consisting of ribs 8, 11, 22, and 23 form a square. The second group consisting of ribs 9, 10, 26, and 27 forming a second group or a square within the concentric confines of previously outlined ribs and sides.
Referring to the sectional view of FIG. 4, it is noted that ribs 9 and 10 and their associated ribs 26 and 27 do not extend as far down as the ribs in the square consisting of ribs 8, 11, 22, and 23 which are the same length as the sides 6, 7, 21, and 24. The shorter ribs are provided so that a certain amount of compression can occur when the coin enclosure is positioned within the vault against the vault liner 4.
Referring to FIGS. 2 and 6, where burglary is of concern, a stainless steel plate 12 is placed beneath the bottom of the vault liner. For this purpose, ribs 8, 11, 22, and 23 will all be shortened to allow the placement of the stainless steel plate. The plate is properly positioned when placed beneath the vault liner 4 and held in proper position by ribs 19 and 20 which can be seen in FIG. 5 and also seen in sectional view of FIG. 4 with cut out corners 17 and 18 of steel plate 12 as may be seen in FIG. 6. It was noted previously the steel plate 12 includes a number of projections, features, or bosses 13, 14, 15, and 16 to provide additional depth to the plate to provide the proper spacing of the vault liner within the vault so that the coin enclosure will be properly positioned against the top of the vault section of the coin telephone.
When the security plate use is desired, the internal ribs of the vault liner must be machined down to match the thickness of the plate. It is advantageous to adhesively bond the plate to the liner to become an assembly for easy insertion into the vault. The front corners of the plate 12 are notched not only to provide proper fit but also for clearance of the vault bar in certain paystation telephone vaults.
When the liner or liner assembly is placed within the paystation at the factory, it will be put into before the lock is positioned. The lock, after it is installed, will block unauthorized removal. Should it be desirable to place the liner or liner assembly in proper position within the paystation vault section in the field, the lock would normally prevent assembly. However, if pre-notched corners 17 and 18 are removed with a cutting device, assembly will be possible. After this has been done, however, unauthorized removal will also be possible.
Once the liner is in place, coin receptacle insertion is identical to that found in previous designs. When the coin receptacle 2 is inserted, the center of the liner will be depressed such as found in a bevel spring and applies an upward positive force. As noted previously, ribs on the underside of the liner are concentric squares or rectangles as opposed to centrally radiating ribs thereby allowing the convex shape of the liner to elastically flex. It should also be noted that the ribs act as stops so that overflexing cannot result.
After the receptacle has been removed, the vault liner 4 acts as a smooth platform from which to receive any overflow coins that may be present within vault section of the coin telephone.
While but two embodiments of the present invention are shown, it will be obvious to those skilled in the art that numerous modifications could be made without departing from the spirit of the present invention which shall be limited only by scope of the claims appended hereto. | A plastic vault liner for use in paystations for the purpose of providing a spacer underneath the coin receptable. Two versions are shown: a standard one piece plastic version and a high security version which provides a stainless steel anti-drill plate as an integral part of the liner. The liner is designed as a bevel spring to insure positive upward pressure on various coin enclosures. | 7 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] The present application claims priority under 35 USC section 119(e) to U.S. Provisional application Serial No. 60/384,478, filed May 31, 2002, which is incorporated by reference herein as if fully set forth.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a process for preparing polycyclic xanthine phosphodiesterase V (“PDE V”) inhibitors. The invention further relates to compounds useful for preparing PDE V inhibitors.
[0004] 2. Background
[0005] Processes for preparing PDE V inhibitor compounds can be found in U.S. Pat. No. 6,207,829, U.S. Pat. No. 6,066,735, U.S. Pat. No. 5,955,611, U.S. Pat. No. 5,939,419, U.S. Pat. No. 5,393,755, U.S. Pat. No. 5,409,934, U.S. Pat. No. 5,470,579, U.S. Pat. No. 5,250,534, WO 02/24698, WO 99/24433, WO 93/23401, WO 92/05176, WO 92/05175, EP 740,668 and EP 702,555. One type of PDE V inhibitor compound contains a xanthine functionality in its structure. Xanthines can be prepared as described by Peter K. Bridson and Xiaodong Wang in 1-Substituted Xanthines, Synthesis, 855 (July, 1995), which is incorporated herein by reference in its entirety. WO 02/24698, which is incorporated herein by reference in its entirety, teaches a class of xanthine PDE V inhibitor compounds useful for the treatment of impotence. A general process disclosed therein for preparing xanthine PDE V inhibitor compounds having the formula (I) follows:
[0006] (i) reacting a compound having the formula (III) with an alkyl halide in the presence of a base (introduction of R II or a protected form of R II );
[0007] (ii) (a) debenzylating and then (b) alkylating the compound resulting from step (i) with an alkyl halide, XCH 2 R III ;
[0008] (iii) (a) deprotonating and then (b) halogenating the compound resulting from step (ii);
[0009] (iv) reacting the compound resulting from step (iii) with an amine having the formula R IV NH 2 ; and
[0010] (v) removing a protecting portion of R II , if present, on the compound resulting from step (iv) to form the compound having the formula (I).
[0011] R I , R II , R III and R IV correspond to R 1 , R 2 , R 3 and R 4 , respectively, in WO 02/24698, and are defined therein. WO 02/24698 (pages 44 and 68-73) also teaches a synthesis for the following xanthine compound (identified therein as Compound 13 or Compound 114 of Table II): 1-ethyl-3,7-dihydro-8-[(1R,2R)-(hydroxycyclopentyl)amino]-3-(2-hydroxyethyl)-7-[(3-bromo-4-methoxyphenyl)methyl]-1H-purine-2,6-dione:
[0012] It would be beneficial to provide an improved process for preparing polycyclic xanthine PDE V inhibitor compounds. It would further be beneficial if the process provided high yields without the need for chromatographic purification. It would still further be beneficial if the process provided compounds of high thermodynamic stability. It would be still further beneficial to provide intermediate compounds that can be used in the improved process. The invention seeks to provide these and other benefits, which will become apparent as the description progresses.
SUMMARY OF THE INVENTION
[0013] One aspect of the invention is a method for preparing a Compound 13, comprising:
[0014] (a) reacting glycine ethyl ester or a salt thereof with
[0015] wherein Et is CH 3 CH 2 —,
[0016] (b) reducing
[0017] to form a Compound 1:
[0018] (c) reacting cyanamide with an excess of triethylorthoformate to form a Compound 2:
[0019] (d) reacting the Compound 2 with the Compound 1 to form a Compound 3:
[0020] (e) reacting the Compound 3 with a base to form a Compound 4:
[0021] (f) reacting the Compound 4 with R 2 NHCO 2 R 1 in the presence of a metallic base to form a Compound Salt 5K:
[0022] wherein M + is a metal ion,
[0023] (g) optionally, reacting the Compound Salt 5K with an acid to form a Compound 5:
[0024] (h) reacting the Compound Salt 5K or the Compound 5 with BrCH 2 L in the presence of a phase transfer catalyst to form a Compound 6:
[0025] wherein L is R 3 or a protected form of R 3 comprising R 3 with a protective substituent selected from the group consisting of acetate, propionate, pivaloyl, —OC(O)R 5 , —NC(O)R 5 and —SC(O)R 5 group, wherein R 5 is H or C 1-12 alkyl;
[0026] (i) dihalogenating the Compound 6 to form a Compound 7:
[0027] (j) reacting the Compound 7 with R 4 NH 2 , and adding a base thereto, to form a Compound 9:
[0028] (k) (i) when L is R 3 , the Compound 9 is a Compound 13, and
[0029] (ii) when L is a protected form of R 3 , reacting the Compound 9 with a base to form the Compound 13:
[0030] wherein,
[0031] R 1 , R 2 and R 3 are each independently selected from the group consisting of:
[0032] H, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, allyl, —OR 5 ,
[0033] —C(O)OR 5 , —C(O)R 5 , —C(O)N(R 5 ) 2 , —NHC(O)R 5 and —NHC(O)OR 5 , wherein each R 5 is independently H or alkyl;
[0034] provided that R 2 and R 3 are not both —H;
[0035] R 4 is an alkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, aryl or heteroaryl group;
[0036] wherein R 1 , R 2 , R 3 and R 4 are optionally substituted with one or more moieties independently selected from the group consisting of: alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, heteroaryl, heterocycloalkyl, halo, thio, nitro, oximino, acetate, propionate, pivaloyl, —OC(O)R 5 , —NC(O)R 5 or —SC(O)R 5 , —OR 50 , —NR 5 OR 51 , —C(O)OR 50 , —C(O)R 50 , —SO 0-2 R 5 , —SO 2 NR 50 R 51 , —NR 52 SO 2 R 50 , ═C(R 50 R 51 ), ═NOR 50 , ═NCN, ═C(halo) 2 , ═S, ═O, —C(O)N(R 50 R 51 ), —OC(O)R 50 , —OC(O)N(R 50 R 51 ), —N(R 52 )C(O)(R 50 ), —N(R 52 )C(O)OR 50 and —N(R 52 )C(O)N(R 5 OR 51 ), wherein each R 5 is independently H or alkyl and R 50 , R 51 and R 52 are each independently selected from the group consisting of: H, alkyl, cycloalkyl, heterocycloalkyl, heteroaryl and aryl, and when chemically feasible, R 50 and R 51 can be joined together to form a carbocyclic or heterocyclic ring;
[0037] Et is CH 3 CH 2 —;
[0038] Hal is a halogen group; and
[0039] L is a protected form of R 3 comprising R 3 with a protective substituent selected from the group consisting of acetate, propionate, pivaloyl, —OC(O)R 5 , —NC(O)R 5 and —SC(O)R 5 group, wherein R 5 is H or C 1-12 alkyl.
[0040] A further understanding of the invention will be had from the following detailed description of the invention.
DETAILED DESCRIPTION
Definitions and Usage of Terms
[0041] The following definitions and terms are used herein or are otherwise known to a skilled artisan. Except where stated otherwise, the definitions apply throughout the specification and claims. Chemical names, common names and chemical structures may be used interchangeably to describe the same structure. These definitions apply regardless of whether a term is used by itself or in combination with other terms, unless otherwise indicated. Hence, the definition of “alkyl” applies to “alkyl” as well as the “alkyl” portions of “hydroxyalkyl,” “haloalkyl,” “alkoxy,” etc.
[0042] Unless otherwise known, stated or shown to be to the contrary, the point of attachment for a multiple term substituent (two or more terms that are combined to identify a single moiety) to a subject structure is through the last named term of the multiple term substituent. For example, a cycloalkylalkyl substituent attaches to a targeted structure through the latter “alkyl” portion of the substituent (e.g., structure-alkyl-cycloalkyl).
[0043] The identity of each variable appearing more than once in a formula may be independently selected from the definition for that variable, unless otherwise indicated.
[0044] Unless stated, shown or otherwise known to be the contrary, all atoms illustrated in chemical formulas for covalent compounds possess normal valencies. Thus, hydrogen atoms, double bonds, triple bonds and ring structures need not be expressly depicted in a general chemical formula.
[0045] Double bonds, where appropriate, may be represented by the presence of parentheses around an atom in a chemical formula. For example, a carbonyl functionality, —CO—, may also be represented in a chemical formula by —C(O)— or —C(═O)—. Similarly, a double bond between a sulfur atom and an oxygen atom may be represented in a chemical formula by —SO—, —S(O)— or —S(═O)—. One skilled in the art will be able to determine the presence or absence of double (and triple bonds) in a covalently-bonded molecule. For instance, it is readily recognized that a carboxyl functionality may be represented by —COOH, —C(O)OH, —C(═O)OH or —CO 2 H.
[0046] The term “substituted,” as used herein, means the replacement of one or more atoms or radicals, usually hydrogen atoms, in a given structure with an atom or radical selected from a specified group. In the situations where more than one atom or radical may be replaced with a substituent selected from the same specified group, the substituents may be, unless otherwise specified, either the same or different at every position. Radicals of specified groups, such as alkyl, cycloalkyl, heterocycloalkyl, aryl and heteroaryl groups, independently of or together with one another, may be substituents on any of the specified groups, unless otherwise indicated.
[0047] The term “optionally substituted” means, alternatively, not substituted or substituted with the specified groups, radicals or moieties. It should be noted that any atom with unsatisfied valences in the text, schemes, examples and tables herein is assumed to have the hydrogen atom(s) to satisfy the valences.
[0048] The term “chemically-feasible” is usually applied to a ring structure present in a compound and means that the ring structure (e.g., the 4- to 7-membered ring, optionally substituted by . . . ) would be expected to be stable by a skilled artisan.
[0049] The term “heteroatom,” as used herein, means a nitrogen, sulfur or oxygen atom. Multiple heteroatoms in the same group may be the same or different.
[0050] As used herein, the term “alkyl” means an aliphatic hydrocarbon group that can be straight or branched and comprises 1 to about 24 carbon atoms in the chain. Preferred alkyl groups comprise 1 to about 15 carbon atoms in the chain. More preferred alkyl groups comprise 1 to about 6 carbon atoms in the chain. “Branched” means that one or more lower alkyl groups such as methyl, ethyl or propyl, are attached to a linear alkyl chain. The alkyl can be substituted by one or more substituents independently selected from the group consisting of halo, aryl, cycloalkyl, cyano, hydroxy, alkoxy, alkylthio, amino, —NH(alkyl), —NH(cycloalkyl), —N(alkyl) 2 (which alkyls can be the same or different), carboxy and —C(O)O-alkyl. Non-limiting examples of suitable alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, n-pentyl, heptyl, nonyl, decyl, fluoromethyl, trifluoromethyl and cyclopropylmethyl.
[0051] “Alkenyl” means an aliphatic hydrocarbon group (straight or branched carbon chain) comprising one or more double bonds in the chain and which can be conjugated or unconjugated. Useful alkenyl groups can comprise 2 to about 15 carbon atoms in the chain, preferably 2 to about 12 carbon atoms in the chain, and more preferably 2 to about 6 carbon atoms in the chain. The alkenyl group can be substituted by one or more substituents independently selected from the group consisting of halo, alkyl, aryl, cycloalkyl, cyano and alkoxy. Non-limiting examples of suitable alkenyl groups include ethenyl, propenyl, n-butenyl, 3-methylbut-enyl and n-pentenyl.
[0052] Where an alkyl or alkenyl chain joins two other variables and is therefore bivalent, the terms alkylene and alkenylene, respectively, are used.
[0053] “Alkoxy” means an alkyl-O— group in which the alkyl group is as previously described. Useful alkoxy groups can comprise 1 to about 12 carbon atoms, preferably 1 to about 6 carbon atoms. Non-limiting examples of suitable alkoxy groups include methoxy, ethoxy and isopropoxy. The alkyl group of the alkoxy is linked to an adjacent moiety through the ether oxygen.
[0054] The term “cycloalkyl” as used herein, means an unsubstituted or substituted, saturated, stable, non-aromatic, chemically-feasible carbocyclic ring having preferably from three to fifteen carbon atoms, more preferably, from three to eight carbon atoms. The cycloalkyl carbon ring radical is saturated and may be fused, for example, benzofused, with one to two cycloalkyl, aromatic, heterocyclic or heteroaromatic rings. The cycloalkyl may be attached at any endocyclic carbon atom that results in a stable structure. Preferred carbocyclic rings have from five to six carbons. Examples of cycloalkyl radicals include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, or the like.
[0055] The term “hydrocarbon,” as used herein, means a compound, radical or chain consisting of only carbon and hydrogen atoms, including aliphatic, aromatic, normal, saturated and unsaturated hydrocarbons.
[0056] The term “alkenyl,” as used herein, means an unsubstituted or substituted, unsaturated, straight or branched, hydrocarbon chain having at least one double bond present and, preferably, from two to fifteen carbon atoms, more preferably, from two to twelve carbon atoms.
[0057] The term “cycloalkenyl,” as used herein, means an unsubstituted or substituted, unsaturated carbocyclic ring having at least one double bond present and, preferably, from three to fifteen carbon atoms, more preferably, from five to eight carbon atoms. A cycloalkenyl goup is an unsaturated carbocyclic group. Examples of cycloalkenyl groups include cyclopentenyl and cyclohexenyl.
[0058] “Alkynyl” means an aliphatic hydrocarbon group comprising at least one carbon-carbon triple bond and which may be straight or branched and comprising about 2 to about 15 carbon atoms in the chain. Preferred alkynyl groups have about 2 to about 10 carbon atoms in the chain; and more preferably about 2 to about 6 carbon atoms in the chain. Branched means that one or more lower alkyl groups such as methyl, ethyl or propyl, are attached to a linear alkynyl chain. Non-limiting examples of suitable alkynyl groups include ethynyl, propynyl, 2-butynyl, 3-methylbutynyl, n-pentynyl, and decynyl. The alkynyl group may be substituted by one or more substituents which may be the same or different, each substituent being independently selected from the group consisting of alkyl, aryl and cycloalkyl.
[0059] The term “aryl,” as used herein, means a substituted or unsubstituted, aromatic, mono- or bicyclic, chemically-feasible carbocyclic ring system having from one to two aromatic rings. The aryl moiety will generally have from 6 to 14 carbon atoms with all available substitutable carbon atoms of the aryl moiety being intended as possible points of attachment. Representative examples include phenyl, tolyl, xylyl, cumenyl, naphthyl, tetrahydronaphthyl, indanyl, indenyl, or the like. If desired, the carbocyclic moiety can be substituted with from one to five, preferably, one to three, moieties, such as mono- through pentahalo, alkyl, trifluoromethyl, phenyl, hydroxy, alkoxy, phenoxy, amino, monoalkylamino, dialkylamino, or the like.
[0060] “Heteroaryl” means a monocyclic or multicyclic aromatic ring system of about 5 to about 14 ring atoms, preferably about 5 to about 10 ring atoms, in which one or more of the atoms in the ring system is/are atoms other than carbon, for example nitrogen, oxygen or sulfur. Mono- and polycyclic (e.g., bicyclic) heteroaryl groups can be unsubstituted or substituted with a plurality of substituents, preferably, one to five substituents, more preferably, one, two or three substituents (e.g., mono- through pentahalo, alkyl, trifluoromethyl, phenyl, hydroxy, alkoxy, phenoxy, amino, monoalkylamino, dialkylamino, or the like). Typically, a heteroaryl group represents a chemically-feasible cyclic group of five or six atoms, or a chemically-feasible bicyclic group of nine or ten atoms, at least one of which is carbon, and having at least one oxygen, sulfur or nitrogen atom interrupting a carbocyclic ring having a sufficient number of pi (π) electrons to provide aromatic character. Representative heteroaryl (heteroaromatic) groups are pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, furanyl, benzofuranyl, thienyl, benzothienyl, thiazolyl, thiadiazolyl, imidazolyl, pyrazolyl, triazolyl, isothiazolyl, benzothiazolyl, benzoxazolyl, oxazolyl, pyrrolyl, isoxazolyl, 1,3,5-triazinyl and indolyl groups.
[0061] The term “heterocycloalkyl,” as used herein, means an unsubstituted or substituted, saturated, chemically-feasible cyclic ring system having from three to fifteen members, preferably, from three to eight members, and comprising carbon atoms and at least one heteroatom as part of the ring.
[0062] The term “heterocyclic ring” or “heterocycle,” as used herein, means an unsubstituted or substituted, saturated, unsaturated or aromatic, chemically-feasible ring, comprised of carbon atoms and one or more heteroatoms in the ring. Heterocyclic rings may be monocyclic or polycyclic. Monocyclic rings preferably contain from three to eight atoms in the ring structure, more preferably, five to seven atoms. Polycyclic ring systems consisting of two rings preferably contain from six to sixteen atoms, most preferably, ten to twelve atoms. Polycyclic ring systems consisting of three rings contain preferably from thirteen to seventeen atoms, more preferably, fourteen or fifteen atoms. Each heterocyclic ring has at least one heteroatom. Unless otherwise stated, the heteroatoms may each be independently selected from the group consisting of nitrogen, sulfur and oxygen atoms.
[0063] The term “carbocyclic ring” or “carbocycle,” as used herein, means an unsubstituted or substituted, saturated, unsaturated or aromatic (e.g., aryl), chemically-feasible hydrocarbon ring, unless otherwise specifically identified. Carbocycles may be monocyclic or polycyclic. Monocyclic rings, preferably, contain from three to eight atoms, more preferably, five to seven atoms. Polycyclic rings having two rings, preferably, contain from six to sixteen atoms, more preferably, ten to twelve atoms, and those having three rings, preferably, contain from thirteen to seventeen atoms, more preferably, fourteen or fifteen atoms.
[0064] The term “hydroxyalkyl,” as used herein, means a substituted hydrocarbon chain preferably an alkyl group, having at least one hydroxy substituent (-alkyl-OH). Additional substituents to the alkyl group may also be present. Representative hydroxyalkyl groups include hydroxymethyl, hydroxyethyl and hydroxypropyl groups.
[0065] The terms “Hal,” “halo,” “halogen” and “halide,” as used herein, mean a chloro, bromo, fluoro or iodo atom radical. Chlorides, bromides and fluorides are preferred halides.
[0066] The term “thio,” as used herein, means an organic acid radical in which divalent sulfur has replaced some or all of the oxygen atoms of the carboxyl group. Examples include —R 53 C(O)SH, —R 53 C(S)OH and —R 53 C(S)SH, wherein R 53 is a hydrocarbon radical.
[0067] The term “nitro,” as used herein, means the —N(O) 2 radical.
[0068] The term “allyl,” as used herein, means the —C 3 H 5 radical.
[0069] The term “phase transfer catalyst,” as used herein, means a material that catalyzes a reaction between a moiety that is soluble in a first phase, e.g., an alcohol phase, and another moiety that is soluble in a second phase, e.g., an aqueous phase.
[0070] The following abbreviations are used in this application: EtOH is ethanol; Me is methyl; Et is ethyl; Bu is butyl; n-Bu is normal-butyl, t-Bu is tert-butyl, OAc is acetate; KOt-Bu is potassium tert-butoxide; NBS is N-bromo succinimide; NMP is 1-methyl-2-pyrrolidinone; DMA is N,N-dimethylacetamide; n-BU 4 NBr is tetrabutylammonium bromide; n-Bu 4 NOH is tetrabutylammonium hydroxide, n-Bu 4 NH 2 SO 4 is tetrabutylammonium hydrogen sulfate, and equiv. is equivalents.
[0071] In certain of the chemical structures depicted herein, certain compounds are racemic, i.e., a mixture of dextro- and levorotatory optically active isomers in equal amounts, the resulting mixture having no rotary power.
[0072] General Synthesis One aspect of the invention comprises a general synthesis of xanthines based on a one-pot, five-step sequence from cyanamide and N-aryl glycine ester. Compound 1 can be prepared from glycine ethyl ester or a salt thereof (e.g., hydrochloric or sulfuric acid salt) and an aromatic aldehyde. As shown in Scheme I below, Compound 1 is prepared from glycine ethyl ester hydrochloride and an aromatic aldehyde. Compound 2 is prepared by reacting cyanamide with an excess of triethylorthoformate. Compound 3 is prepared by reacting Compound 2 with Compound 1. Compound 3 is converted into Compound 4 by reacting it with a base (e.g., potassium tert-butoxide). Compound 4 is reacted with a N—R 2 -substituted carbamate (e.g., urethane) in the presence of a base to obtain Compound Salt 5K. Based on the N—R 2 -substituent of the carbamate used, a desired N-1-R 2 -substituted xanthine Compound Salt 5K is obtained. Compound Salt 5K is then N-3-L-substituted with an L-halide using a phase transfer catalyst to provide a tri-substituted (R 1 , R 2 and L) xanthine Compound 6. Alternatively, Compound Salt 5K can be neutralized to Compound 5, which can then be selectively N-L-substituted to provide Compound 6. A selective dihalogenation of Compound 6 leads to a dihalo Compound 7, which is then coupled with an R 4 -substituted amine, followed by an addition of a base (e.g., sodium bicarbonate), to provide a tetrasubstituted (R 1 , R 2 , R 3 and R 4 ) xanthine Compound 13 when L is the same as R 3 . If L is a protected form of R 3 , intermediate Compound 9 is deprotected with a base (e.g., tetrabutylammonium hydroxide) to provide the tetrasubstituted (R 1 , R 2 , R 3 and R 4 ) xanthine Compound 13. Scheme I depicts this process:
[0073] wherein,
[0074] R 1 , R 2 and R 3 are each independently selected from the group consisting of:
[0075] H, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, allyl, —OR 5 ,
[0076] —C(O)OR 5 , —C(O)R 5 , —C(O)N(R 5 ) 2 , —NHC(O)R 5 and —NHC(O)OR 5 , wherein each R 5 is independently H or alkyl;
[0077] provided that R 2 and R 3 are not both —H;
[0078] R 4 is an alkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, aryl or heteroaryl group;
[0079] wherein R 1 , R 2 , R 3 and R 4 are optionally substituted with moieties independently selected from the group consisting of: alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, heteroaryl, heterocycloalkyl, halo, thio, nitro, oximino, acetate, propionate, pivaloyl, —OC(O)R 5 , —NC(O)R 5 or —SC(O)R 5 , —OR 50 , —NR 50 R 51 , —C(O)OR 50 , —C(O)R 50 , —SO 0-2 R 50 , —SO 2 NR 50 R 51 , —NR 52 SO 2 R 50 , ═C(R 50 R 51 ), ═NOR 50 , ═NCN, ═C(halo) 2 , ═S, ═O, —C(O)N(R 50 R 51 ), —OC(O)R 50 , —OC(O)N(R 50 R 51 ), —N(R 52 )C(O)(R 50 ), —N(R 52 )C(O)OR 50 and —N(R 52 )C(O)N(R 50 R 51 ), wherein each R 5 is independently H or alkyl and R 50 , R 51 and R 52 are each independently selected from the group consisting of: H, alkyl, cycloalkyl, heterocycloalkyl, heteroaryl and aryl;
[0080] Hal is a halogen group;
[0081] L is R 3 or a protected form of R 3 comprising R 3 with a protective substituent selected from the group consisting of acetate, propionate, pivaloyl, —OC(O)R 5 , —NC(O)R 5 and —SC(O)R 5 group, wherein R 5 is H or alkyl; and
[0082] M + is a metal ion.
[0083] While some compounds are shown in Scheme I as non-isolated intermediates, it is understood that they can be isolated using routine chemistry techniques.
[0084] Preferred embodiments of the invention utilize compounds with the following R 1 , R 2 , R 3 and R 4 radicals:
[0085] R 1 is preferably alkyl, aryl, heteroaryl, —OR 5 , —C(O)OR 5 , —C(O)R 5 or —C(O)N(R 5 ) 2 , wherein R 5 is H or alkyl. Each R 1 group is optionally substituted as defined above. More preferably, R 1 is —OR 5 , wherein R 5 is H or alkyl. Even more preferably, R 1 is alkoxy, such as methoxy.
[0086] R 2 is preferably C 1-12 alkyl, C 3-8 cycloalkyl, aryl or heteroaryl. Each R 2 group is optionally substituted as defined above. More preferably, R 2 is C 1-6 alkyl, optionally substituted as defined above. Even more preferably, R 2 is ethyl.
[0087] R 3 is preferably C 1-12 alkyl, C 3-8 cycloalkyl, aryl, heteroaryl, allyl, —NHC(O)R 5 or —NHC(O)OR 5 , wherein R 5 is H or C 1-12 alkyl. Each R 3 group is optionally substituted as defined above. More preferably, R 3 is C 1-6 alkyl, optionally substituted with one of the groups defined above. Even more preferably, R 3 is C 1-6 alkyl, substituted with —OR 50 , wherein R 50 is H, such as hydroxymethyl.
[0088] R 4 is preferably C 1-12 alkyl, C 3-8 cycloalkyl, C 5-8 cycloalkenyl, heterocycloalkyl, aryl or heteroaryl. Each R 4 group is optionally substituted as defined above. More preferably, R 4 is C 3-8 cycloalkyl, optionally substituted as defined above. Even more preferably, R 4 is C 4-7 cycloalkyl, substituted with —OR 50 , wherein R 50 is defined as above. For example, R 4 can be 2-hydroxy cyclopentyl.
[0089] In some embodiments of the invention, L is the same as R 3 . In other embodiments of the invention, L is a protected form of R 3 , in which case the protective substituent on R 3 is preferably an acetate, propionate, pivaloyl, —OC(O)R 5 , —NC(O)R 5 or —SC(O)R 5 group, wherein R 5 is H or C 1-12 alkyl.
[0090] Hal is preferably chlorine, bromine and fluorine. More preferably, Hal is chlorine or bromine. Even more preferably, Hal is bromine.
[0091] M + is, preferably, an alkali metal or alkaline earth metal ion. More preferably, M + is a potassium or sodium ion.
[0092] Compound 1 can be prepared by reacting about equimolar amounts of p-anisaldehyde and glycine ethyl ester hydrochloride (or its free form) in the presence of a base (e.g., potassium carbonate, sodium carbonate, sodium bicarbonate, potassium butoxide, or the like) and in an alcoholic solvent (e.g., ethanol, isopropanol, or the like). Preferably, up to about 2 moles (e.g., about 1.3-1.5 moles) of glycine ethyl ester hydrochloride and up to about 2 moles (e.g., about 1 mole) of inorganic salt can each be used per mole of p-anisaldehyde. The reaction proceeds through an intermediate imine (not shown), which is reduced with a reducing agent (e.g., NaBH 4 , catalytic hydrogenation, H 2 /Pd/C, or the like), preferably, a borohydride reducing agent. The reaction can be run at room temperature. Preferably, the reaction is run at about 20-45° C., more preferably, about 30-40° C. At the end of the reaction, Compound 1 is isolated in a solution form in an organic solvent (e.g., toluene), and used as such for the next step.
[0093] Compound 2 is N-cyanomethanimidic acid ethyl ester, and is prepared by reacting cyanamide with an excess of triethylorthoformate. Preferably, from about 1.2 to about 1.5 moles of triethylorthoformate (e.g., 1.33 moles) are reacted with about 1 mole of cyanamide. Preferably, the reaction mixture is gradually heated up to about 85-95° C. for about 2 hours. Compound 2 is not isolated, and is used in-situ for the next step.
[0094] The structure of Compound 3 is novel. An equimolar reaction mixture of Compound 2 (obtained in-situ above) is added to a solution of Compound 1 in an anhydrous, ethereal organic solvent (e.g., tetrahydrofuran (“THF”), diethyl ether, monoethyl ether, monoglyme, diglyme, ethylene glycol, or the like), and heated to about 65-70° C. for about 1 hour. About 1.1 to about 1.3 moles (e.g., 1.2 moles) of Compound 2 is used per mole of Compound 1. At the end of the reaction, the product is not isolated, and is used in-situ for the next step.
[0095] The structure of Compound 4 is novel. Compound 4 is prepared by reacting Compound 3 (obtained in-situ above) with a base (e.g., potassium tert-butoxide, potassium pentoxide, potassium tert-amylate, sodium ethoxide, sodium tert-butoxide, or the like) in an alcoholic solvent (e.g., anhydrous EtOH). A catalytic amount of base is preferably used, generally, about 5-20 mol % per mol of Compound 3 in the alcoholic solvent. More preferably, about 15 mol % of base is used. Preferably, the reaction mixture is heated to about 75-85° C. for about 1 hour. At the end of reaction, the product is not isolated, and is used in-situ for the next step.
[0096] The structure of Compound Salt 5K is novel. Compound 4 can be converted to Compound Salt 5K by reacting it in-situ with from about 1 to about 3 moles (e.g., 1.5 moles) of a N—R 2 -substituted carbamate, R 2 NHCO 2 R 1 (e.g., the urethane EtNHCO 2 Et), and from about 1 to about 3 moles (e.g., 2.1 moles) of a base (e.g., potassium tert-butoxide, potassium pentoxide, potassium tert-amylate, sodium ethoxide, sodium tert-butoxide, or the like), in an ethereal organic solvent (e.g., THF, diethyl ether, monoethyl ether, monoglyme, diglyme, ethylene glycol, or the like) or a sulfolane, at 80-130° C. (preferably 115-125° C.), wherein R 1 and R 2 are each independently defined as above. The base provides a metal ion (M + ) to Compound Salt 5K. Potassium tert-butoxide provides a potassium ion (K + ), while sodium tert-butoxide provides a sodium ion (Na + ) to Compound Salt 5K. The inventive methodology provides an efficient synthesis for directly converting (in one step) Compound 4 to Compound Salt 5K in solution without the use of any toxic chemicals or harsh thermal conditions.
[0097] The potassium Compound Salt 5K is isolated by filtration, but not dried. Compound Salt 5K is selectively N-3 alkylated in-situ to Compound 6 with BrCH 2 -L (e.g., 2-bromoethyl acetate in an anhydrous, organic solvent (e.g., THF, methyl tert-butyl ether, or the like) in the presence of a phase transfer catalyst (e.g., tetrabutylammonium bromide, tetrabutylammonium hydrogen sulfate, or the like), wherein L is defined as above. The reaction takes place rapidly (e.g., about 1 hour at about 65-70° C.), and no base is required. This is in contrast to known N-alkylation reactions, many of which use dimethylformamide (“DMF”) and potassium carbonate or an organic base (e.g., triethylamine, diisopropylethylamine, etc.) to achieve the N-alkylation, and which generally take from several hours to days to complete.
[0098] Alternatively, the potassium Compound Salt 5K can be neutralized with an acid (e.g., aqueous acetic acid, dilute hydrochloric acid, dilute sulfuric acid, or the like) to provide Compound 5. Under this alternative process, Compound 5 can be selectively N-3 alkylated by treatment with an inorganic base (e.g., potassium carbonate, sodium carbonate, sodium bicarbonate, potassium butoxide, or the like) in a polar solvent (e.g., acetonitrile and its higher homologs, DMF, N,N-dimethylacetamide (“DMA”), 1-methyl-2-pyrrolidinone (“NMP”), or the like) in the presence of a phase transfer catalyst (e.g., tetrabutylammonium bromide, tetrabutylammonium hydrogen sulfate, or the like) and an alkylating agent (e.g., BrCH 2 -L, where L is defined as above) to provide Compound 6.
[0099] The structure of Compound 6 is novel. The conversion from Compound 1 to Compound 6 is a 5-step process that can be carried out in one pot or container. The overall yield for Compound 6 is generally about 45-55%.
[0100] The structure of Compound 7 is novel. Compound 6 is regioselectively dihalogenated (e.g., dibrominated or dichlorinated) to Compound 7 under mild conditions with about 2-3 moles (preferably, about 2.7-2.8 moles) of a dihalogenating agent (e.g., a dibrominating agent, such as N-bromo succinimide (“NBS”), dibromo-1,3-dimethyl hydantoin or N-bromo acetamide). The use of a strong acid (e.g., triflic or sulfuric acid) as a catalyst in an amount of about 1-10 mol %, preferably, about 3 mol %, allows the reaction to proceed at room temperature. Alternatively, tetrabutylammonium hydrogensulfate can be used as the catalyst, but it would require an application of heat (e.g., about 80° C.) to drive the reaction to completion. It is preferred that the reaction is run in a dry polar solvent, such as acetonitrile, DMF, NMP, DMA, or a mixture thereof. Under these conditions, the amounts of mono- and tri-bromo side products are minimized.
[0101] Compound 7 is coupled with Compound 8 (an R 4 NH 2 amine) to form Compound 13 via Compound 9, a novel intermediate. Typical coupling reaction conditions for this step generally require the use of a polar, aprotic solvent (e.g., NMP, DMA, or the like), an inorganic base (e.g., potassium carbonate, sodium carbonate, sodium bicarbonate, or the like), and an excess of Compound 8, preferably, up to about 3 moles of Compound 8 per mole of Compound 7. A preferred mild, inorganic base is sodium bicarbonate. The application of heat will drive the reaction to completion faster. For example, at about 130-140° C., the reaction time can be shortened in half, from about 24 hours to about 12 hours.
[0102] L is R 3 or a protected form of R 3 (i.e., where a moiety is attached to R 3 for protecting it from reacting with other ingredients). When L is the same as R 3 , Compound 9 is the same as Compound 13, so the addition of an inorganic base to the intermediate Compound 9 (step (k) (ii) of the summary of the invention) is not necessary. On the other hand, when L is a protected form of R 3 , deprotection can be accomplished in the same pot, without isolating Compound 9, by using a catalytic amount of an inorganic base (e.g., potassium carbonate, tetrabutylammonium hydroxide, or the like). Protected forms of R 3 include R 3 moieties substituted with protective groups such as acetate, propionate, pivaloyl, —OC(O)R 5 , —NC(O)R 5 or —SC(O)R 5 groups, wherein R 5 is H or C 1-12 alkyl. When the protecting substituent is an acetate group, deprotection is preferably carried out with tetrabutylammonium hydroxide because it results in a faster and cleaner reaction, and product isolation is facile. In another embodiment of the invention, a pivaloyl protecting group can be used in place of the acetate protecting group, and the application of similar chemistry will lead from Compound 5K (or Compound 5) to Compound 13. The deprotection and work-up conditions are adjusted so as to minimize formation of isomeric impurities. For instance, care should be taken to monitor the basicity of the reaction during deprotection because when the deprotection steps are carried out under very strong basic conditions, diastereomers may form.
Specific Synthesis
[0103] The general synthesis of Scheme I can be applied to prepare specific xanthines. For example, if R 1 is —OCH 3 , R 2 is —CH 2 CH 3 , L is —CH 2 CO 2 CH 3 , R 3 is
[0104] then the product obtained from Scheme I (Compound 13) can be called 1-ethyl-3,7-dihydro-8-[(1R,2R)-(hydroxycyclopentyl)amino]-3-(2-hydroxyethyl)-7-[(3-bromo-4-methoxyphenyl)methyl]-1H-purine-2,6-dione (Compound 13A), a PDE V inhibitor useful for the treatment of erectile dysfunction. An illustration of this synthesis is shown in the following Scheme II, which allows for an efficient, commercial scale preparation of Compound 13A, without the need for chromatographic purification of intermediates:
[0105] The experimental conditions disclosed herein are preferred conditions, and one of ordinary skill in the art can modify them as necessary to achieve the same products.
EXAMPLES
[0106] Compound 1A: glycine-N-[(4-methoxyphenyl)methyl] Ethyl Ester
[0107] To a mixture of glycine ethyl ester hydrochloride (about 1.4 equiv) and potassium carbonate (about 1.0 equiv) was added anhydrous ethanol. The mixture was stirred at about 40-45° C. for about 3 hours. Then, p-anisaldehyde (about 1.0 equiv.) was added, and the reaction mixture was stirred for a minimum of about 3 hours to provide an imine (not shown). Upon reaction completion (about ≦5.0% p-anisaldehyde remaining by GC analysis), the reaction mixture was cooled to about 0-10° C. Then, an aqueous solution of sodium borohydride (about 0.50 equiv) was added to the reaction mixture at a temperature of between about 0° C. and about 20° C., and stirred for about 1 hour to provide Compound 1A. Upon completion of the reduction reaction, the reaction mixture was quenched with the slow addition of an aqueous solution of aqueous glacial acetic acid. After quenching, the reaction mixture was warmed to room temperature and filtered to remove solids. The filtrate was then concentrated under vacuum, followed by the addition of toluene and water to facilitate layer separation. Aqueous potassium carbonate solution was added to adjust the pH of the mixture to about 8-9. The organic layer was separated and the aqueous layer was extracted with toluene. The combined toluene extracts were concentrated to provide the product in about a 80-85% yield (based on GC and HPLC in solution assay).
[0108] [0108] 1 H NMR 400 MHz (CDCl 3 ): δ 7.23 (d, J=8.5 Hz, 2H), 6.85 (d, J=8.5 Hz, 2H), 4.17 (q, J=7.1 Hz, 2H), 3.78 (s, 3H), 3.73 (s, 2H), 3.38 (s, 2H), 1.88 (s, br, 1H), 1.26 (t, J=7.1 Hz, 3H); 13 C NMR 100 MHz (CDCl 3 ): δ 172.8, 159.2, 132.0, 129.9, 114.2, 61.1, 55.6, 53.1, 50.4, 14.6.
[0109] Compound 2: N-cyanomethanimidic Acid Ethyl Ester
[0110] To cyanamide (about 1.2 mole) was added triethylorthoformate (about 1.33 mole), and the reaction mixture was heated to about 85-95° C. for approximately 2 hours to form Compound 2. Estimated in-solution yield was about 95-100%. The product was optionally purified by vacuum distillation.
[0111] [0111] 1 H NMR 400 MHz (CDCl 3 ): δ 8.38 (s, 1H), 4.28 (t, J=6.7 Hz, 2H), 1.29 (t, J=6.8 Hz, 3H); 13 C NMR 100 MHz (CDCl 3 ): δ 171.5, 113.4, 65.5, 13.1.
[0112] Compound 3A: cis- and trans-glycine N-[(cyanoimino)methyl]-N-[(4-methoxyphenyl)methyl] Ethyl Ester
[0113] A solution of Compound 1A (about 1.0 mole) in toluene was concentrated under vacuum to distill off toluene. Anhydrous tetrahydrofuran (“THF”) was added to the concentrate, then Compound 2 (about 1.2 moles, obtained above) was added to that, and the solution was heated at reflux for about 1 hour. At this stage, the formation of Compound 3A was complete. Estimated in-solution yield was about 95% (about 2:1 mixture of cis and trans isomers).
[0114] Compound 4A: 1H-imidazole-5-carboxylic Acid, 4-amino-1-[(4-methoxyphenyl)methyl Ethyl Ester
[0115] Compound 3A (obtained above) was concentrated by distilling off THF. Then, anhydrous ethanol was added to afford a reaction mixture solution. Separately, potassium t-butoxide (about 0.15 mole) was dissolved in anhydrous ethanol to afford a solution. The potassium t-butoxide solution was added to the reaction mixture solution and heated to about 75-85° C. for about 1 hour. The overall in-solution yield of Compound 4A was about 85-90%.
[0116] [0116] 1 H NMR 400 MHz (CDCl 3 ): δ 7.16 (s, 1H), 7.08 (d, J=8.6 Hz, 2H), 6.82 (d, J=8.7 Hz, 2H), 5.23 (s, 2H), 4.93 (s, br, 2H), 4.23 (q, J=7.1, 2H), 3.76 (s, 3H), 1.26 (t, J=7.1 Hz, 3H); 13 C NMR 400 MHz (CDCl 3 ): δ 160.9, 159.2, 139.0, 128.6, 128.5, 114.0, 101.8, 59.5, 55.2, 50.1, 14.4.
[0117] Compound 5AK: 1-ethyl-3,7-dihydro-7-[(4-methoxyphenyl)methyl]-1H-Purine-2,6-dione Potassium Salt
[0118] The reaction mixture containing Compound 4A in ethanol (obtained above) was added to diglyme and distilled under vacuum to remove the ethanol. After being cooled to room temperature, N-ethylurethane (about 1.2 equiv.) was added and the reaction mixture was heated to about 110-120° C. A solution of potassium t-butoxide (2.2 equiv.) in diglyme was added to the hot solution. The reaction mixture was cooled to room temperature. THF was added to precipitate additional product, which was filtered and washed to provide Compound Salt 5AK in 55-65% overall yield. The wet cake can be used as such for conversion to Compound 6A.
[0119] [0119] 1 H NMR (DMSO-d 6 , 400 MHz): δ 7.73 (s, 1H) 7.31 (d, J=8.6 Hz, 2H) 6.86 (d, J=8.6 Hz, 2H) 5.24 (s, 1H) 3.88 (q, J=6.8 Hz, 2H) 3.71 (s, 3H) 1.07 (t, J=6.8 Hz, 3H); 13 C NMR (DMSO-d 6 , 100 MHz): 6161.1, 159.0, 158.4, 157.2, 141.4, 131.0, 129.5, 114.1, 105.6, 55.4, 48.2, 34.4, 14.3.
[0120] Optional Neutralization of Compound Salt 5AK to Compound 5A:
[0121] Compound 5A: 1-ethyl-3,7-dihydro-7-[(4-methoxyphenyl)methyl]-1H-Purine-2,6-dione
[0122] The wet cake filtered solid of Compound Salt 5AK (obtained above) was suspended in water and then acidified to a pH of about 5 using glacial acetic acid. The resulting slurry was filtered to obtain the neutralized product, which was then washed with water and dried. The overall isolated yield of neutralized Compound 5A from Compound 1A was about 45-55%. Spectroscopic data for neutralized Compound 5A was identical to that of Compound Salt 5AK.
[0123] Compound 6A: 3-[2-(acetyloxy)ethyl]-1-ethyl-3.7-dihydro-7-[(4-methoxyphenyl)methyl]-1H-purine-2,6-dione
[0124] To the wet cake filtered solid of Compound Salt 5AK (obtained above) were added tetrabutylammonium bromide (about 0.05 mole) and 2-bromoethyl acetate (about 1.2 moles) in THF. After being heated to reflux for about 2 hours, part of the THF was distilled off, and isopropyl alcohol was added to the reaction mixture. The reaction mixture was then concentrated under reduced pressure and cooled to around room temperature. Water was added to precipitate the product. After being cooled to about 0-5° C. for about a few hours, the product was isolated by filtration. The wet cake was washed with aqueous isopropyl alcohol (about 30% in water), and dried under vacuum to afford Compound 6A as a pale yellow solid in about a 45-55% overall yield (based on Compound 1A). The crude product may be purified further by decolorizing with Darco in methanol, followed by filtration and concentration to afford crystalline Compound 6A.
[0125] [0125] 1 H NMR (CDCl 3 , 400 MHz): δ 7.54 (s, 1H) 7.32 (d, J=8.6 Hz, 2H) 6.90 (d, J=8.6 Hz, 2H) 5.43 (s, 2H) 4.41 (m, 2H) 4.38 (m, 2H) 4.10 (q, J=7.2 Hz, 2H) 3.79 (s, 3H) 1.96 (s, 3H) 1.25 (t, J=7.2 Hz, 3H); 13 C NMR (CDCl 3 , 100 MHz): δ 171.1, 160.2, 155.3, 151.4, 148.9, 140.9, 130.1, 127.7, 114.8, 107.5, 61.7, 55.6, 50.2, 42.4, 36.9, 21.2, 13.6.
[0126] After Optional Neutralization of Compound Salt 5AK to Compound 5A:
[0127] Compound 6A: 3-[2-(acetyloxy)ethyl]-1-ethyl-3,7-dihydro-7-[(4-methoxyphenyl)methyl]-1H-purine-2,6-dione
[0128] Acetonitrile was added to a mixture of Compound 5A (about 1.0 mole), anhydrous potassium carbonate (about 1.5 moles) and tetrabutylammonium hydrogen sulfate (about 0.05 mole). 2-bromoethyl acetate (about 1.5 moles) was added in three separate portions (0.72 mole in the beginning, another 0.45 mole after about 2 hours of reaction, and then the remaining 0.33 mole after about another 1 hour of reaction) during the course of the reaction at about 80-85° C. The total reaction time was about 7 hours. The reaction mixture was cooled to about room temperature and filtered. The filtrate was concentrated. Aqueous isopropanol was added to crystallize the product. The product was filtered, washed with aqueous isopropanol, and dried to provide Compound 6A in about a 75-80% yield.
[0129] Compound 7A: 8-bromo-1-ethyl-3-[2-(acetyloxy)ethyl]-3,7-dihydro-7-[(3-bromo-4-methoxyphenyl)methyl]-1H-Purine-2,6-dione
[0130] Compound 6A (about 1 mole) and NBS (about 2.8 moles) were dissolved in dry acetonitrile and agitated at about 15-20° C. To this reaction mixture, a solution of sulfuric acid (about 0.03 mol) in acetonitrile was added, while maintaining the reaction temperature below about 25° C. The reaction mixture was agitated at about 20-25° C. for about 12-15 hours until complete consumption of the starting material was indicated. The reaction mixture was cooled to about 0-5° C. and a cold (about 5-10° C.) aqueous solution of sodium sulfite was added, keeping the temperature below about 10° C. The reaction was agitated for about 2 hours at about 0-10° C., and then filtered. The isolated cake was washed with water, followed by methanol, then dried under a vacuum to obtain Compound 7A in about an 85% yield.
[0131] [0131] 1 H NMR (CDCl 3 , 400 MHz): □ 7.60 (d, J=2.0 Hz, 1H), 7.35 (dd, J=8.4 Hz, 2.0 Hz,1H), 6.83 (d, J=8.4 Hz, 1H), 5.43 (s, 2H), 4.35 (m, 4H), 4.05 (q, J=7.0 Hz, 2H), 3.85 (s, 3H), 1.96 (s, 3H), 1.23 (t, J=7.0 Hz, 3H); 13 C NMR (CDCl 3 , 100 MHz): □ 171.0, 156.2, 154.2, 150.8, 148.2, 138.3, 128.9, 128.7, 127.5, 112.1, 112.0, 109.1, 61.5, 56.5, 49.3, 42.5, 37.0, 21.0, 13.3. MS (ES) m/e 545.2 (M+H) + .
[0132] Compound 13A: 1-ethyl-3,7-dihydro-8-l(1R,2R)-(hydroxycyclopentyl)amino]-3-(2-hydroxyethyl)-7-[(3-bromo-4-methoxyphenyl)methyl]-1H-purine-2,6-dione
[0133] Compound 7A (about 1 mole) was combined with (R,R)-2-amino-1-cyclopentanol hydrochloride (Compound 8A, about 1.2 moles) and sodium bicarbonate (about 3 moles). To this reaction mixture was added N,N-dimethylacetamide (“DMA”), and the reaction mixture was agitated at about 135-140° C. for about 15-17 hours until complete consumption of the starting material was indicated. Compound 9A is an intermediate that is formed, but not isolated, from the reaction mixture. The reaction mixture was then cooled to about 45-50° C., and tetrabutylammonium hydroxide (about 0.05 moles of about a 40% solution in water) was charged therein, followed by methanol. The reaction mixture was refluxed at about 80-85° C. for about 8-9 hours until complete deprotection of the acetate group was indicated. The reaction mixture was cooled to about 40-45° C. and concentrated under vacuum. The pH of the reaction mixture was adjusted to about 5-6 with dilute acetic acid, and the reaction mixture was heated to about 55-65° C., and seeded with a small amount of Compound 13A. The reaction mixture was then cooled to about 30-35° C. over a period of about 2 hours, and water was added over a period of about 1 hour. The reaction mixture was further cooled to about 0-5° C. over a period of about 1 hour, and agitated at that temperature for about 4 hours. The Compound 13A product was isolated by filtration, washed with water and dried to provide about an 85-90% yield.
[0134] [0134] 1 H NMR (CDCl 3 , 400 MHz): □ 7.47 (d, J=2.1 Hz, 1H), 7.18 (dd, J=8.4 Hz, 2.0 Hz, 1H), 6.87 (d, J=8.4 Hz, 1H), 5.23 (s, 2H), 5.01 (s, 1H), 4.22 (m, 2H), 4.15 (m, 1H), 4.05 (q, J=7.0 Hz, 2H), 3.93 (m, 3H), 3.88 (s, 3H), 3.77 (m,1H), 2.95 (m,1H), 2.15 (m, 1H), 2.05 (m, 1H), 1.60-1.80 (m, 4H), 1.35 (m, 1H), 1.23 (t, J=7.0 Hz, 3H); 13 C NMR (CDCl 3 , 100 MHz): □ 156.2, 154.0, 153.5, 151.8, 148.3, 132.6, 129.1, 127.9, 112.5, 103.2, 79.5, 77.8, 63.2, 61.3, 56.7, 46.5, 45.9, 36.8, 32.9, 31.5, 21.4, 13.8. MS (ES) m/e 523.4 (M+H) + .
[0135] Micronization
[0136] Materials prepared by the above-described processes without further processing can exhibit particle sizes that are greater than optimal for purposes of bioabsorption, and thus, bioavailability. In certain preferred embodiments of the invention, the compounds disclosed herein are subject to a micronization process to generate particle size distributions more favorable for bioabsorption.
[0137] Form 2 of Compound 13 (disclosed in the co-pending patent application “Xanthine Phosphodiesterase V Inhibitor Polymorphs,” incorporated by reference thereto) was micronized on a fluid energy mill (Jet Pulverizer Micron Master, model 08-620). A feeder (K-Tron Twin Screw Feeder) was used to feed material to the mill at a rate of about 80 grams/min. A mill jet pressure of 110 psig was used. The resulting material was then heated to convert amorphous material generated during micronization to crystalline material. The setpoint on the dryer (Stokes Tray Dryer, model 438H) was set to 95° C. The batch was heated at a temperature between 90 and 100° C. for 8 hours. Differential Scanning Calorimetry (“DSC”) analysis indicated no amorphous material was present. The particle size distribution of the resulting material was characterized, using a Sympatec particle size analyzer, as having a volume mean diameter of 8.51 μm and a median particle diameter of 5.92 μm. Cryogenic micronization processes may result in even more favorable particle size distributions.
[0138] The above description is not intended to detail all modifications and variations of the invention. It will be appreciated by those skilled in the art that changes can be made to the embodiments described above without departing from the inventive concept. It is understood, therefore, that the invention is not limited to the particular embodiments described above, but is intended to cover modifications that are within the spirit and scope of the invention, as defined by the language of the following claims. | A process for preparing xanthine phosphodiesterase V inhibitors, and compounds utilized in said process. The process includes a five-step methodology for efficient synthesis of Compound 5 without intermediate purifications or separations, a dihalogenation step to synthesize Compound 7, and a coupling reaction to produce Compound 9. | 2 |
BACKGROUND OF THE INVENTION
[0001] Since the early 1970s the increased cost of petroleum products has driven a growing interest in the recycling of asphalt paved road surfaces. It has become increasingly important to recycle in order to preserve these non-renewable resources and save cost.
[0002] An asphalt paved road surface is made up of a combination of graded aggregates (crushed rock and sand) and asphalt cement (a dark, sticky petroleum based adhesive) and air voids. These materials are typically blended together in a central plant, delivered to the roadway by trucks and spread and compressed onto the road surface.
[0003] It is well known that over time asphalt-paved road surfaces age and deteriorate for a number of reasons. Temperature fluctuations, precipitation, and UV exposure cause the pavement to lose its flexibility, which causes the surface to crack and deteriorate. Moreover, chemicals within the asphalt cement gradually dissipate or their properties change (harden and lose adhesive properties) further causing the eventual failure of the surface.
[0004] Originally, pavement recycling involved cold milling machines that were used to grind out an aged or damaged pavement which was then hauled back to a central processing plant where it would be heated and mixed with new material. The mixture would then be hauled back to the road site and be reinstalled back on the road surface. Generally speaking the cold grinding of aged or damaged pavement tends to fracture the aggregate requiring the selected addition of new aggregate material to compensate for the fractured aggregate.
[0005] Subsequently insitu processes for the recycling of asphalt have been developed. Some such processes involve heating and are frequently referred to as “hot in-place asphalt recycling” (hereinafter referred to as HIPAR).
[0006] HIPAR consists of many known methods and machines but generally it involves insitu heating the asphalt pavement to soften, loosening the softened pavement with scarifiers or grinders, adding and mixing in new asphalt mix and rejuvenating oils and then reinstalling the combined mixture back on the road surface at substantially the same grade elevation. It is important not to add too much new asphalt mix using this technique or the newly repaved lane will be too high in relation to the adjoining lane resulting in a safety hazard to motorists.
[0007] The prior art has evolved a number of techniques for carrying out HIPAR on asphalt road surfaces. Typically the prior art incorporates large infrared or hot air heaters, which heat the road surface to about 275to 350 F. When the pavement is heated to this temperature range it becomes softened enough to remove it without crushing the aggregates. Overheating the surface to greater temperatures can result in hardening and loss of adhesive properties of the asphalt cement. Moreover overheating result in excessive blue and black smoke emissions which not only damage the environment but also cause a safety hazard to the workers and motorists in the area.
[0008] When recycling a paved surface it is advantageous to achieve a depth of processing of least 1.5 to 2 inches in order to sufficient remove cracks and defects and prevent or delay their return. Due to the poor thermal conductivity of aged asphalt pavement achieving this depth without overheating has generally not been possible.
[0009] One technique that was developed comprised heating and processing the pavement in two or more stages (hereinafter referred to as Multi-Stage), which in one example consisted of heating and removing layers of 0.5 to 1inch thickness per stage. The Multi-Stage technique overcame some of the previously mentioned challenges but faced new problems resulting from managing the asphalt removed from the first removed layer while heating and grinding the second layer. In the case of three and four stage machines this problem progressed beyond the first and second layers.
[0010] One prior art Multi-Stage technique of dealing with this problem is described U.S. Pat. No. 4,929,120 issued to Wiley and Rorison. A conveyor is used to carry the asphalt removed from the first layer over top of the subsequent heater. Although this patent represents an advance over the prior art, considerable capital cost and maintenance cost can be incurred for such a conveyor.
[0011] A second prior art method of dealing with this problem is described in U.S. Pat. No. 4,850,740 issued to Wiley. This patent describes a prior art method and apparatus whereby there is a longitudinal gap in the center of the second and subsequent heaters banks to allow the heated, windrowed asphalt removed from the first and subsequent layers to pass through without overheating. Again while this patent represents an additional advance over the prior art, issues can arise in that the existing paved surface beneath the gap in the subsequent heaters does not get heated sufficiently. This is partly due to the poor heat transfer from the hot windrow to the unground pavement surface below. The windrow is simply not hot enough to sufficiently heat the unground pavement surface below. In addition air voids present in the loosened asphalt in the windrow inhibit heat transfer to a sustained temperature right against the unground pavement below the windrow. The resulting lack of heating and softening in the area below the previous removed windrow causes the aggregates in this lower area to become fractured during milling which reduces the quality of final recycled asphalt product. Another problem encountered is that this asphalt cement within this unheated material does not become hot enough to become liquid or pliable and, therefore, it does not bind with the other material in the roadway or become mixed with the later added rejuvenators. Another issue to be considered is the cooling effect this unheated material has on the total final mixture. This means the other materials not in this area below the heated windrow must be heated to a higher temperature to compensate to achieve the desired temperatures for proper mixing in of rejuvenates and pressing (compacting) back on the road. This can result in overheating of the road surface damaging the asphalt cement and causing smoke emissions as mentioned previously.
[0012] It is an object of this invention to provide an improved method of rejuvenating an asphalt paved road surface and its associated apparatus.
[0013] It is an aspect of this invention to provide a method of rejuvenating an asphalt paved road surface comprising: grinding a portion of the road surface to produce a first ground or loosened asphalt portion; removing the first loosened asphalt portion to present a recess in the remaining portion of the road; heating the remaining portion of said road; grinding the heated remaining portion of the road to present a second loosened asphalt portion; gathering the second loosened asphalt portion on to the recess means and exposing a lower layer of remaining portion of the road; heating the lower layer of the remaining portion of the road; gathering the heated lower layer of the remaining portion of the road to present a third loosened asphalt portion; commingling the third loosened asphalt portion with the second loosened asphalt portion onto the recess means; introducing fresh asphalt to the commingled asphalt portion so as to repair the road.
[0014] It is another aspect of this invention to provide a method of rejuvenating an asphalt paved road surface comprising: grinding a first portion of the road surface to a selected depth and width to produce a first loosened asphalt portion; removing the first loosened asphalt portion to present a strip in the central region of the remaining portion of the road surface; heating the remaining portion of the road surface to a selected temperature and time duration; grinding the heated remaining portion of the road surface to a selected depth to present a second loosened asphalt portion; windrowing the second loosened asphalt portion onto the strip to expose a lower layer of the remaining portion of the road; heating the lower layer of the remaining portion of the road to a selected temperature and time duration; grinding the heated lower layer of the remaining portion of the road to a selected depth to present a third loosened asphalt portion; windrowing the third loosened asphalt portion on to the strip and commingling the third loosened asphalt portion with the second loosened asphalt portion; introducing fresh asphalt to the commingled asphalt portions so as to repair the road.
[0015] These and other objects and features of the invention shall now be described in relation to the drawings.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic illustration depicting a series of machines employed to rejuvenate an asphalt-paved road surface in accordance with the preferred embodiment of the invention.
[0017] FIG. 2 is a pictorial illustration depicting the sequence of steps employed in practicing the invention according to its preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Vehicle 6 is a vehicle with a truck box 8 for hauling away removed asphalt. Self propelled machine 12 is equipped with a powered milling drum 14 that grinds a first recess means, or strip portion 15 of the road surface to a desired depth and width. The recess means or recess generally consists of a strip that is formed in the longitudinal direction L of the road and is generally located in the central region of the road. However, the strip 15 could be to the side of the road and consist of two narrower strips on either side.
[0019] Machine 12 then removes the ground up or loosened asphalt from first strip portion 15 with a conveyor 10 and loads it into truck box 8 to be hauled away as a first ground, loosened or ruptured asphalt portion. In the embodiment illustrated, the grinding can comprise cold grinding, although the surface could also be preheated.
[0020] The first strip portion 15 provides a recess means or region to receive or store the subsequent portions of asphalt in a manner described below. Once the longitudinal section of strip 15 is formed, there is a remaining transverse portion 80 and 82 . In other words, as the machine moves along a longitudinal direction L, a first loosened portion of asphalt is produced, and once removed a strip 15 is defined in the remaining outer strips 80 and 82 .
[0021] A second self-propelled machine 16 is equipped with a bank of under slung heaters 18 which may be lowered to within a few inches of the upper layer of the road surface 100 . Machine 16 is driven along a section of road surface 100 which in one example can be recycled at a speed of about 12 to 25 feet per minute to heat the upper layer 102 of the road surface to temperature of about 180 to 300 F to a depth of about 0.5 inch to 1 inch. A transversely mounted grinder 20 is mounted at the rear end of heater 18 . Grinder 20 removes the outer strips 80 and 82 of heated upper asphalt layer 102 from road surface 100 to form a second loosened asphalt portion and augers the second loosened asphalt portion to form a first windrow 108 contained within the first strip portion 15 . The outer strips 80 and 82 are disposed generally transversally of the road surface as shown.
[0022] Although the invention has been described in the context of grinding, the benefits of the invention may also be realized by loosening the asphalt by any mechanical means, which includes scarifying.
[0023] The heater 18 could heat the entire transverse width of the surface 100 (in which case this first strip portion 15 could also be heated or preheated); or the heater 18 could heat the upper layer of the road surface 100 except in the area of the first strip portion. Alternatively, the heater could be all the way across and the heater turned down over the windrow.
[0024] A third, self-propelled machine 22 follows behind machine 16 . is equipped with two side by side under slung heaters 25 and 28 which heat and soften the exposed second layer outer strips 104 and 105 . Under slung heaters 25 and 28 have a longitudinal space the width of the first strip portion 15 between them in order to prevent overheating of the asphalt windrow 108 . A transversely mounted grinder 26 is mounted at the rear end of heaters 25 and 28 . Grinder 26 removes the exposed second layer outer strips 104 and 105 from road surface 100 or a third loosened asphalt portion and augers the third loosened asphalt portion to be commingled with second loosened asphalt portion windrowed 108 to form a larger or commingled windrow 210 in the center of the road surface 100 . The lower layer of the remaining portions of the road comprises a transverse section of the road.
[0025] Hauling truck 32 has a truck box 33 for delivering fresh asphalt. Machine 42 has a front mounted receiving hopper 36 capable of receiving new asphalt mix from hauling truck box 33 . Machine 42 includes a feed conveyor 39 capable of adding the fresh asphalt to the windrowed asphalt 210 . Machine 42 also has storage and metering system 34 capable of adding rejuvenators to the windrowed asphalt 210 . The machine 42 also includes a conveyor 38 which elevates the larger windrow 210 which consists of the combination of the first windrow 108 and ground heated strips 104 and deposits them into mixing chamber 40 where they are mixed together by rotating mixers 41 to form a final rejuvenated asphalt mixture 46 . The final rejuvenated asphalt mixture 46 is then deposited into the receiving hopper 44 of conventional paving machine. The final rejuvenated asphalt mixture 46 is then spread back onto the road surface by screed device 48 and this is compacted using conventional methods.
[0026] Alternatively, the windrowed loosened asphalt 210 that consists of commingled second and third loosened asphalt portions can be consolidated by paving. The thickness in this case would not reach the original thickness of the asphalt road since the first loosened asphalt portion was removed. A thin layer of fresh or repaved asphalt may be added later. In other words, the fresh asphalt may be commingled with the second and third loosened asphalt portion or the fresh asphalt can be added later as a surface layer.
[0027] Advantages of the invention described herein include:
1. Once the initial ground asphalt from the first strip portion 15 is hauled away, there is no need to pick up any further ground material and convey it along or over subsequent heating elements or grinders. The absence of any conveyors required for such purposes considerably reduces the capital cost and increases the reliability of the equipment. 2. The full width and depth of the entire asphalt layer being rejuvenated will be heated sufficiently to become softened for grinding with substantially reduced damage to the aggregates. 3. The asphalt cement contained within the full width and depth of the entire asphalt layer being rejuvenated will be heated sufficiently for it to be lignified so that it can be mixed properly with rejuvenators within the process and properly adhere to other asphalt within the total mixture. 4. By removing a first strip portion of existing asphalt new rejuvenating asphalt can be added without changing the grade elevation of the recycled lane. This reduces safety hazards for motorists relating to uneven lane elevations. 5. Typically 10-25% new asphalt is added for existing technologies in order to avoid uneven lane elevations. By selecting the volume of ground or loosened asphalt removed from the first strip portions higher ratios of new asphalt could be added which is desirable for higher quality resurfacing characteristics such as strength and density of the rejuvenated surface; while at the same time reducing capital costs of conveyor equipment, and reducing operation costs in hauling away the ground heated material to be mixed with the new asphalt offsite. 6. The speed of the process described herein is increased over the prior art. For example, in one embodiment when a 2 foot strip was removed in first portion 15 , time savings were experienced in resurfacing the surface 100 .
[0034] As described above, the final rejuvenated asphalt mixture comprises a ratio of:
1. new mix 2. existing mix. 3. rejuventating oils This ratio can be measured by the volume of new mix added to the existing mix.
[0038] Generally speaking the volume of the new mix added will be the same or slightly greater than the volume of the first ground asphalt portion which is removed when producing the recess as previously described. The accuracy of the final ratio is depended on the accuracy of controlling the volume of the first ground asphalt portion which is milled and then removed.
[0039] Therefore, if one finds a way of improving the accuracy of the volume of the first ground asphalt portion to be removed, the accuracy of the method of rejuvenating an asphalt paved road surface will be enhanced such that the addition of the new mix will more accurately reflect the volume of the first ground asphalt portion that is removed so as to ensure that the height of the rejuvenated surface more closely reflects the height of the pre-rejuvenated asphalt surface of the road.
[0040] It has been found that the accuracy of the ratio can be more tightly controlled for a given volume of first ground asphalt portion which is removed by increasing the milling depth and decreasing the milling width of the strip 15 . In other words, one can remove the same volume asphalt surface by decreasing the width of the strip 15 while at the same time increasing the depth of the milling cut.
EXAMPLE
[0041] If one attempted to mill the entire width of a typical 12 foot wide road (144 inches) to a depth of 2 inches, where 25 percent of the 2 inch depth was milled to produce the first ground asphalt portion previously described, it would be normal to obtain a variance of up to (Var) of ± 1/4 inch in the depth of cut due to existing technologies of the machines used and the normal longitudinal and transverse surface variations including frost heaves, bumps, wheel path ruts, studded tire wear and raveling. The milling of the width of the road surface is generally more easily controlled by utilizing a single grinding drum of a desired width. There would still be a variance in the width of cut, but this variance would be typically small and insignificant in comparison to the variance in the depth of cut.
[0042] Accordingly, per unit length L of cut in the road surface (i.e., in the longitudinal direction), the volume of the first ground asphalt portion which is removed can be represented by the following formula:
[0000] Volume= W (width of cut in strip 25 )× D (depth of cut)× L (unit length in longitudinal direction)
[0043] Therefore, if one cuts the entire width of the 12 foot lane to a depth of 1/2 inch having a variance in the depth of cut of ± 1/4 inch, the volume V and Var is:
[0000] V= 144×½ inch×1=72 in 3 with a Var of ±36 in 3 since the variance is equal to 1/2 of the depth of cut (namely ± 1/4 on 1/2 inch of cut , or 50%).
[0044] However, if one removed the same volume i.e. 72 cubic inches by using a grinder that was half the width i.e. 6 feet per unit length L of road one would cut to a depth of 1 inch with a variance of ± 1/4 inch. Therefore, the volume of first ground asphalt portion that would be removed would be represented by the formula V=W×D×L with a Var of ±¼=72 inches×1 inch×1 =72 in 3 Var ±18 in 3 ,
[0000] (i.e. ±¼ inch on 1 inch cut or 25% of 72 in 3 ).
[0045] If one was to cut a three foot wide strip with two inch cut in depth per cut:
[0000] V =36×2×1 =72 cubic inches Var ±9 cubic inches.
[0046] Therefore, the accuracy of the new mix that is added to substitute for the first ground asphalt portion that is removed can be improved by increasing the depth of cut. Stated another way, the accuracy of the new mix to be added is directly proportional to the depth of cut for a constant volume, i.e.:
[0000] Accuracy≈D
[0047] In other words, if we increase the depth by 2 the accuracy of controlling the removed volume is improved by a factor of 2.
[0048] In other words, the amount of new asphalt to be added can be better controlled. In the example referred to above, the volume was constant.
[0049] However, the same improved level of accuracy controlling the ratio can be realized by keeping the width W of cut constant and cutting to a greater depth.
[0050] Moreover, the invention described above has applicability to a single stage version of the process previously described, namely:
[0051] 1 . a method of rejuvenating an asphalt-paved road surface comprising
(a) grinding a first portion of the road surface to a selected depth and width to produce a first loosened asphalt portion; (b) removing the first loosened asphalt portion to present a strip in the central region of the remaining portion of the road surface; (c) heating the remaining portion of the road surface; (d) grinding said heated remaining portion of the road surface to a selected depth to present a second loosened asphalt portion, and (e) introducing fresh asphalt to loosen the asphalt portion so as to repair said road.
[0057] The accuracy of the method described above as well as the method previously described can be improved by increasing the depth of cut. The examples referred to above dealt with the issue of a constant volume. However, improved control of the ratio can also be realized by keeping the width W constant and increasing the depth of cut within the physical limitations of the grinding or loosening machine.
[0058] Various embodiments of the invention have been described herein. Since changes in and/or additions to the above described invention may be made without departing from the nature, spirit or scope of the invention, and the invention should not be limited the details which have been given as an example only. | An asphalt-paved road surface is rejuvenated in a multi-stage recycling process. The first process stage involves grinding, to a selected depth and width, a first strip portion of the surface and transporting it away from the site. The second process stage involves heating and grinding, to a selected temperature and depth, the upper layer of a second strip portion and moving it to the first strip portion to expose a lower layer. The third process stage involves heating and grinding, to a selected temperature and depth, the exposed lower layer of the second strip portion and moving it to the first strip portion. New asphalt is then added to rejuvenate the recycled asphalt and to maintain the grade elevation. The mixture is then placed back on the road surface using conventional means. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
Applicant claims priority from German patent application No. 102006041951.0 filed Aug. 30, 2006.
BACKGROUND OF THE INVENTION
The present invention relates to a rocker switch. In a rocker switch of such a type that is known from DE 101 17 597 C1 the actuating angle in both directions of motion is formed exclusively by the limit-stop elements on the switch housing, on the one hand, and on the actuating rocker, on the other hand. This means that in each direction there is only a single switching function in each
given case.
The object of the present invention is to configure a rocker switch of such a type with the aid of an overcompression function so as to render it capable of being employed for further switching functions.
SUMMARY OF THE INVENTION
By virtue of the measures according to the invention, an overcompression function towards the one or other side, or towards both sides, is enabled in straightforward manner in an analog rocker switch. Depending on the configuration of the overcompression stop and/or limit stop, various actuating angles between the initial position and the overcompression stop, and also between the overcompression stop and the limit stop, can be provided in a straightforward manner. These may, in addition, be variable in both directions.
In order to obtain variable actuating angles in the direction towards the overcompression point and thereafter, and in order to obtain overcompression functions in the one or other direction or in both directions or even in no direction, the features are provided individually or in combination. Hence by simple replacement, for example of the inner part of the switch housing, an appropriate variability in the actuating angles and in the locations of the overcompression functions is obtained. This variability can be produced in straightforward manner by the molding tool with which the inner part of the switch housing made of plastic is molded—for example, injection-molded—being provided with removable cores which can be employed for the purpose of producing the differing lengths of the domes for the overcompression-function stops and/or of the domes for the limit stops.
Further particulars of the invention can be gathered from the following description, in which the invention has been described and elucidated in greater detail on the basis of the exemplary embodiment represented in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of an analog rocker switch with overcompression function, in the neutral position.
FIG. 2 is a sectional view similar to FIG. 1 , but in an end position after the overcompression position, and showing a modified stop element.
FIG. 3 is another sectional view similar to FIG. 1 , in the end position according to FIG. 2 .
DESCRIPTION OF THE INVENTION
A rocker 16 ( FIG. 3 ) has a swivel shaft 31 that carries permanent magnets M that operate Hall-effect sensors S to close electrical circuits; in a known manner (e.g. U.S. Pat. No. 6,642,459). The rocker has a lug 19 that is pivoted to the left or right (arrows A′ and A″) to pivot the rocker. The rocker carries ram ends 44 ( FIG. 1 ) that abut overcompression stops 46 , 47 at the end of rocker pivoting. However, even after a ram end 44 abuts a stop such as 46 , the rocker can pivot slightly further by the ram 44 compressing a compression spring 39 , until a limit stop 48 ( FIG. 3 ) on the rocker abuts a stop 51 on a switch housing 11 .
FIG. 1 shows an analog rocker switch 10 , which is provided with an overcompression function between its neutral position or initial position ( FIG. 1 ) and its end position(s) in accordance with one or two directions of motion. The rocker switch has a mechanical switch unit which is composed of a switch housing 11 made of plastic, which exhibits an outer part 12 and an inner part 13 , and also a switching element 14 and an actuating rocker 16 firmly connected thereto, which covers the switching element by way of a cap.
The outer part 12 of the switch housing 11 , which is approximately rectangular in cross-section, has at its upper end a cover 18 with a recess 17 through which the actuating rocker 16 , which exhibits an actuating lug 19 , projects. The lug projects to such to an extent that an actuation of the actuating rocker 16 in one of two directions according to the double-headed arrow A in each given case is possible as far as the respective limit stop or over the respective maximum actuating-angle displacement. Within a certain height range, the outer part 12 has an inner ring 21 , against which an intermediate bottom 22 of the inner part 13 bears. At its lower end 23 the inner part 13 which has been inserted from the underside of the outer part 12 is firmly connected to the outer part 12 in a manner which is not represented in any detail. A printed circuit board 26 is arranged within the lower part of the inner part 13 , and a further printed circuit board 27 is arranged below the lower end 23 of the inner part 13 , within the outer part 12 , the two printed circuit boards, which are equipped with electrical and electronic components, being electrically connected to one another via a cable 28 .
The unit consisting of the switching element 14 and the actuating rocker 16 is retained on the inner part 13 of the switch housing 11 by means of a swivel shaft 31 so as to be capable of swivelling in the directions according to the double-headed arrow A. The swivel shaft 31 is surrounded by a spiral spring 32 which brings about a reset into the neutral position or initial position represented in FIG. 1 from each displacement of the actuating rocker 16 after the release thereof.
On the inside of an approximately semicylindrical casing 33 , which is provided with the actuating lug 19 on the upper side, of the actuating rocker 16 a cage 35 which includes an overcompression function element 36 is fastened to the switching element 14 .
The overcompression function element 36 has two rams 37 and 38 , directed diametrically against each other, between which a compression spring 39 is arranged. The compression spring 39 is located in a blind bore 41 pertaining to each of the rams 37 , 38 , each of the blind bores 41 being less deep than half the length of the optionally biased compression spring 39 . The two rams 37 and 38 are pressed, in a manner biased by the compression spring 39 , by an outer-ring edge 42 facing away from the blind bore 41 against a stop ring 43 in the cage 35 , whereby a conically tapered ram end 44 of the two rams 37 and 38 projects beyond the stop ring 43 constituting the edge of the cage. In the neutral position or initial position both of the actuating rocker 16 or, to be more exact, the switching element 14 and of the two rams 37 and 38 moving in opposite senses in the directions of the double-headed arrow A there is a certain spacing between the two inner ends of the rams 37 and 38 . If the overcompression is to act in one direction only, a single spring-loaded ram is sufficient.
According to FIG. 1 , the inner part 13 of the switch housing 11 is provided with overcompression stops, or domes 46 and 47 projecting perpendicularly—that is to say, parallel to the outer walls of the inner part 13 and also of the outer part 12 —from its intermediate bottom 22 , which are configured in such a manner that they project into the preferentially circular path, according to the double-headed arrow A, of the ram ends 44 of the overcompression function element 36 of the switching element 14 or, to be more exact, of the actuating rocker 16 . The two overcompression stops 46 and 47 may be equal in length, corresponding to FIG. 1 , so that the actuating angle between the neutral position or initial position of the actuating rocker 16 on the one or other overcompression stop 46 , 47 is the same. But it is also possible, as represented in FIG. 2 , to configure the overcompression stop 47 ′ to be, for example, less high than the overcompression stop 46 . This means that the actuating angle from the neutral position or initial position of the actuating rocker 16 as far as the overcompression function in the one direction A′ is smaller than in the other direction A″. It is also possible to arrange an overcompression stop 46 or 47 in the path of motion of the overcompression function element 36 in only one of the two directions according to the double-headed arrow A.
In FIG. 3 the maximum actuating angle in the direction of arrow A′ is represented in a longitudinal section parallel to FIG. 2 . It follows from this that the one lower free edge 48 of the switching element 14 directly forms a stop end which bears against a stop dome 51 which likewise projects perpendicularly upwards from the intermediate bottom 22 , parallel to the overcompression dome 46 . It is self-evident that in the other direction of motion A″ a lower free edge 49 of the switching element 14 comes to abut a stop 52 of corresponding arrangement. The two stops 51 and 52 may have the same length, but, as represented in FIG. 3 , they may also have differing lengths, for example in such a manner that stop dome 51 is shorter than stop 52 . This means that the actuating angle of the actuating rocker 16 as far as the limit stop in the one direction A′ is larger than in the other direction A″.
The overcompression function of the overcompression function element 36 described above is the following. If the actuating rocker 16 ( FIG. 2 ) with the switching element 14 moves out of the neutral position or initial position represented in FIG. 1 in direction A′, the ram end 44 of the one ram 37 comes to abut—after, for example, an actuating angle from 10° to 15°—the overcompression dome 46 in question. If the actuating rocker 16 moves further in direction A′, by reason of the compression spring 39 which then comes into action a greater force, having to overcome the spring pressure, has to be expended for the purpose of further motion in direction A′. This higher expenditure of force is necessary until the limit stop 51 according to FIG. 3 is reached. In this position the compression spring 39 is wholly or partly compressed, in which connection an axial spacing between the inner ends of the two rams 37 and 38 is still present. This spacing is smallest when the actuating angle between the overcompression stop 46 and the limit stop 51 is largest. It is self-evident that the mode of operation that has been described obtains correspondingly in the case of actuation in direction A″; according to the arrangement of FIG. 2 , the actuating angle between the neutral position or initial position and the attaining of the overcompression stop 47 is larger in that case, so that when the limit stop 52 ( FIG. 3 ) is reached the compression spring 39 is less compressed.
In order to enable the variable actuating angles, described above, between the neutral position or initial position and the attaining of the overcompression stop 46 , 47 , on the one hand, and between the overcompression stops 46 , 47 and the limit stop 51 , 52 , on the other hand, in straightforward manner in terms of construction and production technology, the inner part 13 of the switch housing 11 , which is provided with the stops 46 and 47 as well as 51 and 52 , is shaped in accordance with the desired stop lengths in the course of production by means of injection molding. This is obtained by the molding tool or injection-molding tool for producing the inner part 13 of the switch housing 11 being capable of being provided with removable cores which, on the one hand, take account of the differing lengths of the overcompression stops 46 and 47 and/or, on the other hand, the differing lengths of the stops 51 and 52 . In corresponding manner the inner part 13 which is provided for the type of rocker switch 10 is introduced into the outer part 12 of the switch housing 11 .
In the rocker switch 10 which has been described, the electrical switching of a component, which is provided in accordance with the direction of motion A′ or A″ of the actuating rocker 16 , is effected, for example, by the swivel shaft 31 being provided with permanent magnets spaced over its periphery, whereas, for example, the printed circuit board 26 is equipped with Hall-effect sensors which react to the angular position of the permanent magnet or permanent magnets. | A rocker switch ( 10 ) is provided with a mechanical switch unit consisting of a switch housing ( 11 ) made of plastic, a switching element ( 14 ) supported in spring-loaded manner on said switch housing so as to be capable of moving back and forth, and an actuating rocker ( 16 ) connected to the switching element ( 14 ), and also with limit-stop elements ( 48, 49, 51, 52 ) for limiting the actuating angle of the actuating rocker ( 16 ), and with an electrical switch unit. In order to obtain variable actuating angles and overcompression functions, the invention provides that the actuating rocker ( 16 ) is provided with an overcompression element ( 36 ) which in one or both of the actuating directions comes to be operationally connected to an overcompression stop ( 46, 47 ) on the switch housing ( 11 ) before the limit-stop elements ( 51, 52 ) come into operation. | 7 |
FIELD
[0001] This description relates to pulling pipe underground beneath an obstacle from a first side to a second side of the obstacle.
BACKGROUND
[0002] It is known to pull a pipe through a borehole drilled in the earth beneath an obstacle from a first side to a second side of the obstacle This process can be used to run the pipe underneath the obstacle, such as a river, a roadway, or the like, from one side to the other.
[0003] In the conventional process, a pull head is attached to the pipe at the first side. The pipe is then pulled underground through the borehole from the first side to the second side. At the second side, the pull head is removed from the pipe, a section of pipe is then cut from the pipe end, and a pipe adaptor is then fused to the end of the pipe. The end of a new section of pipe is then joined to the pipe adaptor to continue the pipeline.
[0004] The fusing or welding of the pipe adaptor to the end of the pipe at the second side typically occurs within a trench or bell hole that is dug at the second side. The trench accommodates the fusing or welding equipment, the pipe cutting equipment, the pipe pulling equipment and other equipment, as well as personnel operating the equipment. The trench or bell hole is typically deep, for example 6 to 8 feet deep. Therefore, the sides of the trench or bell hole need to be reinforced to prevent collapse of the trench onto personnel working in the trench. In addition, the trench can be muddy which increases the danger to personnel working in the trench. Therefore, the process of fusing or welding the pipe adaptor to the end of the pipe at the second side within the trench can be a lengthy process and it can be dangerous to personnel.
SUMMARY
[0005] A pipe pulling technique is described where the adaptor is attached to the end of the pipe at the first side prior to the pipe being pulled underground, for example through a pre-drilled hole. The attachment of the adaptor to the pipe at the first side occurs above ground, e.g. not within a trench. As a result, attaching the adaptor to the pipe end at the first side while the pipe end is above ground, and prior to pulling the pipe underground, is faster and reduces danger to workers compared to the conventional process of attaching the adaptor at the second side within a trench.
[0006] In one embodiment, the pipe and adaptor are both made of plastic, and the adaptor is attached to the pipe end by fusing the end of the adaptor to the end of the pipe. However, the pipe and the adaptor can be made of any materials, including but not limited to metal, that are suitable to permit attaching the adaptor and the pipe together in any manner that satisfies the intended application(s) of the pipe.
[0007] In one embodiment, the pipe can be part of a pipeline that is intended to carry liquids and/or gases. In another embodiment, the pipe can be part of pipeline through which cables, for example electrical and/or fiber optic cables, can be run.
[0008] The adaptor can be configured to connect to an end of any pipeline component at the second side that is intended to be part of the pipeline. In one embodiment, the adaptor can be a plastic pipe adaptor that is configured to connect to an end of a second plastic pipe at the second side. However, the pipeline component can be a section of pipe, a valve, a coupler that splits flow through the first pipe into multiple flow paths or that gathers flow from multiple flow paths into a single path for flow through the first pipe, and other components used in pipelines.
[0009] In one embodiment, a method of pulling a pipe underground from a first side to a second side includes at the first side, attaching an adaptor to an end of the pipe, the adaptor being configured to connect to a pipeline component at the second side. At the first side, attaching a pull head to the adaptor. The pipe is then pulled underground from the first side to the second side by applying a pulling force to the pull head from the second side. At the second side, the pull head is removed, and the pipeline component is connected to the adaptor.
[0010] As used herein, the term “first side” refers to the side at which the end of the pipe is first polled underground, while the “second side” refers to the side at which the end of the pipe exits after the pipe is pulled underground from the first side. From the perspective of the drilling equipment used to drill the hole through which the pipe is pulled, the first side may be considered an “exit side” as it is the side through which the drill exits after drilling the hole, while the second side may be considered an “entrance side” as it is the side through which the drill initially enters the earth for drilling the hole. Alternatively, from the perspective of the pipe to be pulled underground, the first side may also be considered an “entrance side” as it is the side through which the end of the pipe being pulled initially enters the hole through which the pipe is being pulled, while the second side may also be considered an “exit side” as it is the side through which the end of the pipe exits the hole after being pulled underground.
[0011] In another embodiment, a method of pulling a pipe underground from a fast side to a second side includes at the first side, fusing or welding a first end of a pipe adaptor to an end of the pipe, a second end of the pipe adaptor being configured to connect to a pipeline component at the second side. In addition, at the first side, a pull head is attached to the pipe adaptor after the pipe adaptor is fused to the end of the pipe. Thereafter, the pipe is pulled underground from the first side to the second side by applying a pulling force to the pull head from the second side. At the second side, the pull head is removed, and the pipeline component is connected to the end of the pipe adaptor after removing the pull head.
[0012] In still another embodiment, a pull head is provided that is used to pull a pipe underground from a first side to a second side. The pull head includes a pull head collar formed by at least first and second shell pieces that are detachably connectable to one another, where the at least first and second shell pieces are sized to surround an end of the pipe when the at least first and second shell pieces are connected together. Each of the at least first and second shell pieces includes an interior surface and a channel is firmed on the interior surface of each of the at least first and second shell pieces, wherein when the at least first and second shell pieces are connected together the channels of the at least first and second shell pieces align with one another to form a substantially continuous circumferential channel that in use receives a flange on the pipe. In addition, a pull head cap is connected to first ends of the at least first and second shell pieces when the at least first and second shell pieces are connected together, wherein in use the pull head cap connects to a pull line that applies a pulling force to the pull head.
DRAWINGS
[0013] FIG. 1 illustrates an example application of the pipe pulling technique described herein.
[0014] FIG. 2 is an exploded perspective view of the adaptor attached to the end of the pipe and the parts of the pull head.
[0015] FIG. 3 is a cross-sectional side view of the adaptor attached to the end of the pipe and the pull head mounted in place.
[0016] FIG. 4 is a perspective view of the pull head mounted in place.
[0017] FIG. 5 illustrates an example of a pipe that is connected to the adaptor at the exit side.
[0018] FIG. 6 illustrates another example of a pull head.
[0019] FIG. 7 illustrates another example of a pull head.
[0020] FIG. 8 illustrates still another example of a pull head.
[0021] FIG. 9 illustrates still another example of a pull head.
[0022] FIG. 10 is a side view of another embodiment of an adaptor attached to the end of the pipe.
[0023] FIG. 11 is a cross-sectional side view of another embodiment of an adaptor attached to the end of the pipe.
[0024] FIG. 12 is an exploded view of another embodiment of a pull head.
[0025] FIG. 13 shows the pull head of FIG. 12 assembled.
DETAILED DESCRIPTION
[0026] FIG. 1 illustrates an example application of the pipe pulling technique described herein. In this example, a pipeline needs to be extended underneath an obstacle 10 , such as, but not limited to, a river. The obstacle 10 could be a roadway, or any other obstacle under which one may wish to extend a pipeline. The pipeline can be intended to carry liquids and/or gases, or the pipeline can act as a conduit through which cables, for example electrical and/or fiber optic cables, can be run underneath the obstacle 10 .
[0027] A hole 14 is initially drilled into the ground underneath the obstacle 10 , with the hole 14 extending from a first side 16 on one side of the obstacle 10 to a second side 18 on the other side of the obstacle 10 using any suitable directional drilling technique. In one embodiment, the hole 14 is drilled by directional drill equipment the employs a drill that drills into the earth starting from the second side 18 and that exits the first side 16 . Directional drilling is well known in the art. Thereafter, a pipe 20 that forms part of the pipeline is pulled underground through the hole 14 from the first side 16 to the second side 18 as indicated by the arrows in FIG. 1 . As discussed in further detail below, prior to pulling the pipe 20 , an adaptor 30 (seen in FIGS. 2-3 and 5 ) is attached to an end of the pipe 20 at the first side 16 , and a pull head 32 is secured around the adaptor 30 at the first side 16 . A pull line (not shown), such as a cable or rope or pipe, is affixed to the pull head 32 and applies a pulling force to the pull head 32 and the pipe 20 via a suitable pulling mechanism (not shown) located at or near the second side 18 .
[0028] The adaptor 30 will now be described with reference to FIGS. 2-5 . In general, the adaptor 30 is configured to be attached to the pipe 20 at or near the first side 16 while the end of the pipe 20 is above ground and prior to the pipe 20 being pulled underground. The adaptor 30 is also configured to connect to a pipeline component at the exit side 18 that is intended to form part of the pipeline. For example, the pipeline component can be another section of pipe, a valve, a coupler that splits flow through the pipe 20 into multiple flow paths or that gathers flow from multiple flow paths into a single path for flow through the pipe 20 , and other pipeline components used in pipelines. FIG. 5 illustrates the pipe 20 and the adaptor 30 after being pulled to the second side 18 and connected to a pipeline component 34 in the form of another section of pipe.
[0029] The adaptor 30 and the pipe 20 can be attached to one another in any manner so that the adaptor 30 and the pipe 20 are attached together substantially permanently and a liquid-tight joint is formed therebetween. For example, the adaptor 30 and the pipe 20 can each be made of plastic and the adaptor 30 and the pipe 20 can be fused, i.e. “welded”, to one another whereby a molecular bond creating a liquid-tight joint is formed between the adaptor 30 and the pipe 20 . Fusing of a plastic adaptor to a plastic pipe is well known in the art. If the adaptor 30 and the pipe 20 are made of metal, the adaptor 30 and the pipe 20 could be welded together using conventional metal welding techniques.
[0030] Referring to FIGS. 2 and 3 , in one embodiment the adaptor 30 is a substantially cylindrical, tubular structure, and the pipe 20 is also substantially cylindrical. The adaptor 30 has a first end 40 , a second end 42 , an exterior surface 44 (best seen in FIG. 5 ), and an interior surface 46 . The first end 40 is attached, for example fused, to an end 48 of the pipe 20 as shown in FIGS. 3 and 5 to form a liquid-tight joint 49 therebetween. In the illustrated example, a thickness t a of the adaptor 30 measured between the exterior surface 44 and the interior surface 46 at the first end 40 is substantially equal to the thickness t p of the pipe 20 at the end 48 so that the interior surface 46 substantially forms a continuation of the interior surface of the pipe 20 . However, in some embodiments, the thickness t s can be different than the thickness t p .
[0031] Between the first end 40 and the second end 42 , the exterior surface 44 of the adaptor 30 is provided with at least one flange 50 that extends radially outwardly from the exterior surface 44 . The flange 50 is configured to engage with the pull head 32 to transfer a pulling force acting on the pull head 32 to the adaptor 30 and to the pipe 20 . More than one flange 50 can be used as described further below with respect to FIG. 10 . The flange 50 can have any configuration that is suitable for achieving this function. In one embodiment, the flange 50 is circumferentially continuous around the entire circumference of the adaptor 30 although other configurations are possible. The flange 50 can be located anywhere along the length of the adaptor 30 but in the illustrated example, the flange 50 is located closer to the second end 42 than it is to the first end 40 .
[0032] Referring to FIG. 3 , a step 51 is formed to the rear of the flange 50 , for example integrally extending from the flange 50 and located between the flange 50 and the first end 40 . The step 51 helps to reduce loading applied to the flange 50 by the pull head 32 so that the flange 50 does not take all of the load.
[0033] Still referring to FIG. 3 , the interior surface 46 defines a portion extending from the first end 40 toward the second end 42 that has a substantially constant diameter D 1 . The constant diameter portion extends up to approximately a location of a front edge 52 of the flange 50 , where the interior surface 46 increases in diameter to form a portion having a substantially constant diameter D 2 that is larger than the diameter D 1 . The transition between the two diameters D 1 and D 2 forms a shoulder 54 . Due to the increase in diameter, the thickness of the adaptor 30 at the second end 42 is less than the thickness t a at the first end 40 . In some embodiment, an end of a mechanism 53 for connecting the pipeline component 34 (see FIG. 5 ) can abut against the shoulder 54 when the pipeline component 34 is connected to the adaptor 30 . In other embodiments, the mechanism 53 does not abut against the shoulder 54 as shown in FIG. 5 , in which case the shoulder 54 can be eliminated and the interior surface 46 can have a substantially constant diameter D 1 from end to end.
[0034] FIG. 10 illustrates another embodiment of the adaptor 30 that is attached to the end of the pipe 20 . In this embodiment, the adaptor 30 includes two or more flanges 50 a , 50 b that are spaced apart from one another. Each flange 50 a , 50 b can be received within a corresponding channel, similar to the channel 70 discussed further below, formed by the pull head 32 . In the illustrated example, the flanges 50 a , 50 b can have the same or similar thickness t f and the same of similar height h f from the exterior surface 44 of the adaptor 30 . A larger number of flanges can be utilized and the flanges can be spaced apart from one another or the flanges can abut one another. In addition, the flanges 50 a , 50 b can have different thicknesses t f and heights f f . As discussed further below, the pull head 32 would be modified accordingly to engage with the flanges 50 a , 50 b . Any number and sizes of the flanges 50 a , 50 b can be used on the adaptor 30 to give added strength to pull against while pulling the pipe underground.
[0035] FIGS. 3 and 10 illustrate the flange(s) 50 , 50 a , 50 b as being rectangular in side view. However, the flanges 50 , 50 a , 50 b can have other shapes including, but not limited to, round, triangular, etc. when viewed in side view. In addition, although the flanges 50 a , 50 b are illustrated as being of the same size, the flanges 50 a , 50 b can have different sizes.
[0036] In addition, referring to FIG. 11 , the use of one or more flanges on the adaptor is not required. Instead, FIG. 11 illustrates an adaptor 30 ′ that includes one or more channels 180 formed in the outer surface thereof. In one embodiment, the channel(s) 180 is circumferentially continuous about the periphery of the adaptor 30 ′. However, the channel(s) 180 need not be circumferentially continuous but can be interrupted by one or more non-recessed portions. In some embodiments, if required to accommodate pulling forces and forces during use, the thickness of the end of the adaptor 30 ′ may be increased to better accommodate the channel(s) 180 . If a channel(s) 180 is used, the pull heads described below will be modified to include corresponding one or more radially inwardly extending flanges that extend into the channel(s) 180 to secure the pull head 32 to the adaptor 30 ′ and transfer the pulling forces to the adaptor 30 ′.
[0037] Referring now to FIGS. 2-4 , an example of the pull head 32 will now be described. The pull head 32 is configured to detachably connect to the adaptor 30 to apply pulling forces to the adaptor 30 and the pipe 20 to pull the adaptor 30 and the pipe 20 underground to the exit side 18 . The pull head 32 can have any configuration that is suitable for achieving this function.
[0038] In the embodiment illustrated in FIGS. 2-4 , the pull head 32 includes a plurality of pieces that are connectable together. The pull head 32 can have any number of pieces that are connectable together in order to perform the intended functions of the pull head 32 . In one embodiment, the pull head 32 includes a pull head collar 58 that is removably disposable around the adaptor 30 , and a pull head cap 86 that connects to the pull head collar 58 . However, other configurations are possible.
[0039] In the example illustrated in FIGS. 2-4 , the pull head collar 58 includes a plurality of, for example first and second, shell pieces 60 a , 60 b that are detachably connectable to one another so as to surround the adaptor 30 when the shell pieces 60 a , 60 b are connected together. When there are two of the shell pieces 60 a , 60 b , each of the shell pieces 60 a , 60 b can be configured as a half shell surrounding about half of the adaptor 30 . However, in the case of two shell pieces, the shell pieces 60 a , 60 b can be configured to cover more or less than half of the adaptor 30 . For example, the shell pieces 60 a , 60 b can be sized at ratios of 75/25, 60/40, etc.
[0040] For sake of convenience in describing the concepts, the description will hereinafter refer to first and second shell pieces 60 a , 60 b although a different number of shell pieces can be used, and the shell pieces 60 a , 60 b sized at a 50/50 ratio, i,e, the shell pieces 60 a , 60 b are half shells. However, other configurations are possible. The first and second shell pieces 60 a , 60 b are substantially identical in construction to one another. Each shell piece 60 a , 60 b forms a half cylinder with an exterior surface 62 , an interior surface 64 , a first end 66 , and a second end 68 . In the illustrated example, when the pull head collar 58 is mounted in place, the first ends 66 terminate at approximately the joint 49 so that the shell pieces 60 a , 60 b only overlap the adaptor 30 and do not overlap, or only minimally overlap, the pipe 20 . However, the shell pieces 60 a , 60 b ) can be sized such that the first ends 66 extend past the joint 49 so that the shell pieces 60 a , 60 b overlap the adaptor 30 as well as a portion of the pipe 20 .
[0041] Referring to FIGS. 2 and 3 , a channel 70 is formed on the interior surface 64 of each of the shell pieces 60 a , 60 b so that when the shell pieces 60 a , 60 b are connected together around the adaptor 30 , the channels 70 of the shell pieces 60 a , 60 b align with one another to form a substantially continuous circumferential channel that in use receives the flange 50 of the adaptor 30 . In addition to the channel 70 , the shell pieces 60 a , 60 b each include a smaller channel 71 so that when the shell pieces 60 a , 60 b are connected together around the adaptor 30 , the channels 71 of the shell pieces 60 a , 60 b align with one another to form a substantially continuous circumferential channel that in use receives the step 51 of the adaptor 30
[0042] Referring to FIGS. 2 and 4 , side edges 72 , 74 of each shell piece 60 a , 60 b form mating surfaces that abut against and mate with one another to form a joint 76 . Fastener holes 78 are formed along the lengths of the side edges 72 , 74 that allow passage of fasteners 80 , such as bolts, that removably secure the shell pieces 60 a , 60 b to one another surrounding the adaptor 30 .
[0043] The interior surface 64 of each shell piece 60 a , 60 b is also formed with a friction enhancement section 82 , best seen in FIGS. 2 and 3 , that is configured to enhance frictional engagement between the pull head 32 and the exterior surface 44 of the adaptor 30 . The friction enhancement section 82 can have any configuration that is suitable for achieving this function. In the illustrated example, the friction enhancement section 82 can be formed by teeth, knurling, rubber pads, or other friction enhancement features that engage with the exterior surface 44 of the adaptor 40 . The exterior surface 44 opposite the friction enhancement section 82 can be substantially smooth or the exterior surface 44 can be provided with friction enhancement features that engage with the friction enhancement features of the friction enhancement section 82 . The friction enhancement features can be integrally formed with the interior surface 64 of each shell piece 60 a , 60 b , or the friction enhancement features can be formed by a separate layer of material that is fixed to the interior surface 64 or simply disposed between the interior surface 64 and the exterior surface 44 . In addition, in the illustrated example, the friction enhancement section 82 extends from one side edge 72 to the other side edge 74 , is spaced inwardly from and does not extend all the way to the first end 66 , and extends toward but stops short of the channel 70 . However, other sizes and arrangements of the friction enhancement section 82 are possible.
[0044] Returning to FIGS. 2 and 3 , each of the shell pieces 60 a , 60 b further includes an inwardly projecting flange 84 adjacent to the end 68 thereof. When the shell pieces 60 a , 60 b are connected together, the flanges 84 align with one another to form a substantially continuous circumferential flange the purpose of which is discussed further below.
[0045] The pull head cap 86 of the pull head 32 is disposed at the front end of the pull head 32 and is connected to the end 68 of the shell pieces 60 a , 60 b when the shell pieces 60 a , 60 b are connected together around the adaptor 30 . When the shell pieces 60 a , 60 b are disconnected, the pull head cap 86 can be disconnected from the shell pieces 60 a , 60 b . In another embodiment, the pull head cap 86 can be integrally or permanently attached to one or more of the shell pieces 60 a , 60 b . In use, the pull head cap 86 connects to a pull line, such as a cable or rope or pipe, that applies a pulling force to the pull head 32 . The pull head cap 86 can have any configuration that is suitable for achieving the functions of the pull head cap 86 . In the illustrated example, the pull head cap 86 has a housing member 88 , a pull eye 90 , and a securement disk 92 .
[0046] Referring to FIG. 3 , the housing member 88 is a generally hollow, circular disk with a convex front surface 94 and a rearwardly extending flange 96 . A slot 98 is formed in the front surface 94 through which a portion of the pull eye 90 extends forwardly. The pull eye 90 includes a hole 100 for connecting to the pull line. A disk 102 of the pull eye 90 is disposed within the housing member 88 and includes a curved surface 104 that engages with an interior curved surface of the front surface 94 .
[0047] The securement disk 92 is configured to close the open end of the housing member 88 . In particular, the securement disk 92 includes a disk 106 that closely fits within the flange 96 and the securement disk 92 and the housing member 88 are then fastened to one another by welding the disk 106 to the flange 96 . To the rear of the disk 106 is a second disk 108 that has a diameter that is less than, greater than, or equal to the diameter of the disk 106 . The disks 106 , 108 define therebetween a circumferential channel 110 that in use receives the substantially continuous circumferential flanges 84 of the shell pieces 60 a , 60 b to secure the pull head cap 86 to the shell pieces 60 a , 60 b.
[0048] In some embodiments, it is desirable to prevent ingress of moisture, soil and other contaminants into the interior of the pipe 20 when pulling the pipe 20 underground. The joint 49 between the adaptor 30 and the pipe 20 is liquid tight and prevents ingress of moisture, soil and other contaminants. In addition, suitable sealing can be provided between the pull head 32 and the adaptor 30 to prevent ingress of moisture, soil and other contaminants. For example, in the illustrated example, a circumferential sealing groove 112 can be formed in the outer surface of the disk 108 that is designed to receive a sealing gasket therein which seals with the interior surface 64 of the shell pieces 60 a , 60 b . In addition, the interior surface 64 of each shell piece 60 a , 60 b can be formed with a sealing groove 114 which combine to form a circumferential sealing groove that is designed to receive a sealing gasket therein which seals with the exterior surface 44 of the adaptor 30 . However, other sealing arrangements and configurations can be utilized including a seal between the rear surface of the disk 108 and the front facing surface of the adaptor 30 .
[0049] Referring to FIG. 6 , another example of a pull head 132 is illustrated. The pull head 132 can be generally similar in construction to the pull head 32 in that the pull head 132 includes the pull head collar 58 formed by the shell pieces 60 a , 60 b , as well as including the pull head cap 86 . However, in this embodiment, the shell pieces 60 a , 60 b are hinged to one another along one of the side edges 72 , 74 , for example the side edge 74 in this example. The shell pieces 60 a , 60 b are connected together by one or more hinges 134 , for example two of the hinges 134 , that permits the shell piece 60 a to open or close relative to the shell piece 60 b while the shell pieces 60 a , 60 b remain connected to one another. FIG. 6 shows the shell piece 60 a at an open position relative to the shell piece 60 b . The shell piece 60 a can swing to a closed position relative to the shell piece 60 b so as to fit around the adaptor 30 similar to what is shown in FIGS. 3 and 4 . This embodiment eliminates the need for a second row of fasteners 80 along the side edges 74 of the shell pieces 60 a , 60 b . The construction of the shell pieces 60 a , 60 b of the pull head collar 58 and the pull head cap 86 are otherwise similar to the construction described in FIGS. 2-4 .
[0050] FIG. 7 illustrates another example of a pull head 140 that has a pull head collar 141 that is formed by three shell pieces 142 a , 142 b , 142 c . In this example, each shell piece 142 a , 142 b , 142 c covers approximately 120 degrees, and when the shell pieces 142 a , 142 b , 142 c are connected together, they combine to encircle the adaptor 30 . Each shell piece 142 a , 142 b , 142 c is configured generally similarly to the shell pieces 60 a , 60 b , including each shell piece 142 a , 142 b , 142 c having the channel 70 and the smaller channel 71 the purpose of which is the same as for the shell pieces 60 a , 60 b . In addition, the pull head 140 can include a pull head cap 144 that can be identical in construction to the pull head cap 86 .
[0051] FIG. 8 illustrates another example of a pull head 150 that includes a pull head collar 151 that is formed by at least two shell pieces 152 a , 152 b , and a pull head cap 154 . For sake of convenience, the pipe 20 is not illustrated in FIG. 8 . In this example, the shell pieces 152 a , 152 b have a length that is shorter than the length of the shell pieces 60 a , 60 b so that an end 156 of each shell piece 152 a , 152 b stops well short or forward of the first ends 40 of the adaptor 30 . In addition, in this example, the shell pieces 152 a , 154 include the channel 70 to receive the flange 50 but do not include the smaller channel 71 for the step 51 on the adaptor 30 . The second end 42 of the adaptor 30 is also spaced from the disk 108 of the pull head cap 154 .
[0052] With continued reference to FIG. 8 , the pull head cap 154 is generally similar in construction to the pull head cap 86 . However, the disk 106 does not fit within the flange 96 . Instead, the end of the flange 96 abuts against the face of the disk 106 and the end of the flange 96 is then welded to the face of the disk 106 .
[0053] FIG. 9 illustrates another example of a pull head 160 that includes a pull head collar 162 and a pull head cap 164 . For sake of convenience, the pipe 20 is not illustrated in FIG. 9 . The pull head collar 162 can be formed by two or more shell pieces that are constructed as discussed above for FIGS. 2-4 and 6-8 . In this embodiment, the pull head cap 164 is a single piece construction. In addition, instead of having a pull eye 90 , the pull head cap 164 includes a central boss 166 that extends from a disk 168 . The central boss 166 includes a threaded aperture 170 . In use, a threaded connector (not shown) of a pull line will thread into the aperture 170 to secure the pull line to the pull head 160 while pulling the pipe underground.
[0054] FIGS. 12 and 13 illustrate an embodiment of a pull head 200 that is formed by multiple shell pieces 202 a , 202 b that are connectable together around the adaptor using the fasteners 80 (not shown in FIGS. 12 and 13 ). The interior construction of the shell pieces 202 a , 2026 b can be substantially similar to the interior construction of the shell pieces of the pull heads 32 , 132 , 142 , etc. described above. In this embodiment, the pull head 200 includes a pull head cap 204 that is formed by pull head cap pieces 206 a , 206 b that are integrally formed with the respective shell pieces 202 a , 202 b so that the shell piece 202 a and the pull head cap piece 206 a together form a single, unitary construction, and the shell piece 202 b and the pull head cap piece 206 b together form a single, unitary construction. Each pull head cap piece 206 a , 206 b includes an opening 208 formed therethrough, where the openings 208 align with one another when the shell pieces 202 a , 202 b are secured around the adaptor to form a pull eye. Optionally, one or more fastener openings 210 can be provided on the pull head cap pieces 206 a , 206 b that receive fasteners, such as bolts or screws, help fasten the pull head cap pieces 206 a , 206 b to one another when the shell pieces 202 a , 202 b are secured around the adaptor.
[0055] An example operation and use will now be described with reference to the embodiment illustrated in FIGS. 2-4 . The embodiments in FIGS. 6-9 operate in a similar manner. This example will assume that the pipe 20 and the adaptor 30 are plastic and that the pipe 20 and adaptor 30 are fused to one another. However, a similar operation can be performed when the adaptor 30 is welded to the end of the pipe. Referring to FIG. 1 , the pipe 20 needs to be pulled underground from the first side 16 to the second side 18 underneath the obstacle 10 . At the first side 16 , the end 40 of the adaptor 30 is fused to the end 48 of the pipe 20 , for example while the end 48 of the pipe 20 is disposed above ground. Therefore, the workers and equipment that are performing the fusing are working above ground instead of within a deep trench as with the prior art. Thereafter, the pull head 32 is secured around the adaptor 30 as shown in FIGS. 3 and 4 . The pulling force is then applied to the pull head 32 from the second side 18 . The pulling force pulls the pipe 20 into and through the hole 14 until the pull head 32 emerges from the second side 18 . The pull head 32 is then removed from around the adaptor 30 which remains in place fused with the pipe 20 . Thereafter, the pipeline component 34 is installed to continue the pipeline as shown in FIG. 5 . In this example, installing the pipeline component 34 occurs without having to cut-off any part of the pipe 20 or the adaptor 30 at the second side 18 , or fusing an adaptor to the pipe 20 at the second side 18 within a deep trench. So once the adaptor 30 is fused to the pipe 20 at the first side 16 and the pipe is pulled underground to the second side 18 , the pull head 32 can be removed and connection to the pipeline component 34 can occur without having to cut the pipe 20 or the adaptor 30 or fuse an adaptor to the pipe at the second side 18 .
[0056] The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is 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 intended to be embraced therein. | A pipe pulling technique where an adaptor is attached to the end of the pipe prior to the pipe being pulled underground, for example through a drilled hole. Attaching the adaptor to the pipe end prior to the pipe being pulled underground is faster and reduces danger to workers compared to the conventional process of attaching the adaptor to the end of the pipe after the pipe has been pulled underground. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a hydraulically operated underreamer.
This is a tool that is used to enlarge boreholes. Such tools can be used in drilling oil, gas, water and, in mining, drilling of construction holes and wells and also in the formation of shotholes for blasting. An underreamer has two operative states, one closed or collapsed state where the diameter of the tool is sufficiently small to allow movement of the tool in the narrowest part of the borehole, and one opened or partly expanded state where one or more toolholders (arms) with cutters on the ends thereof pivot out from the body of the tool. In this position the borehole is enlarged as the tool is rotated and lowered.
A drilling type underreamer usually is used in conjunction with a drill bit below the underreamer. The drill bit forms the hole to be underreamed at the same time as the underreamer enlarges the hole formed by the bit. Circulation of drilling fluid must be provided to the drill bit to remove cuttings during the drilling operation.
Underreamers of this type usually have hinged arms (toolholders) that have a tendency to break during the drilling operation and must be fished-up or withdrawn from the borehole. The tool has pockets where the arms are situated in the closed state. These pockets have a tendency to be filled with materials from the drilling operation, which makes collapsing of the arms difficult, thereby providing a substantial chance that the underreamer will become caught or hooked in the borehole, and this will lead to severe problems when attempting to remove the tool. Costs also can be considerable. In addition, this type of reamer is very large and heavy and has a complicated structure composed of many parts. Such type of underreamer is, for example, described in U.S. Pat. No. 4,282,941.
SUMMARY OF THE INVENTION
The object of the invention is to provide an underreamer that is reliable, stable and without risk of being stuck in the borehole, and that has a simple construction and moderate size.
An essential feature of the underreamer of the invention is that it has over its entire length an outer cylinder that protects all movable parts against earth, stones, etc. The cylinder together with a piston movable therein form a slide valve. The cylinder restricts the length of stroke of the piston, and the weight of the cylinder enables self closing of the reamer. The piston is fixed to a pipe of the same dimension as the drilling pipe. The lower part of the piston forms the upper part of a coupling device for transfer of torsional forces to cutter arms. The arms are fixed to the piston by connecting bars. The lower part of the coupling device is a body with a cross section, e.g. triangular, defined by a plurality of planar surfaces having guide grooves for the arms. It is important for the stability of the underreamer that the cutter support arms can be moved in rectilinear directions. When lowering the reamer into a borehole the support arms will be retracted within the cylinder. When mud is pumped down, the support arms with the cutters will be extended outwardly of the cylinder to a required diameter. The reamer has a locking device which prevents the support arms from being extended outwardly by an impact, push, etc. during lowering into the borehole, and also a locking mechanism for locking of the arms in the operative position. Also important for the stability of the reamer is that it is filled with mud and that a negative cutting angle is used.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features of the invention are describe in more detail below with reference to the enclosed drawings, wherein:
FIG. 1 is an elevation view, partially in longitudinal section, of an underreamer with arms thereof shown in an expanded state;
FIG. 2A is a longitudinal section along the line IIA--IIA in FIG. 1;
FIG. 2B is transverse cross-sectional view taken along line IIB--IIB in FIG. 2A;
FIG. 2C is a transverse cross-sectional view taken along line IIC--IIC in FIG. 2A;
FIG. 2D is a transverse cross-sectional view taken along line IID--IID in FIG. 2A;
FIG. 3A is a partial section of an upper part of the underreamer, shown in a locked position with support ams retracted; and
FIG. 3B is a similar view shown in an open position.
DETAILED DESCRIPTION OF THE INVENTION
A reamer or underreamer 1 includes four main parts, a cylinder including an outer cylinder 2, a piston 3 slidable in the cylinder, supporting body 4 having grooves, and arms 5 fitted in such grooves. In FIGS. 1 and 2 the reamer is shown with the arms 5 extending outwardly from the grooves. Outer cylinder 2 extends over the whole length of the reamer. The cylinder forms a cover for the reamer and protects the movable parts thereof against damage from the drill cuttings. In the drawings, the cylinder is shown to be formed by two concentrically located cylinders 2, 6, with the inner cylinder 6 having grooves 7 which together with the outer cylinder form channels for transportation of mud inside the cover. Because the cylinder is a double structure, the channels for mud in an easy way can be coated with ceramic abrasion resistant material. Alternatively the cylinder can be a single member having extending therethrough bores for passage of mud. In the lower part of the cylinder there are formed openings 8 through which pass the support arms 5. Mud can pass out through the openings 8. During the reaming operation there is overpressure inside the cylinder.
The upper part of the supporting body 4 for the cutter support arms has a circular outer circumference, and the middle part of the supporting body has in this case a triangular profile 25 because the reamer as shown is equipped with three arms 5 and respective cutters 29.
The piston 3 is connected to a pipe 9 of the same dimension and threads 10 as a drilling pipe. The piston 3 has radial channels 12 which have openings 13 opening into a chamber above the piston for inlet of drilling fluid. The number of channels 12 is determined by operating parameters such as flow, pressure loss, etc.
The lower part of the piston 3 and the support part of body 4 define therebetween a claw coupling 15 for transference of torsional forces. In the drawings the coupling is shown with three "claws", the same number as the number of cutters and arms. This number can be varied. The coupling is in the form of circumferentially spaced recesses, e.g. spector-shaped, in the piston into which extend complementary protrusions 24 of the body 4. Each portion of coupling claw of the piston includes a groove 16 and pin 17 for transference of sliding forces through a respective connecting bar 18 to the respective cutter support arm 5. The grooves 16 in the claws of the piston are parallel to the respective faces of the triangular profile 25.
The upper part of the cylinder forms a slide valve together with the piston 3. The cylinder and the lower part of the claw coupling limits the complete stroke and thereby the expansion or degree of extension of the cutter support arms 5. A smaller deflection of the arms can be obtained by several guide tracks cut in the triangular part of the reamer. The weight of the cylinder facilitates self closing. The cylinder can be moved in the vertical direction relative to the piston under influence of the drilling fluid.
The piston also is equipped with a locking mechanism to prevent the cutter support arms from projecting outwardly should the tool be subjected to an impact or thrust during lowering thereof into a bore hole. The locking mechanism as shown in the drawings includes a locking piston 11 which is influenced by the pressure of the drilling fluid. The locking piston is arranged in the center of the piston 3 of the reamer. Further, the locking mechanism includes bolts 19 that are radially positioned and guided by guide pins 20. The locking mechanism is supported by a spring 21. In the locked position bolts 19 fit in the grooves in the cylinder and the locking piston closes passage of the drilling fluid to the channels 12 (FIG. 3A).
In the operative position, with the cutter support arms 5 extending outwardly, each arm can be locked by a projection arranged at the lower part of the connecting bar 18 fitting into a groove or recess 23.
In each wall of the triangular profile 25 is milled, at a predetermined angle, a groove 26 for the respective cutter support arm 5. The grooves 26 are arranged in such a way that one can choose between positive and negative cutting angles. Both T-grooves, as shown in the drawings, and dovetailed grooves can be used. This construction provides maximum support and imports minimum moments to the cutter support arms. The body 4 includes, below the triangular profile, a lower circular portion. If more support arms are required, the triangular profile 25 can be replaced with a profile with more side faces.
The cutter support arms 5 can be moved in the grooves and are connected to the respective connecting bars 18 by respective pins 28 fitting in grooves 27 in the connecting bars 18. More than half of the total length of each cutter support arm will remain inside the supporting body 4, and thereby there is provided support during a drilling and reaming operation. The cutting tools of cutters 29 are made with reverse cutters where the cutters are plates fixed to the ends of the cutter support arms in grooves. Each cutter is fixed with screws and can be equipped with diamonds, hard metal or ceramic cutter members.
The lower part of the cylinder can be formed for connection to a drill bit. In FIG. 1 the underreamer is shown with a lower conical portion 30 fixed both to the cylinder and to the body 4 and having threads 31 for fastening to a drilling pipe or drill bit. The lower part of body 4 has therein channels 32 for passage of drilling mud from the underreamer to the drill bit.
When the reamer is suspended by a drilling pipe connected to pipe 9, then the cylinder 2 will move by gravity downwardly relative to piston 3 and the end cover of the cylinder 2 will abut piston 3 as shown in FIGS. 3A and 3B. The cutter support arms 5 will be retracted and be within the reamer structure.
When drilling mud is pumped through the pipe 9 the mud will force the locking piston 11 downwardly and the bolts 19 will be forced out of grooves in the cylinder wall by pins 20 (FIG. 3B). This opens the passage of drilling mud through the channels 12. The mud will exit through the openings 13 and lift the cylinder 2 relative to piston 3, also lifting elements 24, 25 until the two parts 15, 24 of the claw coupling are in complete contact with each other.
Because the cutter support arms 5 are connected to the piston 3 by connecting bars 18, the support arms will be caused to slide in grooves 26 and will project outwardly through openings 8. The projections 22 on the connecting bars will slide into the grooves or recesses 23 and lock the support arms in position. When the underreamer is in operative position, there will be communication between the space 33 and the channels 7 in the cylinder wall. Drilling mud then will pass through the channels 7 and wash the cutter support arms. A part of the drilling mud will pass through channels 32 to a drill bit.
When the underreamer is to be moved out of the bore hole the supply of drilling mud is stopped. The drilling mud will pour out through the channels and through leak holes. A leak hole 34, is provided for emptying of the space 33. When the drill bit is drawn up the piston 3 will slide upwardly relative ot cylinder 2 until the top of the piston abuts the top of the cylinder, and the cutter support arms will be retracted into the cylinder body. The locking piston then will close the further passage of drilling mud into the reamer.
A reamer filled with drilling mud and combined with the use of a negative cutting angle will counteract vibrations and provide stable cutting conditions. The rectilinear movement of the cutter support arms promotes stability.
The operator would be able to notice whether the cutter support arms are in the opened state by observing whether the drilling mud is circulating.
By this construction there is obtained a reamer with good stability. Of importance for good stability is the use of cutter support arms that move rectilinearly and that the reamer is employed with a negative cutting angle. By this construction it is possible to prevent the reamer from being stuck in the bore hole when the reamer is pulled upwardly therein. It is easy to change the cutters and to install spare parts. The underreamer is of small height, low weight and includes fewer parts than reamers presently in use. All movable parts are protected from stones and sand by the outer cylinder and by the over pressure maintained inside the cylinder. | A hydraulically operated underreamer or reamer for enlargement of boreholes is to be connected to a rotating drill string. An outer movable cylinder extends the entire length of the reamer for protection of inner parts thereof. Cutter support arms are movable rectilinearly between an operative state whereat they extend from the cylinder and a closed state whereat they are completely retracted within the cylinder. Cutters are mounted on the support arms and are rectilinearly movable with support arms through openings in the cylinder. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to computer databases. More particularly, this invention relates to improvements in database performance by elimination of redundant processing on the database host and storage servers.
[0003] 2. Description of the Related Art
[0004] When a database manager commits modified data to storage, it does so in two steps: first, by describing the data modification in a log record, and second, by performing the modification in a final storage location. The considerations in this scheme include the need to minimize data loss in the event of system failure, balanced against the need to maximize transaction processing speed. Some message queuing systems have the same general requirement, and also perform redundant write operations.
[0005] Most existing protocols present storage servers simply as resources having write and read data buffers. Logs are used in order to write the data in a sequential fashion. The logs can be revisited later in order to undo specific modifications, or to redo modifications on backup images.
[0006] In one approach, known as log-shipping, the database manager ships the log records to a host in a secondary site, to be applied on a mirrored database at the secondary site. This solution requires two host servers and two storage servers. While this technique provides redundancy, performance is still limited by the need to communicate each data modification twice, once from each host server to a storage device.
[0007] A logged file system is proposed in U.S. Pat. No. 5,832,515 to Ledaine et al., in which data is output to a log pseudo-device driver, bypassing the operating system's main data pathways for output. Using this arrangement, it is suggested that a host can control logging for a file system on a separate device to improve file system performance. The data is written to a log device disk, eventually being migrated to a main disk by the host. Exceptionally, large writes may be directed directly to the main disks, rather than to the log device, but more commonly, smaller writes cannot. While there is provision to use the log device exclusively for data storage in order to avoid data migration, this is feasible only in situations in which write operations are infrequent, and read operations predominate.
[0008] There remains a need to minimize I/O operations in order to reduce traffic between different disk storage systems in order to optimize database performance.
SUMMARY OF THE INVENTION
[0009] According to a disclosed embodiment of the invention, all logging and storage issues in a database are directed to a single storage server. A modification of a database record is written only once from the host server to a log record on the storage server, instead of being written twice, once to the log record and again to a storage server when the page containing the data is flushed out. Subsequently, the storage server interprets the database log records, and modifies the database storage accordingly. Using this method, the number of bytes written from the host to the storage server is potentially reduced by fifty percent.
[0010] Unlike the disclosure of the above-noted U.S. Pat. No. 5,832,515, in which a main disk device driver is responsible for communication between the log and main disk controllers, according to some aspects of the present invention, logic for applying log records has been removed from the host and placed in a storage device. After the log entry is written the storage device operates autonomously with respect to the log entry. This saves host resources and also avoids two data transfers—from the log device to the host, and from the host to the main device. The inventive arrangement is particularly advantageous in a network storage environment.
[0011] One embodiment of the present invention provides a method of modifying a computer-implemented database, which is carried out by executing a database manager on a host server, preparing a modification of a database record of the database on the host server, transmitting a log entry indicative of the modification exactly one time from the host server to a storage server that holds the database record, the log entry including less information than the database record, and interpreting the log entry on the storage server. Responsively to the interpretation of the log entry, the storage server updates the database record according to the modification communicated in the log entry.
[0012] According to one aspect of the method, the log entry is an instruction to the storage server for updating the database record responsively to the modification.
[0013] In one aspect of the method, the storage server has a database table space and a plurality of logical volumes. The method is further carried out by designating one of the logical volumes as a log volume to receive the log entry, establishing a one-to-one mapping between the database table space and the log volume, and identifying the database record using the mapping.
[0014] In another aspect of the method, updating the database record includes establishing a copy of the database manager on the storage server, and executing the copy to identify the database record and to apply the log entry for updating thereof. Optionally, the method includes establishing a virtual machine in the storage server, wherein the copy is a component of the virtual machine.
[0015] In yet another aspect of the method, updating the database record includes emulating the database manager on the storage server to identify the database record and to apply the log entry for updating thereof.
[0016] Still another aspect of the method includes maintaining a heartbeat synchronization between the host server and the storage server.
[0017] In an additional aspect of the method, subsequent to transmitting a log entry and prior to completing the update of the database record by the storage server, a read operation that may be initiated on the database record is thereafter delayed until completion of the update of the database record by the storage server.
[0018] An embodiment of the present invention provides a computer software product, including a computer-readable medium in which computer program instructions are stored, which instructions, when read by one or more computers, cause the computers to perform a method for modifying a database, which is carried out by executing a database manager on a host server, preparing a modification of a database record of the database on the host server, transmitting a log entry indicative of the modification exactly one time from the host server to a storage server that holds the database record, the log entry including less information than the database record, interpreting the log entry on the storage server. Responsively to the interpretation of the log entry, the storage server updates the database record according to the modification communicated in the log entry.
[0019] An embodiment of the present invention provides a database management system, including a host server that has a database manager executing thereon. The host server is operative to prepare a modification of a database record that is managed by the database manager. The system further includes a storage server that stores the database record, and is linked to the host server. The storage server is operative for accepting a transmission of the modification exactly one time as a log entry from the host server, the log entry describing the modification and including less information than the database record. The storage server is operative to update the database record responsively to the log entry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a better understanding of the present invention, reference is made to the detailed description of the invention, by way of example, which is to be read in conjunction with the following drawings, wherein like elements are given like reference numerals, and wherein:
[0021] FIG. 1 is a block diagram of a computer-implemented database system, which is constructed and operative in accordance with a disclosed embodiment of the invention;
[0022] FIG. 2 is a block diagram of a storage server for use in the system shown in FIG. 1 , which is constructed and operative in accordance with a disclosed embodiment of the invention;
[0023] FIG. 3 is a block diagram of a storage server for use in the system shown in FIG. 1 , which is constructed and operative in accordance with an alternate embodiment of the invention;
[0024] FIG. 4 is a block diagram of a storage server for use in the system shown in FIG. 1 , which is constructed and operative in accordance with an alternate embodiment of the invention; and
[0025] FIG. 5 a flow chart illustrating a method of applying log records on a storage server by delaying read operations in accordance with a disclosed embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] 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 to one skilled in the art, however, that the present invention may be practiced without these specific details. In other instances, well-known circuits, control logic, and the details of computer program instructions for conventional algorithms and processes have not been shown in detail in order not to obscure the present invention unnecessarily.
[0027] Software programming code, which embodies aspects of the present invention, is typically maintained in permanent storage, such as a computer readable medium. In a client-server environment, such software programming code may be stored on a client or a server. The software programming code may be embodied on any of a variety of known media for use with a data processing system. This includes, but is not limited to, magnetic and optical storage devices such as disk drives, magnetic tape, compact discs (CD's), digital video discs (DVD's), and computer instruction signals embodied in a transmission medium with or without a carrier wave upon which the signals are modulated. For example, the transmission medium may include a communications network, such as the Internet. In addition, while the invention may be embodied in computer software, the functions necessary to implement the invention may alternatively be embodied in part or in whole using hardware components such as application-specific integrated circuits or other hardware, or some combination of hardware components and software.
[0000] System Architecture
[0028] Turning now to the drawings, reference is initially made to FIG. 1 , which is a block diagram of a computer-implemented database system, which includes a host server 10 , and which is constructed and operative in accordance with a disclosed embodiment of the invention. The host server 10 can be realized as a conventional computer, workstation, or a networked arrangement of computing devices. The host server 10 includes at least one CPU 12 , a suitable memory for an operating system 16 , application programs and data. In particular the memory includes an executing database manager 18 . The operating system 16 includes, or is linked to a logical volume manager 20 . Typically, a data cache memory 22 is available to the database manager 18 in order to improve its performance. A storage server 24 may be co-located with the rest of the system or remotely located and connected via a data network, for example a storage area network (SAN). In any case the storage server 24 is interoperable with the database manager 18 via an I/O facility 26 , and its data 28 may be accessed via a storage controller 30 , using calls of the operating system 16 , or more directly by the database manager 18 . In contrast with conventional database systems, the host server 10 is not provided with a separate log server for maintaining transaction logs. Instead, as is disclosed in further detail hereinbelow, transaction logs 32 are processed directly on the storage server 24 .
[0029] In the following embodiments, the storage server 24 is adapted to process the format of database log records, either by using the proprietary log formats of the database manager 18 , or through an open implementation, which supports any application that enables writing database transactions as physical log records. The principles of the invention are described in these embodiments with reference to traditional database systems. However, they are equally applicable to variants, e.g., message queuing systems, in which a permanent record needs to be stored and referenced.
[0030] The log records that are written by the host server 10 to the storage server 24 are not complete database records. Rather in some embodiments, they are a journal of modifications to specific portions or fields of the database records. The information in the log record is interpretable on the storage server 24 . Alternatively, the log records may be coded or uncoded instructions. In either case, when the information or the instructions are interpreted on the storage server 24 , the storage server 24 executes operations to bring the data structures of the target database into a consistent and up-to-date state responsively to the transaction performed in the host server 10 . These records are typically condensed, as compared with an entire database record, and thus can be transmitted using relatively little bandwidth.
[0031] Log records written to the storage server 24 and the files in which they are stored differ substantially from conventional log-structured file systems and variants thereof. To emphasize the difference, a brief summary of log-structured file systems is presented. A log-structured file system provides for permanent recording of write file data in an effectively continuous sequential log. Typically, data is intentionally written as received continually, appended to the end of the active log. Thus, the effective data bandwidth required can approximate the bandwidth of the disk drive mass storage subsystem. All seek operations for writes are minimized as file data is written to the end of the active log. However, read data, as well as cleaning and data block maintenance operations, produce many seek operations. Log-structured file systems are, however, not entirely effective in all computing environments. For example, log-structured file systems show little improvement over conventional file systems where the computing environment is subject to a large percentage of fragmentary data writes and sequential data reads such as may occur frequently in transactional data base applications. The write data optimizations provided by log-structured file systems can also be rather inefficient in a variety of other circumstances as well, for example, when random and small data block read accesses are dominant. A further description of log-structured file systems is given in the above-noted U.S. Pat. No. 5,832,515, which is herein incorporated by reference.
[0032] By looking at the data flow between the storage and host, in particular when using external storage, e.g., a network storage environment, application of the inventive principles described above should require about one third of the bandwidth on the storage network in comparison with the system disclosed in the above-noted U.S. Pat. No. 5,832,515.
[0000] Storage Server—Embodiment 1
[0033] Reference is now made to FIG. 2 , which is a block diagram illustrating details of a server 34 , which is constructed and operative in accordance with a disclosed embodiment of the invention, and which can be used as the storage server 24 ( FIG. 1 ). The server 34 is capable of differentiating logical units of data that refer to logs and from those that refer to data. The database configuration is predefined, and is available to the storage controller 30 , as shown in a configuration block 36 . In the configuration of the storage server, a logical volume is designated as a log volume by the logical volume manager 20 ( FIG. 1 ). A mapping 38 is provided for the log volume that identifies the structure and location of database tables on the storage server or on other storage servers in the case of a distributed database. Within the context of the configuration block 36 , this is accomplished by assigning the type of storage object as an object property, with “logs” being a first object property corresponding to the log device. A second “data” object property corresponds to data objects, with a reference to the log device that affects them. Without the configuration block 36 , it would be necessary to transfer configuration information from the host server 10 using the operating system 16 , and the logical volume manager 20 ( FIG. 1 ).
[0034] For simplification of presentation it is assumed that there is a one-to-one mapping 38 between database table space and logical volumes of disks on the storage server. This implies a trivial role for the logical volume manager 20 . It will be understood that in more complicated database systems such a simple mapping does not exist. Nevertheless, those skilled in the art can develop a mapping appropriate to a given database system configuration.
[0035] It is recommended that the mapping be verified, as its integrity is essential for proper function of the storage controller 30 .
[0036] This implementation requires special handling of data read requests, particularly in cases where the application of corresponding log entries has not yet completed. Provision for such data reads can be accomplished in two ways. In a first alternative, the storage controller 30 applies all log records in real time on the requested database page read. In a second alternative, the read request is delayed until the storage controller 30 updates the database page, thereby insuring that the reading process receives its current version. The second alternative is shown in further detail in Example 1 below.
[0037] The server 34 includes a log application engine 40 , which applies log transactions in accordance with the format of database storage records in order to update the database records. It should be noted that the log application engine 40 is independent of any disaster recovery mechanisms, which are often based on a primary site and a secondary site. As noted above, a secondary site is not required for the implementation of the log application engine 40 . The storage controller 30 is a high-end device, providing full support for applications, including support for an operating system environment. Thus it is feasible to implement the log application engine 40 by establishing a virtual machine 42 on the server 34 , and including an instance or copy of the database manager copy 44 as a component of the virtual machine 42 . Alternatively, only a portion of the database manager code is placed in the virtual machine 42 , no more than is necessary to perform log application functions. The necessary code can be implemented either as a shared library or as an executable.
[0000] Storage Server—Embodiment 2
[0038] Reference is now made to FIG. 3 , which is a block diagram of a server 46 , which is constructed and operative in accordance with an alternate embodiment of the invention, and which can be used as the storage server 24 ( FIG. 1 ). The server 46 is similar to the server 34 ( FIG. 2 ), but instead of employing a virtual machine, a log application engine 48 is implemented as a software program at the application level, which emulates the database manager operations. Alternatively, the log application engine 48 may handles a more generic form of log application.
[0000] Storage Server—Embodiment 3
[0039] Reference is now made to FIG. 4 , which is a block diagram of a server 50 , which is constructed and operative in accordance with an alternate embodiment of the invention, and which can be used as the storage server 24 ( FIG. 1 ). This embodiment takes advantage of log-shipping functionality inside the database manager, also known as high-availability data replication. This functionality is available on several commercial database managers, for example the DB2 product family, available from International Business Machines Corporation, New Orchard Road, Armonk, N.Y. 10504. The server 50 is treated by the database manager 18 ( FIG. 1 ) as a secondary server, which keeps a consistent copy of the primary server's crash recovery procedures 52 . This architecture may be further optimized to anticipate crash recovery using a modified storage controller 54 . A synchronization process 56 in the storage controller 54 maintains a heartbeat with the database manager. If the heartbeat fails, then all uncompleted transactions must be rolled back. Alternatively, in a simpler implementation, one simply populates a cache 58 with pages, which will be needed during crash recovery, thus avoiding the random I/O costs during crash recovery.
[0040] In the above described embodiments of the present invention, only a primary server exists for local log application activity. Optionally, a secondary server may exist in order to perform substantially real time log application. Alternatively, both a primary and a secondary server may perform log application activity substantially in real time. If there are multiple controllers, applying the log entries and servicing reads is much more difficult. The servers have to cooperatively maintain a system of tables indicating which tables have been modified. In any case, only one write operation for each log transaction need be executed by the database manager 18 ( FIG. 1 ) to the target that was designated as a log device during server configuration. Subsequently, writes to more than one disk or file system may occur as a consequence of activity in the log device itself.
EXAMPLE 1
[0041] Reference is now made to FIG. 5 , which is a flow chart illustrating a prospective example, wherein log records are applied on a storage server in accordance with a disclosed embodiment of the invention. The process steps are shown in a particular sequence in FIG. 5 for clarity of presentation. However, it will be evident that many of them can be performed in parallel, asynchronously, or in different orders.
[0042] The process begins at initial step 60 , where a log volume is defined, typically by setting a bit in a configuration table of the storage server.
[0043] Next, at step 62 , an existing pre-write and post-write intercept mechanism on the storage server is used to activate a background log application process that will apply newly written log entries to the database tables.
[0044] Next, at step 64 , a log record of a creation or other modification of a database record is written out to the storage server.
[0045] Next, at step 66 an attempt is initiated to read the database record that was affected by the write operation in step 64 .
[0046] Next, at step 68 a read intercept occurs in order to prevent the read operation initiated in step 66 from reading out-of-date data. In applications involving high transaction volumes, it is likely that data related to newly written log updates is still in the database buffer pool. Thus, a read operation on data that is still waiting for the background log application process to complete is likely to be rare.
[0047] Control now proceeds to delay step 70 , where the read operation waits until the background log application process finishes the update. The delay is only necessary if there is a log entry relevant to the data being read. This delay step is particularly desirable when the log volume defined in initial step 60 is in the same storage device as the related database tables. However, even when this is not the case, there may still be some benefits (mostly in terms of the database server CPU utilization), although communication between the log volume and other devices on which table data is stored will be required.
[0048] Alternatively, a new log entry may be processed in real time, in which case step 68 and delay step 70 can be omitted, as shown by the broken line in FIG. 5 .
[0049] At final step 72 , the read operation completes.
[0050] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof that are not in the prior art, which would occur to persons skilled in the art upon reading the foregoing description. | Logging and storage transactions in a database are directed to a single storage server. A modification of a database record is written only once to a log record on the storage server. Subsequently, the storage server interprets the database log records, and modifies the database storage accordingly. The number of bytes written to storage is potentially reduced by fifty percent as compared to writing the log record and then writing the modified database record to the storage server. | 6 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 61/590,284; entitled “USER INTERFACE USING DEVICE AWARENESS”, filed on Jan. 24, 2012, which is hereby incorporated by reference as if set forth in full in this document for all purposes.
BACKGROUND
[0002] Many conventional computing devices such as computers, tablets, game consoles, televisions, monitors, phones, etc., include a touchscreen. A touchscreen enables a user to interact directly with displayed objects on the touchscreen by touching the objects with a hand, finger, stylus, or other item. Such displayed objects may include controls that control functions on a phone. Using the touchscreen, the user can activate controls by touching corresponding objects on the touchscreen. For example, the user can touch an object such as a button on the touchscreen to activate a voice recognition application on the phone. The user can touch the touchscreen and swipe up and down to scroll a page up and down on the touchscreen.
SUMMARY
[0003] Embodiments generally relate to a phone. In one embodiment, a method includes detecting a voice and checking if a mouth is detected. The method also includes activating a voice recognition application or voice command input on a phone if both the voice and the mouth are detected.
[0004] One embodiment provides a method comprising: detecting a voice; checking if a mouth is detected; and activating a voice recognition application on a phone if both the voice and the mouth are detected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates a diagram of a phone that is held up to the mouth of a user, where the user is talking into the phone, according to one embodiment.
[0006] FIG. 2 illustrates a block diagram of a phone, which may be used to implement the embodiments described herein.
[0007] FIG. 3 illustrates an example simplified flow diagram for enhancing phone functionality based on detection of a mouth of a user, according to one embodiment.
DETAILED DESCRIPTION
[0008] Embodiments described herein enhance phone functionality based on detection of a mouth of a user. In one embodiment, if a phone detects both a voice and mouth, the phone automatically activates a voice recognition application on a phone. In other words, if a user holds the phone up to the user's mouth and talks, the phone automatically interprets what the user is saying without the user needing to manually activate the voice recognition application.
[0009] FIG. 1 illustrates a diagram of a phone 100 that is held up to the mouth 102 of a user, where the user is talking into phone 100 , according to one embodiment. In one embodiment, phone 100 includes a display screen 104 and a camera lens 106 of a camera. Camera lens 106 is configured to detect objects (e.g., mouth 102 ) that are within a predetermined distance from display screen 104 . In one embodiment, camera lens 106 may be configured with a field of view 108 that can detect mouth 102 when it is within a close proximity (e.g., 3 to 6 inches, or more) to display screen 104 .
[0010] In one embodiment, camera lens 106 may be a wide angle lens that can capture an object that is anywhere in front of display screen 104 . In one embodiment, camera lens 106 may be a transparent cover over an existing camera lens, where camera lens 106 alters the optics to achieve a wider field of view and closer focus. As an overlay, camera lens 106 may be a film or button placed over an existing lens to alter the optics. In one embodiment, if camera lens 106 overlays an existing camera lens, phone 100 corrects any distortions to an image that may occur. Camera lens 106 may be permanently fixed to phone 100 or temporarily fixed to phone 100 . In one embodiment, camera lens 106 may be a permanent auxiliary lens on phone 100 , which may be used by an existing camera or a separate dedicated camera with the purpose of detecting a user finger.
[0011] While camera lens 106 is shown in the upper center portion of phone 100 , camera lens 100 may be located anywhere on the face of phone 100 One or more lenses or cameras may be used, placed and oriented on the device as desired. FIG. 2 illustrates a block diagram of a phone 100 , which may be used to implement the embodiments described herein. In one embodiment, phone 100 may include a processor 202 and a memory 204 . A phone aware application 206 may be stored on memory 204 or on any other suitable storage location or computer-readable medium. In one embodiment, memory 204 may be a non-volatile memory (e.g., random-access memory (RAM), flash memory, etc.). Phone aware application 206 provides instructions that enable processor 202 to perform the functions described herein. In one embodiment, processor 202 may include logic circuitry (not shown).
[0012] In one embodiment, phone 100 also includes a detection unit 210 . In one embodiment, detection unit 210 may be a camera that includes an image sensor 212 and an aperture 214 . Image sensor 212 captures images when image sensor 212 is exposed to light passing through camera lens 106 ( FIG. 1 ). Aperture 214 regulates light passing through camera lens 106 . In one embodiment, after detection unit 210 captures images, detection unit 210 may store the images in an image library 216 in memory 204 .
[0013] In other embodiments, phone 100 may not have all of the components listed and/or may have other components instead of, or in addition to, those listed above.
[0014] The components of phone 100 shown in FIG. 2 may be implemented by one or more processors or any combination of hardware devices, as well as any combination of hardware, software, firmware, etc.
[0015] While phone 100 is described as performing the steps as described in the embodiments herein, any suitable component or combination of components of phone 100 may perform the steps described.
[0016] FIG. 3 illustrates an example simplified flow diagram for enhancing phone functionality based on detection of a mouth of a user, according to one embodiment. Referring to both FIGS. 1 and 3 , a method is initiated in block 302 , where phone 100 detects a voice. In one embodiment, the voice includes speech. In block 304 , phone 100 checks if a mouth 102 is detected. In block 306 , phone 100 activates a voice recognition application on a phone if both the voice and mouth 102 are detected. In one embodiment, a face is sufficient determine that the user intends to speak into phone 100 . In other words, phone 100 activates a voice recognition application on a phone if both the voice and a face are detected.
[0017] In one embodiment, phone 100 activates a voice recognition application on a phone if both the voice and mouth 102 with moving lips are detected. In one embodiment, if phone 100 detects moving lips, phone 100 activates a lip reading application. In one embodiment, phone 100 may interpret commands from the user solely by voice recognition, solely by lip reading, or a combination of both voice recognition and lip reading.
[0018] In one embodiment, to detect a mouth, phone 100 takes a picture if the voice is detected. Phone 100 then determines if a mouth is in the picture. If the mouth is in the picture, phone 100 determines a distance between the mouth and the phone. In one embodiment, a mouth is determined to be detected if the mouth is within a predetermined distance from the phone. One or more pictures can be taken. Video can also be used.
[0019] In one embodiment, the predetermined distance (e.g., 0 to 12 inches, or more, etc.) is set to a default distance that is set at the factory. In one embodiment, the user may modify the predetermined distance. The user may also modify the field of view 108 angle. A face or mouth 102 that is close to display screen 102 is indicative of the user intending to speak into phone 100 . For example, if the users mouth/face is within 12 inches from display screen 104 , the user probably intends to speak into phone 100 to activate a control.
[0020] In one embodiment, any detection device or sensor may be used to check for a mouth. For example, such a sensor can be an image sensor, a proximity sensor, a distance sensor, an accelerometer, an infrared sensor, and an acoustic sensor, etc.
[0021] Although the description has been described with respect to particular embodiments thereof, these particular embodiments are merely illustrative, and not restrictive.
[0022] Any suitable programming language may be used to implement the routines of particular embodiments including C, C++, Java, assembly language, etc. Different programming techniques may be employed such as procedural or object-oriented. The routines may execute on a single processing device or on multiple processors. Although the steps, operations, or computations may be presented in a specific order, the order may be changed in particular embodiments. In some particular embodiments, multiple steps shown as sequential in this specification may be performed at the same time.
[0023] Particular embodiments may be implemented in a computer-readable storage medium (also referred to as a machine-readable storage medium) for use by or in connection with an instruction execution system, apparatus, system, or device. Particular embodiments may be implemented in the form of control logic in software or hardware or a combination of both. The control logic, when executed by one or more processors, may be operable to perform that which is described in particular embodiments.
[0024] A “processor” includes any suitable hardware and/or software system, mechanism or component that processes data, signals or other information. A processor may include a system with a general-purpose central processing unit, multiple processing units, dedicated circuitry for achieving functionality, or other systems. Processing need not be limited to a geographic location, or have temporal limitations. For example, a processor may perform its functions in “real time,” “offline,” in a “batch mode,” etc. Portions of processing may be performed at different times and at different locations, by different (or the same) processing systems. A computer may be any processor in communication with a memory. The memory may be any suitable processor-readable storage medium, such as random-access memory (RAM), read-only memory (ROM), magnetic or optical disk, or other tangible media suitable for storing instructions for execution by the processor.
[0025] Particular embodiments may be implemented by using a programmed general purpose digital computer, by using application specific integrated circuits, programmable logic devices, field programmable gate arrays, optical, chemical, biological, quantum or nanoengineered systems, components and mechanisms. In general, the functions of particular embodiments may be achieved by any means known in the art. Distributed, networked systems, components, and/or circuits may be used. Communication or transfer of data may be wired, wireless, or by any other means.
[0026] It will also be appreciated that one or more of the elements depicted in the drawings/figures may also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. It is also within the spirit and scope to implement a program or code that is stored in a machine-readable medium to permit a computer to perform any of the methods described above.
[0027] As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0028] While one or more implementations have been described by way of example and in terms of the specific embodiments, it is to be understood that the implementations are not limited to the disclosed embodiments. To the contrary, they are intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
[0029] Thus, while particular embodiments have been described herein, latitudes of modification, various changes, and substitutions are intended in the foregoing disclosures, and it will be appreciated that in some instances some features of particular embodiments will be employed without a corresponding use of other features without departing from the scope and spirit as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the essential scope and spirit. | Embodiments generally relate to portable electronic devices such as a phone with a camera and touchscreen. In one embodiment, a method includes detecting a voice and checking if an image of a mouth is detected by using the camera. An embodiment also includes activating a voice recognition application on a phone if both the voice and the mouth are detected. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 195 20 248.1 filed Jun. 2, 1995, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a method and an apparatus for severing ties made, for example, of wire, straps and the like and/or wrapper material for textile fiber bales, particularly cotton fiber bales or artificial fiber bales. The fiber bales and a tie and/or wrapper cutter and the fiber bales are moved relatively to one another and the cutter severs the tie and/or the wrapper. The fiber bales are moved through the region of the cutter on a conveyor device such as a conveyor belt, a roller track, a carriage or the like, while the cutter is stationarily supported during severance.
In a known process the fiber bale is in a free-standing state during the severing process. Prior to processing of the fiber bale the ties have to be cut and removed therefrom.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved method and apparatus of the above-outlined type which makes possible a secure severance of the bale ties.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus for severing a fiber bale tie surrounding a fiber bale includes a bale advancing device for moving the fiber bale in an advancing direction along a travel path; a tie cutter for severing the tie; a bale position determining device for emitting a signal when the bale has reached a predetermined location along the travel path; and a device for moving the tie cutter transversely to the conveying direction from a remote position spaced from the bale into engagement with a bale surface when the bale has reached the predetermined location to effect severance of the tie as relative movement between the bale and said tie cutter takes place. After the severing step the tie cutter is moved away from the bale towards the remote position.
By moving the cutter up to the fiber bale before the severing process and moving the cutter away from the bale after the severing process, an adaptation to the actual width of the fiber bale is possible so that the severing operation allows a reliable cutting of the bale ties. By moving the pressing element, the fiber bale is accurately positioned for engagement with the cutter, independently from the bale width. Further, the flat pressing element, together with the counterface, forms a guide trough so that the fiber bale is advantageously guided and laterally supported to ensure that a secure engagement by the cutter with all the bale ties is achieved during the severing process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top plan view of the apparatus according to the invention, situated between a bale supplying device and a bale removing device.
FIG. 2a is a schematic top plan view of a part of a preferred embodiment of the invention operating with four metal sensors.
FIG. 2b is a schematic side elevational view of the construction shown in FIG. 2a, as seen in the direction of the arrow IIb in FIG. 2a.
FIG. 2c is a schematic side elevational view of the construction shown in FIG. 2a, as seen in the direction of the arrow IIc in FIG. 2a.
FIGS. 3a-3e are schematic top plan views of different, subsequent operational phases performed by the apparatus according to the invention.
FIG. 4 is a sectional view taken along line IV--IV of FIG. 2a.
FIG. 5 is a schematic side elevational view of a tie cutter forming part of the apparatus according to the invention.
FIG. 6 is a schematic side elevational view of a driving device for a bale shifting element forming part of the apparatus according to the invention.
FIG. 7 is a block diagram illustrating the electronic control of the apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to FIG. 1, the apparatus according to the invention is positioned between a bale supplying apparatus 2 and a bale removing apparatus 3. The bale supplying apparatus 2 includes a chain conveyor 31 and a bale hoisting pivotal fork 4 supported in a rotary bearing. The bale ties 5 usually consist of narrow steel bands or wires. Prior to processing the fiber bale 6, for example, by means of a non-illustrated bale opener, the ties 5 which circle the highly-compressed fiber bale, have to be removed. For this purpose, the bale 6 is admitted in the direction A to a bale preparing apparatus 1 and is moved by a pusher element 7 in the direction B against a tie cutter 8 and is also moved past a tie removing device 9 for removing the severed ties 5 from the fiber bale. Thereafter the bale 6 is advanced in the direction C and is admitted to the bale removing apparatus 3 which may be an endless conveyor, a bale carriage or the like which transports the bale to a non-illustrated bale opener which may be a BLENDOMAT BDT model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany.
Also referring to FIGS. 2a, 2b and 2c, an inductive proximity sensor 10, operating as a contactless metal detector, is oriented towards a side face 6a of the fiber bale 6. The metal sensor 10 is situated upstream of the tie cutter 8 as viewed in the direction of fiber bale advance and serves for detecting (recognizing) metal bale ties 5a-5n. Two additional, second inductive proximity sensors 11a and 11b operating as contactless metal detectors are provided which are oriented towards the side face 6b of the fiber bale 6. The two sensors 11a and 11b are at a vertical distance a from one another and are situated downstream of the tie cutter 8 and the tie removing device 9. The sensors 11a, 11b serve for detecting those bale ties or tie parts 5a-5n which were not severed and/or removed by the tie cutter 8 and/or the tie removing device 9. The sensors 11a, 11b are connected with a signalling device 11c to indicate the presence of a tie or tie parts detected by the sensor 11a and/or 11b. As an alternative, or in addition, the sensors 11a, 11b are connected to a fiber bale removing device which, when the sensors 11a and/or 11b detect the presence of a tie or tie parts in the bale, prevents the bale from being admitted to the conveyor 3, and, for example, directs the bale to a location where the residual ties or tie parts are removed. There is further provided a third metal detector 12 which is also an inductive proximity sensor and which is oriented towards the tie cutter 8, as shown in FIG. 5. The sensor 12 determines the presence and position of a bale tie 5a-5n in the tie cutter 8. Further, a fourth metal detector 13 is provided which is also an inductive proximity sensor 13 and which is associated with the tie removing device 9. The sensor 13 responds to the presence and position of a bale tie 5a-5n in the tie removing device 9.
The tie cutter 8 and a pressing device generally designated at 15 are, as shown in FIG. 2a, mounted on a common holding device 16 which is pivotally held by two levers 17a, 17b supported for rotation about a stationary rotary bearing 18 driven by a motor 29 for counterclockwise and clockwise pivotal motions as indicated by respective arrows D and E. Thus, the levers 17a, 17b and the holding device 16 form part of a parallelogram linkage, whereby the holding device 16 is moved parallel to itself. The pressing device 15, as shown in FIG. 2b, is formed of four bars 15a, 15b, 15c and 15d arranged on a surface 19 of the holding device 16. The bar 15a is in a longitudinal alignment with the bar 15b and the bar 15c is in a longitudinal alignment with the bar 15d. Further, the bars 15a, 15b are parallel to the bars 15c, 15d and are arranged thereabove at a distance b. The tie removing device 9 is secured on a stationary surface 20 which also supports longitudinally arranged bars 21a, 21b, 21c and 21d. The bars 21a and 21b are positioned above bars 21c and 21d at a distance c therefrom.
The fiber bale 6 is positioned on a bale supporting surface, such as a smooth slide plate 14. In operation the bale 6 is, as shown in FIG. 3a, pushed from its initial position by the driven pusher element 7 in the direction of the arrow B up to an optical barrier 22 into the position as shown in FIG. 3b. The optical barrier 22 is situated upstream of the tie cutter 8 as viewed in the direction B. Subsequently, the holding device 16, together with the tie cutter 8 and the pressing device 15 is pivoted in the direction of the arrow F until the bars 15a and 15c of the holding device 16 firmly engage the side 6a of the bale 6, as shown in FIG. 3c. The motion of the holding device 16 and the tie cutter 8 is thus toward an imaginary reference plane 14a which extends parallel to the bale advancing direction B and perpendicularly intersects the slide plate 14. In this position the bale 6 is firmly pressed by the bars of the pressing device 15 against the bars 21a, 21c which, together with bars 21b, 21d act as counter supports. Thus, the opposing wall surfaces 19 and 20 and the slide plate 14 act as a trough surrounding the bale 6 on three sides. Thereafter the fiber bale 6 is pushed in the direction B as shown in FIG. 3d by the pusher 7 as the bale ties 5a-5n are in sequence severed by the tie cutter 8. Thereafter, as shown in FIG. 3d, the fiber bale 6 is pushed along the tie removing device 9 which pulls away the severed ties 5a-5n from the bale 6. Subsequently, the holding device 16 is pivoted back into its position in the direction of the arrow G as shown in FIG. 3e.
Turning to FIG. 4, the fiber bale 6 is situated in a slightly oblique orientation and leans against the bars 21a and 21c carried by the surface 20, while its bottom face 6c rests on the slide plate 14. The surfaces 19 and 20 leave openings for the tie cutter 8 and the tie removing device 9. A motor 29 drives the holding element 16 to execute its pivotal motion with the tie cutter 8 and the pressing device 15.
While according to the described preferred embodiment the fiber bale 6 frictionally slides on the bars 15a-15d, the bars 2la-21d and the plate 14, it is understood that any or all of these bale-engaging elements may be formed, with appropriate orientation, as rolling components, for example, as rotatably held roller bars to provide a rolling friction with the respective bale face.
As shown in FIG. 5, the tie cutter 8 comprises a spike 8a and a star-shaped cutter wheel 8b which is slowly rotated in the direction of the arrow H by a motor 32 as shown in FIG. 2b. The spike 8a is pushed through the side face 6a of the fiber bale 6 and underneath the bale tie 5 which is thus lifted off the side face 6a and placed between two points of the star-shaped cutter wheel 8b. As the cutter wheel 8b rotates, the bale tie 5 is severed while it is wedged against the cutter wheel 8b. Underneath the cutter wheel 8b the sensor 12 is oriented towards the spike 8a to determine whether a bale tie 5 is present, while the sensor 10 is situated upstream of the tie cutter 8.
As shown in FIG. 6, the pusher element 7 is secured to an endless belt or chain 30 which is trained about rollers 23a, 23b, 23c and 23d. The roller 23d is driven by an electric motor 24 and carries a counting disk 25 associated with two inductive path sensors 26 and 27 for forward and rearward run. The counting device 25, 26, 27 measures the path travelled by the pusher element 7 and emits signals used for controlling a corresponding motion process for the bale 6.
As shown in FIG. 7, an electronic control and regulating device 28, for example, a microcomputer is provided to which the first proximity sensor 10, the second proximity sensors 11a, 11b, the third proximity sensor 12, the fourth proximity sensor 13, the optical barrier 22, the drive motor 24 for the pusher element 7, the drive motor 29 for the holding device 16 as well as the proximity sensors 26 and 27 are attached.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An apparatus for severing a fiber bale tie surrounding a fiber bale includes a bale advancing device for moving the fiber bale in an advancing direction along a travel path; a tie cutter for severing the tie; a bale position determining device for emitting a signal when the bale has reached a predetermined location along the travel path; and a device for moving the tie cutter transversely to the conveying direction from a remote position spaced from the bale into engagement with a bale surface when the bale has reached the predetermined location to effect severance of the tie as relative movement between the bale and said tie cutter takes place. | 3 |
BACKGROUND
Long Term Evolution (LTE) is a Third Generation Partnership Project (3GPP) standard for mobile network technology. The LTE describes requirements for mobile communications systems in evolved or advanced cellular broadband technologies. Such requirements include Evolved Universal Mobile Telecommunications System (UMTS) Terrestrial Radio Access Network (E-UTRAN) which is a high-speed radio access technique to meet increased network demands, including improving user throughputs and network capacity, reducing latency, and increasing mobility.
The LTE includes protocols, such as a Radio Resource Control (RRC) protocol, which is responsible for the assignment, configuration, and release of radio resources between a user device (e.g., a mobile telephone, a smartphone, etc.) and a base station or other access or LTE equipment. According to the RRC protocol, the two basic RRC modes for the user device (also referred to as a user equipment) are a “connected mode” and an “idle mode.” During the connected mode or state, the user device may exchange signals with a network and may perform other related operations. During the idle mode or state, the user device may shut down at least some of its connected mode operations.
In mobile communications, applications can generally be classified as data channel intensive traffic or access/control channel intensive traffic. Data channel intensive traffic includes video streaming, video-telephony, and transferring of large files. In contrast, access/control channel intensive traffic (also referred to as “thin traffic”) does not require large data channel usage. Examples of access/control channel intensive traffic include instant messaging (IM), online chat, and real-time online discussion forums. For such thin traffic connections, the most likely radio frequency (RF) bottlenecks, depending on configuration, are the setup or release of a RRC connection for each time messages need to be exchanged between user devices, or control channel overhead associated with maintaining RRC connections.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of an example network in which systems and/or methods described herein may be implemented;
FIG. 2 is a diagram of example components of a base station of the network depicted in FIG. 1 ;
FIG. 3 is a diagram of an example user device of the network illustrated in FIG. 1 ;
FIG. 4 is a diagram of example components of the user device depicted in FIG. 3 ;
FIG. 5 is a diagram of example operations capable of being performed by an example portion of the network illustrated in FIG. 1 ;
FIG. 6 is a diagram of example functional components of the user device and/or the base station;
FIG. 7 is a diagram of example functional components of a dormancy timer depicted in FIG. 6 ; and
FIGS. 8-10 are flow charts of an example process for optimizing LTE capacity using an adaptive dormancy timer according to implementations described herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.
Systems and/or methods described herein may adaptively and dynamically optimize a setting of a dormancy timer to improve a capacity of a LTE system. The dormancy timer may be provided in a user device and/or a base station, and may be used to time a dormant (or inactive) state of the user device. In one example implementation, the systems and/or methods may classify access and/or control channel signals into a first class and a second class, and may initialize a dormancy timer. The systems and/or methods may set the dormancy timer to a default value, and may set a signal target utilization threshold. The systems and/or methods may receive signals via the access/control channel, and may identify a particular signal as a first class signal or a second class signal when the signal target utilization threshold is met. If the particular signal is classified in the first class, the value of the dormancy timer may be increased. If the particular signal is classified in the second class, the value of the dormancy timer may be decreased.
As used herein, the term “user” is intended to be broadly interpreted to include a user device or a user of a user device.
FIG. 1 depicts a diagram of an example network 100 in which systems and/or methods described herein may be implemented. As shown, network 100 may include a group of user devices 110 - 1 through 110 -M (referred to collectively as “user devices 110 ”, and in some instances individually, as “user device 110 ”); a radio access network (RAN) 120 that includes a base station 130 and a radio network controller 140 ; and a core network 150 . Two user devices 110 , one radio access network 120 , one base station 130 , one radio network controller 140 , and one core network 150 have been illustrated in FIG. 1 for simplicity. In practice, there may be more user devices 110 , radio access networks 120 , base stations 130 , radio network controllers 140 , and/or core networks 150 . Also, in some instances, a component of network 100 may perform one or more functions described as being performed by another component or group of components of network 100 .
User device 110 may include one or more devices capable of sending/receiving voice and/or data to/from radio access network 120 . User device 110 may include, for example, a radiotelephone, a personal communications system (PCS) terminal (e.g., that may combine a cellular radiotelephone with data processing and data communications capabilities), a personal digital assistant (PDA) (e.g., that can include a radiotelephone, a pager, Internet/intranet access, etc.), a wireless device, a smartphone, a laptop computer (e.g., with a wireless air card), a global positioning system (GPS) device, a content recording device (e.g., a camera, a video camera, etc.), etc. In another example, user device 110 may include a fixed (e.g., provided in a particular location, such as within a user's home) computation and/or communication device, such as a laptop computer, a personal computer, a tablet computer, a set-top box (STB), a television, a gaming system, etc.
Radio access network 120 may include one or more devices for transmitting voice and/or data to user devices 110 and core network 150 . In one example implementation, radio access network 120 may include a group of base stations 130 and a group of radio network controllers 140 . In some instances, a component of radio access network 120 (e.g., base station 130 and radio network controller 130 ) may perform one or more functions described as being performed by another component or group of components in radio access network 120 .
In one example, radio access network 120 may provide a wireless access network for user devices 110 . The wireless access network, in one implementation, may correspond to a LTE network. In another implementation, the wireless access network may include a WiFi network or other access networks (e.g., an enhanced high-rate packet data (eHRPD) network or a WiMax network). In still another implementation, the wireless access network may include a radio access network capable of supporting high data rate, low latency, packet optimization, large capacity and coverage, etc.
Base station 130 (also referred to as “Node Bs”) may include one or more devices that receive voice and/or data from radio network controller 140 and transmit that voice and/or data to user device 110 via an air interface. Base station 130 may also include one or more devices that receive voice and/or data from user device 110 over an air interface and transmit that voice and/or data to radio network controller 140 or other user devices 110 .
In one example implementation, base station 130 may classify access and/or control channel signals into a first class and a second class, and may initialize a dormancy timer. Base station 130 may set the dormancy timer to a default value, and may set a signal target utilization threshold (e.g., a configurable threshold for a number of control signals). Base station 130 may receive signals via the access/control channel, and may identify a particular signal as a first class signal or a second class signal when the signal target utilization threshold is met. If the particular signal is classified in the first class, base station 130 may increase the value of the dormancy timer. If the particular signal is classified in the second class, base station 130 may decrease the value of the dormancy timer.
Radio network controller 140 may include one or more devices that control and manage base station 130 . Radio network controller 140 may also include devices that perform data processing to manage utilization of radio network services. Radio network controller 140 may transmit/receive voice and data to/from base station 130 , other radio network controller 140 , and/or core network 150 . Radio network controller 140 may act as a controlling radio network controller (CRNC), a drift radio network controller (DRNC), or a serving radio network controller (SRNC). A CRNC may be responsible for controlling the resources of a base station 130 . On the other hand, a SRNC may serve a particular user device 110 and may manage connections towards that user device 110 . Likewise, a DRNC may fulfill a similar role to the SRNC (e.g., may route traffic between a SRNC and a particular user device 110 ).
Core network 150 may include one or more devices that transfer/receive voice and/or data to a circuit-switched and/or packet-switched network. In one example implementation, core network 150 may include a Mobile Switching Center (MSC), a Gateway MSC (GMSC), a Media Gateway (MGW), a Serving General Packet Radio Service (GPRS) Support Node (SGSN), a Gateway GPRS Support Node (GGSN), and/or other devices.
Although FIG. 1 shows example components of network 100 , in other implementations, network 100 may contain fewer components, different components, differently arranged components, or additional components than depicted in FIG. 1 .
FIG. 2 is a diagram of example components of base station 130 . As shown in FIG. 2 , base station 130 may include antennas 210 , transceivers (TX/RX) 220 , a processing system 230 , and an Iub interface (I/F) 240 .
Antennas 210 may include one or more directional and/or omni-directional antennas. Transceivers 220 may be associated with antennas 210 and may include transceiver circuitry for transmitting and/or receiving symbol sequences in a network, such as network 100 , via antennas 210 .
Processing system 230 may control the operation of base station 130 . Processing system 230 may also process information received via transceivers 220 and Iub interface 240 . Processing system 230 may further measure quality and strength of a connection, may determine a frame error rate (FER), and may transmit this information to radio network controller 140 . As illustrated, processing system 230 may include a processing unit 232 and a memory 234 .
Processing unit 232 may include one or more processors, microprocessors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or the like. Processing unit 232 may process information received via transceivers 220 and Iub interface 240 . The processing may include, for example, data conversion, forward error correction (FEC), rate adaptation, Wideband Code Division Multiple Access (WCDMA) spreading/dispreading, quadrature phase shift keying (QPSK) modulation, etc. In addition, processing unit 232 may transmit control messages and/or data messages, and may cause those control messages and/or data messages to be transmitted via transceivers 220 and/or Iub interface 240 . Processing unit 232 may also process control messages and/or data messages received from transceivers 220 and/or Iub interface 240 .
Memory 234 may include a random access memory (RAM), a read-only memory (ROM), and/or another type of memory to store data and instructions that may be used by processing unit 232 .
Iub interface 240 may include one or more line cards that allow base station 130 to transmit data to and receive data from radio network controller 140 .
As described herein, base station 130 may perform certain operations in response to processing unit 232 executing software instructions contained in a computer-readable medium, such as memory 234 . A computer-readable medium may be defined as a non-transitory memory device. A memory device may include space within a single physical memory device or spread across multiple physical memory devices. The software instructions may be read into memory 234 from another computer-readable medium or from another device via antennas 210 and transceivers 220 . The software instructions contained in memory 234 may cause processing unit 232 to perform processes described herein. Alternatively, hardwired circuitry may be used in place of or in combination with software instructions to implement processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.
Although FIG. 2 shows example components of base station 130 , in other implementations, base station 130 may contain fewer components, different components, differently arranged components, or additional components than depicted in FIG. 2 . In still other implementations, one or more components of base station 130 may perform one or more other tasks described as being performed by one or more other components of base station 130 .
FIG. 3 is a diagram of an example user device 110 (e.g., a mobile communication device). As illustrated, user device 110 may include a housing 300 , a speaker 310 , a display 320 , control buttons 330 , a keypad 340 , and a microphone 350 . Housing 300 may protect the components of user device 110 from outside elements. Speaker 310 may provide audible information to a user of user device 110 .
Display 320 may provide visual information to the user. For example, display 320 may display text input into user device 110 ; text, images, video, and/or graphics received from another device; and/or information regarding incoming or outgoing calls or text messages, emails, media, games, phone books, address books, the current time, etc. In one example implementation, display 320 may include a touch screen display that may be configured to receive a user input when the user touches display 320 . For example, the user may provide an input to display 320 directly, such as via the user's finger, or via other input objects, such as a stylus. User inputs received via display 320 may be processed by components and/or devices operating in user device 110 . The touch screen display may permit the user to interact with user device 110 in order to cause user device 110 to perform one or more operations described herein. Example technologies to implement a touch screen on display 320 may include, for example, a near-field-sensitive (e.g., capacitive) overlay, an acoustically-sensitive (e.g., surface acoustic wave) overlay, a photo-sensitive (e.g., infrared) overlay, a pressure sensitive (e.g., resistive) overlay, and/or any other type of touch panel overlay that allows display 320 to be used as an input device. The touch-screen-enabled display 320 may also identify movement of a body part or a pointing device as it moves on or near the surface of the touch-screen-enabled display 320 .
Control buttons 330 may permit the user to interact with user device 110 to cause user device 110 to perform one or more operations. For example, control buttons 330 may be used to cause user device 110 to transmit information. Keypad 340 may include a standard telephone keypad. In one example implementation, control buttons 330 and/or keypad 340 may be omitted, and the functionality provided by control buttons 330 and/or keypad 340 may be provided by display 320 (e.g., via a touch screen display). Microphone 350 may receive audible information from the user.
Although FIG. 3 shows example components of user device 110 , in other implementations, user device 110 may contain fewer components, different components, differently arranged components, or additional components than depicted in FIG. 3 . In still other implementations, one or more components of user device 110 may perform one or more other tasks described as being performed by one or more other components of user device 110 .
FIG. 4 is a diagram of example components of user device 110 . As shown, user device 110 may include a processing unit 400 , memory 410 , a user interface 420 , a communication interface 430 , and an antenna assembly 440 . Components of user device 110 may interconnect via wired and/or wireless connections.
Processing unit 400 may include one or more processors, microprocessors, ASICs, FPGAs, or the like. Processing unit 400 may control operation of user device 110 and its components in a manner described herein.
Memory 410 may include a RAM, a ROM, and/or another type of memory to store data and instructions that may be used by processing unit 400 .
User interface 420 may include mechanisms for inputting information to user device 110 and/or for outputting information from user device 110 . Examples of input and output mechanisms might include buttons (e.g., control buttons 330 , keys of keypad 340 , a joystick, etc.) or a touch screen interface to permit data and control commands to be input into user device 110 ; a speaker (e.g., speaker 310 ) to receive electrical signals and output audio signals; a microphone (e.g., microphone 350 ) to receive audio signals and output electrical signals; a display (e.g., display 320 ) to output visual information (e.g., text input into user device 110 ); and/or a vibrator to cause user device 110 to vibrate.
Communication interface 430 may include, for example, a transmitter that may convert baseband signals from processing unit 400 to radio frequency (RF) signals and/or a receiver that may convert RF signals to baseband signals. Alternatively, communication interface 430 may include a transceiver to perform functions of both a transmitter and a receiver. Communication interface 430 may connect to antenna assembly 440 for transmission and/or reception of the RF signals.
Antenna assembly 440 may include one or more antennas to transmit and/or receive RF signals over the air. Antenna assembly 440 may, for example, receive RF signals from communication interface 430 and transmit them over the air, and receive RF signals over the air and provide them to communication interface 430 . In one implementation, for example, communication interface 430 may communicate with a network and/or devices connected to a network.
As described herein, user device 110 may perform certain operations described herein in response to processing unit 400 executing software instructions of an application contained in a computer-readable medium, such as memory 410 . The software instructions may be read into memory 410 from another computer-readable medium or from another device via communication interface 430 . The software instructions contained in memory 410 may cause processing unit 400 to perform processes that will be described later. Alternatively, hardwired circuitry may be used in place of or in combination with software instructions to implement processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.
Although FIG. 4 shows example components of user device 110 , in other implementations, user device 110 may contain fewer components, different components, differently arranged components, or additional components than depicted in FIG. 4 . In still other implementations, one or more components of user device 110 may perform one or more other tasks described as being performed by one or more other components of user device 110 .
FIG. 5 is a diagram of example operations capable of being performed by an example portion 500 of network 100 . As shown, example network portion 500 may include user devices 110 - 1 and 110 - 2 and base station 130 . User devices 110 - 1 and base station 130 may include the features described above in connection with, for example, one or more of FIGS. 1-4 .
In one example, a user of user device 110 - 1 may wish to establish a connection with user device 110 - 2 in order to exchange instant messages (e.g., access/control channel intensive traffic) with user device 110 - 2 . As further shown in FIG. 5 , user device 110 - 1 may generate a RRC connection request 510 , and may provide RRC connection request 510 to base station 130 . RRC connection request 510 may include a RRC establishment cause and an initial terminal identifier (e.g., of user device 110 - 1 ). The initial terminal identifier may be an identifier that is unique to user device 110 - 1 and may permit identification of user device 110 - 1 despite its location. In one example, user device 110 - 1 may provide RRC connection request 510 to base station 130 on a common control channel (CCCH). Upon transmitting RRC connection request 510 , user device 110 - 1 may trigger an internal timer and may wait for a RRC connection setup message 520 on the common control channel.
Base station 130 may receive RRC connection request 510 , may determine that user device 110 - 1 may establish a network connection, and may transmit RRC connection setup message 520 to user device 110 - 1 (e.g., on the common control channel). RRC connection setup message 520 may include a radio network identifier (e.g., to permit base station 130 to identify connected state user devices 110 ), radio bearer setup information, and the initial terminal identifier. User device 110 - 1 may receive RRC connection setup message 520 , and may generate a RRC connection setup complete message 530 . User device 110 - 1 may provide RRC connection setup complete message 530 to base station 130 , and a RRC connection 540 may be established between user device 110 - 1 and base station 530 (e.g., based on RRC connection setup complete message 530 ).
When RRC connection 540 is established, base station 130 may dedicate or reserve a certain amount of RF resources until RRC connection 540 is released. For example, when RRC connection 540 is established, a RF channel 550 may be created between user device 110 - 1 and user device 110 - 2 (e.g., to permit exchange of instant messages between user devices 110 - 1 and 110 - 2 ). A length of a reservation of RRC connection 540 may be controlled by a configurable dormancy timer (e.g., provided in user device 110 - 2 and/or base station 130 ). The dormancy timer may terminate RRC connection 540 between user device 110 - 1 and base station 130 when user device 110 - 1 is dormant (e.g., not exchanging messages with user device 110 - 2 ) for a predetermined period of time.
When user device 110 - 1 wants to exchange messages with user device 110 - 2 through RF channel 550 or when user device 110 - 1 receives messages from user device 110 - 2 through RF channel 550 , user device 110 - 1 may provide a transfer request 560 to base station 130 . Transfer request 560 may inform base station 130 that user devices 110 - 1 and 110 - 2 are going to exchange messages over RF channel 550 . During this time, messages may be transferred between user device 110 - 1 and user device 110 - 2 , as indicated by reference number 570 , RRC connection 540 may be in a RRC connection active state, and user device 110 - 1 may be in a RRC connected or active mode, as indicated by reference number 580 . After completion of message transfer 570 , the dormancy timer may be started, RRC connection 540 may be in a RRC dormant state, and user device 110 - 1 may be in a RRC dormant mode, as indicated by reference number 590 .
During the RRC dormant state, if user device 110 - 1 generates another transfer request 560 , RRC connection 540 may reenter the RRC connection active state and the dormancy timer may be reset (e.g., to a default value). If user device 110 - 1 does not generate another transfer request 560 before the dormancy timer expires, RRC connection 540 may be released and the RF resources (e.g., RF channel 550 ) may be allocated to other traffic associated with base station 130 . Different configurations of the dormancy timer may have different effects on the network resources (e.g., base station 130 ) and capacity of radio access network 120 . For example, if the dormancy timer is set to a larger value (e.g., a longer time period), more control channel overhead is needed for maintaining RRC connections (e.g., RRC connection 540 ). In another example, if the dormancy timer is set to a smaller value (e.g., a shorter time period), more access/control channel resources are needed for message transfers (e.g., message transfer 570 ) associated with the setup or release of RRC connections (e.g., RRC connection 540 ).
Although FIG. 5 shows example components of network portion 500 , in other implementations, network portion 500 may contain fewer components, different components, differently arranged components, or additional components than depicted in FIG. 5 . In still other implementations, one or more components of network portion 500 may perform one or more other tasks described as being performed by one or more other components of network portion 500 .
FIG. 6 is a diagram of example functional components of a device 600 that may correspond to user device 110 and/or base station 130 . In one implementation, the functions described in connection with FIG. 6 may be performed by one or more components of base station 130 ( FIG. 2 ) or one or more components of user device 110 ( FIG. 4 ). As illustrated in FIG. 6 , device 600 may include a RRC connection state component 610 , and a dormancy timer 620 .
RRC connection state component 610 may include hardware or a combination of hardware and software that may receive transfer request 560 (e.g., from user device 110 - 1 ), and may determine a state of a RRC connection (e.g., RRC connection 540 ) based on transfer request 560 . In one example, since transfer request 560 may indicate that messages are going to be exchanged between user devices 110 - 1 and 110 - 2 , RRC connection state component 610 may determine RRC connection 540 to be in a RRC connection active state 630 , and may provide an indication of RRC connection active state 630 to dormancy timer 620 . Upon completion of the transfer messages between user devices 110 - 1 and 110 - 2 , RRC connection state component 610 may receive (e.g., from user device 110 - 1 ) an indication 640 that the transfer is complete. Based upon receipt of indication 640 , RRC connection state component 610 may determine RRC connection 540 to be in a RRC dormant state 650 , and may provide an indication of RRC dormant state 650 to dormancy timer 620 .
Dormancy timer 620 may include hardware or a combination of hardware and software that may receive the indication of RRC connection active state 630 from RRC connection state component 610 . Upon completion of the transfer messages between user devices 110 - 1 and 110 - 2 , dormancy timer 620 may receive the indication of RRC dormant state 650 from RRC connection state component 610 , and may start the dormancy timer, as indicated by reference number 660 . During RRC dormant state 650 , if user device 110 - 1 generates an additional transfer request 670 , RRC connection state component 610 may receive additional transfer request 670 , and may determine RRC connection 540 to be reentering RRC connection active state 630 . Dormancy timer 620 may once again receive the indication of RRC connection active state 630 from RRC connection state component 610 , and may reset the dormancy timer (e.g., to a default value), as indicated by reference number 680 . However, if user device 110 - 1 does not generate additional transfer request 670 before the dormancy timer expires, as indicated by reference number 690 , RRC connection 540 may be released and the RF resources (e.g., RF channel 550 ) may be allocated to other traffic.
Although FIG. 6 shows example functional components of device 600 , in other implementations, device 600 may contain fewer functional components, different functional components, differently arranged functional components, or additional functional components than depicted in FIG. 6 . In still other implementations, one or more functional components of device 600 may perform one or more other tasks described as being performed by one or more other functional components of device 600 .
FIG. 7 is a diagram of example functional components of dormancy timer 620 . In one implementation, the functions described in connection with FIG. 7 may be performed by one or more components of base station 130 ( FIG. 2 ) or one or more components of user device 110 ( FIG. 4 ). As illustrated in FIG. 7 , dormancy timer 620 may include an initialization component 705 , a default/threshold component 710 , a signal classifier component 715 , and a timer adjustment component 720 .
Initialization component 705 may include hardware or a combination of hardware and software that may classify access channel and control channel signals into classes, as indicated by reference number 725 . For example, in one implementation, initialization component 705 may classify, into a first class, access/control channel signals that are needed for setup or release of new RRC connections, and may classify, into a second class, access/control channel signals that are needed to maintain RRC connection states. Initialization component 705 may also initialize the dormancy timer, as indicated by reference number 730 . In one example implementation, initialization component 705 may initialize the dormancy timer to a default value (e.g., a value pre-configured for user device 110 or base station 130 ), a value larger than the default value, or a value smaller than the default value. The value larger than the default value may reduce a number of setups or releases of RRC connections. Whereas, the value smaller than the default value may reduce a number of RRC connections. As further shown in FIG. 7 , initialization component 705 may provide indication 725 of the signal classification to signal classifier component 715 , and may provide indication 730 of the initialized dormancy timer values to timer adjustment component 720 .
Default/threshold component 710 may include hardware or a combination of hardware and software that may set the dormancy timer to a default value 735 , and may set a signal target utilization threshold 740 . Signal target utilization threshold 740 may include a configurable threshold for a number of control signals (e.g., transfer request 560 ) received by user device 110 or base station 130 . As further shown in FIG. 7 , default/threshold component 710 may provide default value 735 of the dormancy timer to timer adjustment component 720 , and may provide signal target utilization threshold 740 to signal classifier component 715 .
Signal classifier component 715 may include hardware or a combination of hardware and software that may receive indication 725 of the signal classification from initialization component 705 , and may receive signal target utilization threshold 740 from default/threshold component 710 . As further shown in FIG. 7 , signal classifier component 715 may receive signals 745 (e.g., transfer requests 560 from user device 110 - 1 ), and may determine if a number of received signals 745 exceeds signal target utilization threshold 740 . When the number of received signals 745 exceeds signal target utilization threshold 740 , signal classifier component 715 may classify (e.g., based on indication 725 of the signal classification) a next received signal 745 as belonging to a first class 750 or to a second class 755 . Signal classifier component 715 may classify the next received signal 745 in first class 750 when the next received signal 745 is a signal needed for setup or release of a new RRC connection. Signal classifier component 715 may classify the next received signal 745 in second class 755 when the next received signal 745 is a signal needed to maintain a RRC connection state. As further shown in FIG. 7 , signal classifier component 715 may provide first class 750 indication or second class 755 indication to timer adjustment component 720 .
Timer adjustment component 720 may include hardware or a combination of hardware and software that may receive indication 730 of the initialized dormancy timer values from initialization component 705 , and may receive default value 735 of the dormancy timer from default/threshold component 710 . Timer adjustment component 720 may also receive either first class 750 indication or second class 755 indication from signal classifier component 715 . If first class 750 indication is received, timer adjustment component 720 may increase default value 735 of the dormancy timer to a value larger than default value 735 (e.g., provided by indication 730 of the initialized dormancy timer values), as indicated by reference number 760 . As described above, increasing default value 735 of the dormancy timer may reduce a number of setups or releases of RRC connections. If second class 755 indication is received, timer adjustment component 720 may decrease default value 735 of the dormancy timer to a value smaller than default value 735 (e.g., provided by indication 730 of the initialized dormancy timer values), as indicated by reference number 765 . As described above, decreasing default value 735 of the dormancy timer may reduce a number of RRC connections.
Although FIG. 7 shows example functional components of dormancy timer 620 , in other implementations, dormancy timer 620 may contain fewer functional components, different functional components, differently arranged functional components, or additional functional components than depicted in FIG. 7 . In still other implementations, one or more functional components of dormancy timer 620 may perform one or more other tasks described as being performed by one or more other functional components of dormancy timer 620 .
FIGS. 8-10 are flow charts of an example process 800 for optimizing LTE capacity using an adaptive dormancy timer according to implementations described herein. In one implementation, process 800 may be performed by base station 130 . In another implementation, some or all of process 800 may be performed by another device or group of devices (e.g., user device 110 ), including or excluding base station 130 .
As shown in FIG. 8 , process 800 may include classifying access/control channel signals into a first class or a second class (block 810 ), and initializing a dormancy timer (block 820 ). For example, in implementations described above in connection with FIG. 7 , initialization component 705 of device 600 may classify access channel and control channel signals into classes, as indicated by reference number 725 . In one example, initialization component 705 access/control channel signals into a first class or a second class. Initialization component 705 may also initialize the dormancy timer, as indicated by reference number 730 .
As further shown in FIG. 8 , process 800 may include setting the dormancy timer to a default value (block 830 ), and setting a signal target utilization threshold (block 840 ). For example, in implementations described above in connection with FIG. 7 , default/threshold component 710 of device 600 may set the dormancy timer to default value 735 , and may set signal target utilization threshold 740 . Signal target utilization threshold 740 may include a configurable threshold for a number of control signals (e.g., transfer request 560 ) received by user device 110 or base station 130 .
Returning to FIG. 8 , process 800 may include receiving signals via an access/control channel (block 850 ), and identifying a particular signal as first class or second class when the signal target utilization threshold is met by the received signals (block 860 ). For example, in implementations described above in connection with FIG. 7 , signal classifier component 715 of device 600 may receive signals 745 (e.g., transfer requests 560 from user device 110 - 1 ), and may determine if a number of received signals 745 exceeds signal target utilization threshold 740 . When the number of received signals 745 exceeds signal target utilization threshold 740 , signal classifier component 715 may classify (e.g., based on indication 725 of the signal classification) a next received signal 745 as belonging to first class 750 or to second class 755 . Signal classifier component 715 may classify the next received signal 745 in first class 750 when the next received signal 745 is a signal needed for setup or release of a new RRC connection. Signal classifier component 715 may classify the next received signal 745 in second class 755 when the next received signal 745 is a signal needed to maintain a RRC connection state.
As further shown in FIG. 8 , when the particular signal is classified as first class, process 800 may include increasing the value of the dormancy timer (block 870 ). When the particular signal is classified as second class, process 800 may include decreasing the value of the dormancy timer (block 880 ). For example, in implementations described above in connection with FIG. 7 , timer adjustment component 720 of device 600 may receive either first class 750 indication or second class 755 indication from signal classifier component 715 . If first class 750 indication is received, timer adjustment component 720 may increase default value 735 of the dormancy timer to a value larger than default value 735 (e.g., provided by indication 730 of the initialized dormancy timer values), as indicated by reference number 760 . If second class 755 indication is received, timer adjustment component 720 may decrease default value 735 of the dormancy timer to a value smaller than default value 735 (e.g., provided by indication 730 of the initialized dormancy timer values), as indicated by reference number 765 .
Process block 810 may include the process blocks depicted in FIG. 9 . As shown in FIG. 9 , process block 810 may include classifying the access/control channel signals into the first class when the signals are needed for setup or release of new RRC connections (block 900 ) or classifying the access/control channel signals into the second class when the signals are needed to maintain RRC connection states (block 910 ). For example, in implementations described above in connection with FIG. 7 , initialization component 705 of device 600 may classify, into a first class, access/control channel signals that are needed for setup or release of new RRC connections, and may classify, into a second class, access/control channel signals that are needed to maintain RRC connection states.
Process block 820 may include the process blocks depicted in FIG. 10 . As shown in FIG. 10 , process block 820 may include initializing the dormancy timer to a default value (block 1000 ), initializing the dormancy timer to a value smaller than the default value (block 1010 ), or initializing the dormancy timer to a value larger than the default value (block 1020 ). For example, in implementations described above in connection with FIG. 7 , initialization component 705 of device 600 may initialize the dormancy timer to a default value (e.g., a value pre-configured for user device 110 or base station 130 ), a value larger than the default value, or a value smaller than the default value. The value larger than the default value may reduce a number of setups or releases of RRC connections. Whereas, the value smaller than the default value may reduce a number of RRC connections.
Systems and/or methods described herein may adaptively and dynamically optimize a setting of a dormancy timer to improve a capacity of a LTE system. The dormancy timer may be provided in a user device and/or a base station, and may be used to time a dormant (or inactive) state of the user device.
The foregoing description of implementations provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention.
For example, while series of blocks have been described with regard to FIGS. 8-10 , the order of the blocks may be modified in other implementations. Further, non-dependent blocks may be performed in parallel.
It will be apparent that example aspects, as described above, may be implemented in many different forms of software, firmware, and hardware in the implementations illustrated in the figures. The actual software code or specialized control hardware used to implement these aspects should not be construed as limiting. Thus, the operation and behavior of the aspects were described without reference to the specific software code—it being understood that software and control hardware could be designed to implement the aspects based on the description herein.
Further, certain portions of the invention may be implemented as a “component” or “logic” that performs one or more functions. These components or logic may include hardware, such as a processor, an ASIC, or a FPGA, or a combination of hardware and software.
Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of the invention. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. Although each dependent claim listed below may directly depend on only one other claim, the disclosure of the invention includes each dependent claim in combination with every other claim in the claim set.
No element, act, or instruction used in the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. | A device classifies access or control channel signals into a first class or a second class, initializes a dormancy timer associated with the device, and sets the dormancy timer to a default value. The device also sets a signal target utilization threshold, receives actual signals via the access or control channel, and identifies, when a number of the actual signals exceeds the signal target utilization threshold, a particular signal, from the actual signals, as belonging to the first class or the second class. The device further increases the default value of the dormancy timer when the particular signal belongs to the first class, and decreases the default value of the dormancy timer when the particular signal belongs to the second class. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/212,213, filed Apr. 8, 2009, the disclosure of which is hereby incorporated in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to an improved system and method for removing surface contamination. More particularly, the system and method of the invention prevent the formation of, or remove, coatings of debris on a surface that interfere with the use of the surface. The invention is particularly useful for the prevention and removal of biofilms, i.e., organic debris and moisture found on a surface during use if not removed. One illustrative example of an application for the invention is dental instruments and more particularly an improved self-cleaning hand dental mirror.
BACKGROUND OF THE INVENTION
[0003] Many surfaces become contaminated during use with debris or other materials which inhibit use of the surface. In particular, many surfaces develop during use a coating or film of organic debris and moisture, sometimes referred to herein as a “biofilm.” It is typically necessary to remove the biofilm manually during use to permit use to continue. Often it is necessary to repeat the removal procedure periodically, interfering with and making use difficult and inefficient.
[0004] As an example of a surface suitable for application of the invention, dentists commonly use hand-held dental mirrors to enable them to clearly see areas inside a patient's mouth while performing a procedure such as drilling in or on a tooth. During use, the reflective surface of the mirror quickly becomes obscured from spray from the high-speed dental drill, dental material and tooth debris, fog, mist, etc. This impaired reflective surface can lead to reduced workmanship in dental procedures unless the mirror is continually cleaned and/or a surface tension reducer is constantly applied. It has therefore been customary for dentists to frequently remove the dental mirror from a patient's mouth, clean the mirror surface, and reposition the mirror in the patient's mouth. This is both inconvenient and inefficient.
[0005] Other surfaces which may develop biofilms or other coatings of contaminants which may advantageously be prevented or removed by the system and method of the invention include, but are not limited to, windows on buildings (especially high-rise buildings); lenses and windows on satellites and spacecraft; windows and windshields on vehicles such as airplanes; glass shower enclosures; mirrors; cooking surfaces; surfaces from which removal of biofilms will facilitate fluid flow, such as surfaces of pipes, ducts and membranes; glass or plastic aquarium surfaces (e.g., to prevent or remove algae growth); tank surfaces; various other glass or mirror surfaces; and surgical sites where there is debris in the field. The foregoing list is illustrative only and is not intended to limit the scope of the invention or its potential applications.
[0006] It is desirable to provide a system and method to prevent or inhibit the formation of biofilms or other coatings of contaminants on surfaces. It is also desirable to provide a system and method to remove biofilms or other coatings of contaminants which have formed on surfaces. It is also desirable to prevent and remove biofilms or other coatings of contaminants during use of the surface without interfering with the use or requiring manual or other action by the user which might require interruption of the use.
SUMMARY OF THE INVENTION
[0007] In accordance with one aspect of the present invention, a system for preventing or removing biofilms or other coatings of contaminants on a surface comprises an apparatus including a substantially enclosed gas pressurization chamber. Where the surface to be cleaned defines a horizontal plane, the chamber includes a generally vertical face extent with a horizontally curved profile, a gas inlet orifice to allow gas under pressure to pressurize the chamber, and a gas outlet orifice in the curved face extent configured so that gas flows from the chamber in divergent directions normal to the gas outlet orifice, thus creating a spreading laminar flow of gas capable of flowing across substantially an entire surface that is wider than the orifice itself. A liquid conduit including a liquid outlet orifice is also provided, the liquid outlet orifice located below the laminar gas flow so that the laminar gas flow propels the layer of liquid in a laminar flow across the surface. Preferably, the liquid outlet orifice is located downstream of the gas outlet orifice so that the laminar gas flow flows over the liquid as it exits the liquid outlet orifice.
[0008] In one embodiment of the invention, the apparatus is incorporated into a self-cleaning dental mirror tool. In the tool, the surface to be cleaned is the reflective surface of a mirror. The liquid outlet orifice is disposed proximate to one edge of the mirror surface for dispensing a thin layer of a liquid onto the mirror surface. The gas outlet orifice is disposed above the liquid outlet orifice for simultaneously dispensing a thin laminar layer of gas across and parallel to the mirror surface at a pressure greater than that of the layer of liquid. Optionally but advantageously, a gas conduit for providing gas to the chamber and the liquid conduit are located in a handle of the tool.
[0009] In another embodiment, the gas outlet orifice is a slit formed in the face extent so that the top and bottom of the slit are spaced apart at least substantially vertically, and in this manner the laminar gas flow passes through the slit at least substantially horizontally, in a direction normal to the slit, and the slit has an at least substantially uniform height. Advantageously, the slit has a vertical height of from about 5% to about 20% of the vertical height of the chamber.
[0010] In another aspect, the invention provides a method for preventing or removing biofilms or other coatings of contaminants on a surface. The method includes providing an apparatus substantially as described, flowing a gas into the chamber so that a pressurized, laminar flow of gas flows from the chamber in a direction normal to the gas outlet orifice, and flowing a liquid from the liquid conduit through the liquid outlet orifice onto the surface so that the laminar gas flow propels the liquid in a laminar liquid flow across the surface. Advantageously, the liquid may be water, and the gas may be air. Optionally, but preferably, a surface tension reducer may be mixed into the stream of liquid upstream of the liquid outlet orifice, to reduce turbulence in the liquid flow (i.e., to make the liquid flow more laminar) and thus to increase visibility through the liquid flow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a cross-sectional view of a circular chamber for producing normal, laminar fluid flow across a surface in accordance with the invention.
[0012] FIG. 1 a is cross-sectional view of the chamber of FIG. 1 taken along line A-A.
[0013] FIG. 1 b is a cross-sectional view of the chamber of FIG. 1 taken along line B-B showing the orifice.
[0014] FIG. 2 is a top plan view of an alternate chamber suitable for use with the invention.
[0015] FIG. 3 is a partial plan view of a dental mirror in accordance with the invention.
[0016] FIG. 4 is a cross-sectional view of the dental mirror of FIG. 3 taken along line 4 - 4 .
[0017] FIG. 5 is a longitudinal section view taken along line 5 - 5 of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] It is known in the art to use a flow of fluid, for example, air and/or water, to clear a surface of debris. An example of a device using this method is the dental mirror disclosed in applicant's U.S. Pat. No. 3,969,824, the disclosure of which is incorporated herein in its entirety by reference. The device disclosed in the earlier patent attempts to disperse the air flow coming down the handle/center air conduit by having the air hit a stationary obstruction that is air foil shaped, being thickest in the center and tapering toward the periphery.
[0019] Rather than using an airfoil-shaped obstruction in the fluid stream, the present invention disperses air using an entrapment chamber wherein the air is further pressurized. It has been found that the air chamber of the present invention allows more control of the air flow than the air foil. The aerodynamic flow lines are more predictable using a chamber than when using an airfoil. Design considerations with a chamber are easier to anticipate, and the chamber design is easier and less expensive to fabricate. The dispersion effect is created by opening a slit in a curved face of this chamber, the slit and chamber being configured such that the air will disperse radially through the curved slit from the pressurized chamber. With sufficient pressure in the chamber, pressure being substantially uniform within the chamber behind the slit, the flow from the slit will be radial (i.e., normal) to the arc extent of the slit. The slit is horizontal and uniform in vertical dimension with respect to the roof and floor of the chamber. In order to build up pressure within the chamber, the slit must be relatively thin in relation to the height of the chamber or else the air will flow “straight” from the chamber. This slit height is to be determined by the amount of pressure in the chamber and the desired velocity of the escapement flow. This escapement flow is preferably approximately 25-50 feet per second, laminar, non turbulent and radial (i.e., normal) to the slit's arc extent.
[0020] This dispersion technique does not create laminar flow by using the gradual air foil shaped obstruction to simply guide the air flow from a center flow by “squeezing” it to the maximum in the center and gradually releasing it through an effectively wider space. Instead, air is pressurized upstream from the surface by using a “holding chamber” and curved outlet orifice versus merely deflecting flow from an inlet orifice with a tapering air foil shaped obstruction.
[0021] As shown in FIGS. 1 , 1 a , and 1 b , a circular gas pressurization chamber 10 has a ceiling 12 , floor 14 and sides 16 and is approximately the shape of a horizontal cylinder segment. For use in a dental mirror tool, the approximate linear and cubic dimensions of the chamber are comparable to that of an aspirin tablet, or about ⅜ inch diameter×⅛ inch height. A gas outlet orifice 18 is provided along approximately 90 to 120 degrees of the chamber's circumference.
[0022] As shown in FIGS. 1 a and 1 b , gas outlet orifice 18 is located generally opposite an air inlet 20 in chamber 10 , and in the side wall 16 of chamber 10 adjacent to floor 14 of chamber 10 . Although not shown, floor 14 of chamber 10 will be positioned adjacent the surface to be cleaned. Orifice 18 preferably has a vertical height approximately 5% to 20% of the vertical height of chamber 10 (i.e., of the height of side 16 ).
[0023] A suitable gas (air will be used as an example) enters inlet 20 under pressure and pressurizes chamber 10 . Air exits chamber 10 through outlet orifice 18 such that the outlet flow “F” is laminar and perpendicular to the tangent “T” to the radius at any point along orifice 18 as shown. In other words, the flow “F” created will be radial to the orifice's arc extent and laminar to the surface over which it flows. The pressure in chamber 10 should be such that air flows from outlet orifice 18 at a pressure greater than ambient pressure.
[0024] A top plan view of an alternate chamber 30 is shown in FIG. 2 . The radial flow lines “F” are created and laminar flow exits chamber 30 across the surface to be cleaned (not shown). In this embodiment, chamber 30 is not circular but has a shape generally as shown in FIG. 2 . Two gas outlet orifices 32 a , 32 b are provided, generally opposite an air inlet 34 , and arranged to direct air flow “F” in a direction perpendicular to orifice tangents “T” as shown, across the surface to be cleaned.
[0025] Generally, in a system for preventing and removing surface contamination incorporating an air chamber according to the invention as just described, liquid such as water is introduced to the surface to be cleaned through a liquid outlet orifice downstream of gas outlet orifice 18 or gas outlet orifices 32 a , 32 b of chamber 10 or 30 , respectively. The air flow draws the liquid across the surface to be cleaned, which may for example be a mirror surface.
[0026] As an example of a system according to the invention for preventing and removing surface contamination, dental mirror tool 36 incorporating air chamber 10 according to the invention is shown in FIGS. 3 through 5 . Pressurized air from an air conduit 38 in a handle 40 of mirror tool 36 enters air chamber 10 through inlet orifice 20 . Air chamber 10 is upstream of and proximal to a mirror surface 42 of mirror tool 36 . To protect gas outlet orifice 18 , for example from debris or impacts, chamber 10 may advantageously be located in a flange cavity 44 between handle air conduit 38 and an edge 46 of mirror surface 42 . Air chamber outlet 18 will dispense air through flange cavity 44 to mirror surface 42 . A liquid such as water is provided from a liquid conduit 48 in handle 40 and exits through a liquid outlet orifice 50 onto mirror surface 42 . Mirror tool 36 includes other structural elements as shown, including mirror holding bottom plate 52 , mirror holding outer frame 54 , mirror holding detent 56 , flange top surface 58 and flange inner surface 60 .
[0027] Pressurized air traversing laminar flow vectors “F,” perpendicular to the tangent “T” of a radial chord along air chamber outlet orifice 18 , propels in a fluid-dynamic manner, by pressure differential and/or entrapment, water from liquid outlet orifice 50 . Water flow is laminar across mirror surface 42 and follows the gas flow lines F in FIGS. 1-3 , as the water flow is propelled by the gas flow. Optionally, but preferably, these effects can be enhanced by introducing a surface tension reducer into the stream of water or other suitable liquid upstream of liquid outlet orifice 50 , which will reduce turbulence in the liquid flow (i.e., make the flow even more laminar) and thus increase visibility of the mirror surface through the liquid flow. For example, the present inventor has found that placing a cartridge of Polyox™ water soluble resin, available from the Dow Chemical Company, in-line with the liquid flow upstream of the handle, so that the surface tension reducer is dissolved into the stream of liquid at a metered rate, effectively improves the laminar quality of the flow of liquid across the mirror surface.
[0028] Generally speaking, the invention utilizes an enclosed chamber with a curved face extent, an inlet orifice to allow gas under pressure to pressurize the chamber, and an outlet orifice in the curved face extent so that gas flows from the chamber perpendicular to the tangent of the radius of the orifice in the curved face extent. In the context of a self cleaning dental mirror, the apparatus comprises in combination: a mirror surface; a first orifice disposed along one edge of the mirror surface for dispensing a thin layer of a liquid onto the surface; and a second orifice disposed above the first orifice for simultaneously dispensing a thin laminar layer of gas flow across and parallel to the mirror surface, the laminar gas flow propelling a laminar flow of the liquid beneath the laminar gas flow.
[0029] Although the invention has been described by reference to one illustrative embodiment, a dental mirror, it will be understood that the invention can be adapted through appropriate choices of dimensions and configurations for use in a wide variety of other applications, including those mentioned herein and others that will be apparent. The shape of the chamber, dimensions of the gas outlet orifice, internal chamber pressure and other design parameters are appropriately selected to so that the liquid is “picked up” by the laminar air flow to create laminar liquid flow across the surface to be cleaned. A device in accordance with the invention will effectively clean the surface and, in the case of a glass or mirror surface, provide a clear, unobstructed, non-distorted view therethrough or therein using a laminar “air curtain” to draw a laminar flow of liquid across the surface.
[0030] While the invention has been described with respect to certain preferred embodiments, as will be appreciated by those skilled in the art, it is to be understood that the invention is capable of numerous changes, modifications and rearrangements, and such changes, modifications and rearrangements are intended to be covered by the following claims. | A system and method are provided in which a laminar flow of pressurized gas from a curved slit in a chamber is directed across a surface to propel a laminar flow of a liquid, below the laminar flow gas, across the surface to prevent surface contamination or remove contaminants from the surface. In a particular application, the system and method are employed in a self-cleaning dental mirror tool including a dental mirror attached to a handle, wherein the gas is air, the liquid is water, and the surface is the reflective surface of the dental mirror. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of my copending U.S. patent application Ser. No. 07/941,525, filed Sep. 8 , 1992, now U.S. Pat. No. 5,230,461.
FIELD OF THE INVENTION
This invention relates to apparatus and techniques for connecting pipe sections together. More particularly, this invention relates to apparatus and techniques for transporting pipe sections and connecting the sections together for laying on top of the ground or in a trench.
BACKGROUND OF THE INVENTION
Pipe is commonly used for conveying fluids from one location to another. For example, pipe is used for conveying oil, water, or other liquids along the surface of the ground or in a horizontal trench below the surface of the ground. Ordinarily, the pipe sections are threaded at each end such that each pipe section can be threadably connected to the next pipe section. Alternatively, the pipe sections are not threaded but rather are welded end-to-end.
Although powered apparatus is commonly used for connecting and disconnecting pipe sections used in vertical environments (e.g., oil wells), pipe sections for use in horizontal environments are conventionally connected manually. That is, one pipe section is aligned with another pipe section and then the pipe sections are either threaded together or are welded together by means of manual labor. This is a time-consuming and labor-intensive process.
Pipe sections which are not threaded may be secured together by welding, zaplocking, or fusing (plastic) pipe. The zaplock method uses pipe which has a bell shape on one end. The other end of the pipe has a groove around it. Epoxy is applied to the grooved end of the pipe which is then forced into the bell shaped end of another pipe section to form a joint.
The conventional process for welding sections of pipe together involves laying pipe sections onto timber skids along the intended path of the pipeline. A bulldozer with a sidearm known as a sideboom is then used to cradle the pipe sections in proper position so that they can be welded together. Sometimes the pipe sections are also doped and taped before the welded pipe is lowered into a ditch.
There has not heretofore been provided apparatus for laying pipe having the advantages of the apparatus of the present invention.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention there is provided apparatus for transporting sections of pipe and connecting the sections together.
Using the apparatus of this invention, there is less binding and lifting required by manual laborers. This reduces the possibility of injury to laborers. There is also less damage to the pipe because it is not dropped to the ground from a trailer when it is laid. With less damage to the pipe coating, the environment surrounding the pipe is safer for a longer period of time than is conventionally provided. Because the pipe is less subject to being damaged, the costs associated with repairing or replacing pipelines are reduced.
In a preferred embodiment, the invention provides apparatus and techniques for use in welding pipe sections together. The apparatus comprises, in one embodiment:
(a) a wheeled frame including forward and rearward ends; wherein the frame includes an area for supporting sections of pipe for transport;
(b) an elevatable arm carried by said wheeled frame which is adapted to elevate one end of a first pipe section;
(c) support means adjacent the rearward end of the wheeled frame for supporting the forward end of a second pipe section to be welded to the first pipe section; and
(d) means for aligning the adjacent ends of the first and second pipe sections to be welded together.
The apparatus herein is very useful for transporting sections of pipe and then supporting pipe sections in end-to-end fashion so that they can be welded together. This saves considerable time and is much more convenient and efficient than conventional procedures.
Other advantages of the apparatus of this invention will be apparent from the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail hereinafter with reference to the accompanying drawings, wherein like reference characters refer to the same parts throughout the several views and in which:
FIG. 1 is a side elevational view of one embodiment of apparatus of the invention;
FIG. 2 is a top view of the apparatus of FIG. 1;
FIG. 3 is a perspective view of a clamp which is useful in holding pipe sections together for welding;
FIG. 4 is a side elevational view showing two sections of pipe held together in preparation for welding; and
FIG. 5 is a sectional view illustrating the means for elevating a support arm on the trailer.
DETAILED DESCRIPTION OF THE INVENTION
In the drawings there is illustrated one embodiment of apparatus 60 of the invention for transporting sections of pipe and supporting them in end-to-end fashion so that they can be welded together.
The apparatus comprises, for example, a trailer having a frame 12 and wheels 14. The upper surface 13 of the trailer is adapted to support several lengths of pipe.
The apparatus preferably includes an arm 16 including one end 16A which is pivotably attached to one side of the trailer.
The arm 16 preferably is parallel to the side of the trailer. It is also preferable for the arm 16 to be mounted on shaft 22 which is rotatable and also extensible. For example, shaft 22 may be slidably mounted in tubular sleeve 23 which is carried under the bed of the trailer. A hydraulic cylinder 24 is adapted to push shaft 22 outwardly from the edge of the trailer when desired, and it is also adapted to pull the shaft 22 inwardly again (e.g., for transport).
Hydraulic cylinder 25 (shown in FIGS. 2 and 5) is adapted to rotate sleeve 23 by means of arm 26. Thus, arm 16 can be caused to pivot upwardly or downwardly relative to the trailer by means of cylinder 25. Arm 16 may be telescoping if desired.
Carried at the forward end of arm 16 are roller means 62. Preferably there are two separate rollers which are axially spaced from each other. At the rear end of the trailer there are additional roller means 64. Again, it is preferred to use two separate rollers which are axially spaced from each other. The roller means 62 and 64 are for the purpose of supporting a pipe section which has been transported on the trailer in preparation for welding the pipe section to another pipe section, as described hereafter.
Mounted rearwardly of the trailer are additional roller means 66. Arms 28 and 28A support these rollers, and rod or brace 28B secures the support arms in proper position.
The apparatus 60 is very useful in transporting pipe sections and then supporting the pipe sections in end-to-end fashion so that they can be welded together. The first pipe section 200 removed from the floor or bed area of the trailer is positioned on rollers 62 and 64 and then moved rearwardly over the rollers so that ultimately the forward end of the pipe is then supported solely by roller means 66.
Then another section 202 of pipe is removed from the trailer and supported on rollers 62 and 64. Section 202 is moved relative to the trailer such that the rearward end of section 202 is in close proximity, but not touching, the forward end of section 200. It is also necessary to longitudinally align sections 200 and 202. Then clamp means 70 is used to temporarily secure the opposing ends of the two pipe sections in proper position to enable them to be welded together. Then the clamp can be removed and the trailer moved forwardly to enable another pipe section to be removed from the trailer bed and welded to the forward end of pipe section 202.
The preferred clamp means 70 used to hold the opposing ends of the pipe sections to enable welding thereof is commercially available and is illustrated in FIGS. 3 and 4. Preferably the clamp means comprises first and second sections 72 and 74 which are pivotably connected by means of pins or bolts 73. Each clamp section includes spaced-apart support members which are curved (generally semicircular). Cross members are secured to the support members. Some of the cross members do not extend completely across the full span of the support members.
The outer ends of the support members of section 72 are curved downwardly or otherwise include hook portions. Pivotably attached to the outer ends of the support members of section 74 is latch means 75. When the clamp sections 72 and 74 are pivotably closed around the ends of the two pipe sections, the latch means can be pivoted over the outer ends of the hook portions of clamp section 72. Then the clamp is secured by moving handle or lever 76 so as to cause latch means 75 to move against the hook portions. This is accomplished by means of an eccentric mounting between the arms of the latch and the support members of section 74.
The clamp means 70 shown herein enables two pipe sections to be firmly supported in an end-to-end manner with a small gap between them. Then the pipe sections can be spot welded together, after which the clamp can be removed. Then the entire circumference of the joint can be welded.
The apparatus described and illustrated herein is very convenient for transporting pipe sections and enabling the sections to be connected together. The apparatus enables very efficient operation with uniform results.
Other variants are possible without departing from the scope of the invention. | Apparatus is described for transporting sections of pipe and connecting them together for laying pipe above ground or in a trench. The apparatus includes a wheeled frame (e.g., a trailer), a support for one end of a first pipe section, and an alignment mechanism for supporting the other end of the first pipe section and the leading end of a second pipe section so that the opposing ends of the pipe section can be welded together. | 8 |
This application is a continuation-in-part of copending application Ser. No. 125,999 filed Nov. 27, 1987, and entitled "Self-Propelled Construction Apparatus."
This invention relates to a trimmer apparatus for grading the round surface in preparation for forming paving material on the ground surface. More particularly, this invention is directed to a trimmer apparatus that is carried by a construction apparatus, preferably of the self-propelled type, wherein the trimmer is mounted by a three-point suspension and each of the three points is individually adjustable. With this improvement, the operator can easily raise, lower, and adjust the angle of the trimmer in accordance with the slope or grade of the ground surface.
A further aspect of the invention is directed to a carriage for supportingly suspending the trimmer from a main frame of a construction apparatus with the carriage being arranged for movement of the trimmer laterally outwardly to one side of the construction apparatus. This permits readily grading the ground surface underneath and alongside of the construction apparatus.
A further feature of the present invention is directed to a trimmer and carriage as described carried by a construction apparatus, and wherein the construction apparatus also carries a mold for forming a strip of paving material and the trimmer is arranged for grading the ground surface ahead of or in front of the mold so the construction apparatus concurrently grades the ground and forms the paving material on the graded ground surface. This allows the operator to do the entire operation in one pass.
Some of the features of the invention having been stated, others will appear as the description proceeds when taken in connection with the accompanying drawings, in which--
FIG. 1 is a rear perspective view looking at the rear and left-hand side of the construction apparatus showing the trimmer apparatus extending outwardly to the left-hand side of the construction apparatus;
FIG. 2 is a perspective view looking at the front and right-hand side of the construction apparatus;
FIG. 3 is a left-hand side elevation of the construction apparatus with the trimmer apparatus attached to its main frame, and with a mold attached to the main frame behind the trimmer apparatus for concurrently grading and molding a paving material on the graded ground surface;
FIG. 4 is a top plan view of the apparatus as shown in FIG. 3;
FIG. 5 is a perspective view of the trimmer apparatus looking in the direction of arrow 5 in FIG. 4, with portions broken away for clarity, and showing the earth grading means of the trimmer apparatus partially moved outwardly to one side of the main frame of the construction apparatus;
FIG. 6 is a top plan view of the trimmer apparatus shown in the retracted position relative to the main frame of the construction apparatus;
FIG. 7 is a schematic perspective view of the trimmer apparatus, with parts broken away for clarity, and showing the earth grading means of the apparatus trimmer in its fully extended position;
FIG. 8 is a schematic perspective view similar to FIG. 7 showing the earth grading means partially extended;
FIG. 9 is another schematic perspective view of the trimmer apparatus wherein the earth grading means is in its fully retracted position; and
FIG. 10 is a schematical vertical sectional view through one of the three fluid actuated cylinder connectors that serve to connect the carriage to the main frame of the construction apparatus and showing a depth limiting means attached thereto.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, particularly FIGS. 1 and 2, the preferred embodiment of the construction apparatus is indicated generally at 10. The construction apparatus comprises a main frame 11 supported by ground engaging members 12, 13 and 14, which are preferably tracks as shown. A conventional prime mover 15 and a hydraulic pump (not shown) are carried by the main frame to operate the various systems and attachments to the apparatus. Hydraulic motors 12a, and 13a (FIG. 2) and 14a (FIG. 1) are connected to the hydraulic pump to propel the construction apparatus along the ground surface.
A trimmer apparatus generally indicated at 30 is shown attached to the main frame 11 for grading the ground surface in preparation for forming a paving material on the ground surface. The trimmer apparatus comprises two basic operating components. The first component is the rotating digger 31a (FIG. 2) which digs into the earth to loosen and redistribute the soil. The digger 31a is followed by an elongate scraper blade B (FIG. 1) which levels the loosened earth to the desired angle and level. The trimmer apparatus has certain common features with the apparatus described in commonly owned U.S. patent to Miller, U.S. Pat. No. 4,197,032, which is incorporated by reference herein.
Referring to FIGS. 3 and 4, the construction apparatus 10 is shown with a mold 20 located rearwardly of the trimmer apparatus generally indicated at 30 for concurrent trimming and molding. However, the mold may be selectively removed in some instances for certain operations. The mold 20 is shown mounted on the left-hand side of the main frame 11 for offset molding, although it is to be understood that it could be mounted on either side. In operation, concrete preferably from a concrete mixing truck (not shown) delivers concrete to the bottom portion of an inclined conveyor 22. The conveyor 22 moves the concrete into the hopper 21 and then into the mold 20. As the machine progresses along a predetermined path, the molded concrete C is extruded out the back portion of the mold 20.
The trimmer apparatus comprises an earth grading means 31 and a carriage which comprises a main carriage 36 and an auxiliary carriage 37 (FIGS. 5-9). Fluid actuated cylinder connectors 40, 41 and 42, which are preferably of the fluid pressure type, connect the carriage, as at 43, to the main frame 11 of the construction apparatus 10 and serves as a three-point suspension for the trimmer apparatus. The fluid actuated cylinder connectors 40, 41 and 42 may be constructed in the same manner substantially as shown more in detail in FIG. 10. Front left-hand fluid actuated cylinder connector 40 is illustrated by way of example although it is understood that fluid actuated cylinder connectors 41 and 42 may be constructed similarly. Accordingly, it will be observed that fluid actuated cylinder connector 40 is formed of concentrically engaged telescoping tubes 40a and 40b. A fluid cylinder and piston assembly 40c is provided internal of the concentric tubes and connected to the outside tube 40a. A piston rod 40d is connected to the other concentric tube 40b.
The fluid actuated cylinder connectors are preferably bolted to the main frame 11 by bolts 43b (FIG. 6); but it is understood that the fluid actuated cylinder connectors may be attached by any conventional means. Each fluid actuated cylinder connector is independently operable to provide the operator with a substantial range of adjustment of the trimmer apparatus, so that the ground can be graded to any desirable angle and level. The fluid actuated cylinder connectors can further adjust the angle of attack of the trimmer, or more precisely, the depth of the rotating digger 31a relative to the elongate scraper blade B. This controls the thickness of the loosened earth upon which the paving material is molded.
Parallel to the concentric tubes 40a and 40b are a pair of depth limiting means 44 (FIG. 10). The limiting means is preferably comprised of a chain 45 attached to the respective upper tube 40a by an adjustment bolt 46. The adjustment bolt 46 is held to a top flange of the outer concentric tube 40a by a pair of nuts 47. The limiting means limits the extension of the fluid pressure actuating means relative to the main frame 11 so that, in operation, the operator preadjusts the limiting means to allow the trimmer to be operated at a selected depth and angle. The operator is then able to simply direct the fluid actuated cylinders to force the trimmer down until the chains pull taut. The trimmer is then in its selected operating position. If a manhole or other obstruction were to lie in the path of the trimmer, the operator would simply raise the trimmer to pass over the obstruction and lower the trimmer back down until the chains pull taut again. The operator does not have to slow down the machine or spend a lot of time adjusting the trimmer into the proper position. This improves the quality of the final product because the rate of movement of the apparatus remains constant and the trimmer depth is correct for the maximum portion of the path.
Turning now to the carriage, it is seen that in the preferred construction, as shown particularly in FIG. 5, the carriage is comprised of a main carriage 36 and an auxiliary carriage 37. The carriage is fastened to the fluid actuated cylinder connectors 40, 41 and 42 as by fasteners 43. In this regard, a link 43a located near the bottom portion of fluid actuated cylinder connector 42 and a slide 43s located at the lower portion of fluid actuated cylinder connector 41 provide the necessary flexibility to allow the carriage to be moved into the various angles and attitudes while being held firmly beneath the main frame 11. The main carriage is comprised of a front rail 36a, a back rail 36b, an inside rail 36c and an outside rail 36d, which are all rigidly attached together as shown, such as by welding. Attached to the outside rail 36d is a pair of standards 36e and 36f each having a collar 36g at the lower end thereof for slidingly receiving a pair of parallel auxiliary slide bars 37 a and 37b, respectively. To stabilize the back ends of the auxiliary slide bars 37a and 37b, a beam 36h which has collars 36i formed thereon is attached to the front and back rails 36a and 36b. The auxiliary bars 37a and 37b are slidably received in the collars 36i as shown. The auxiliary carriage is comprised of the auxiliary slide bars 37a and 37b, an inside plate 37c attached to the ends of the slide bars 37a and 37b, and an outside plate 37d is attached to the auxiliary slide bars 37a and 37b at an intermediate position thereof. Attachment of the plates 37c and 37d can be by any conventional means, such as by bolts. The auxiliary bar 37b is provided with flats 37x to slide in clamping block 37g, so that the alignment of auxiliary bar 37b may be adjusted. The auxiliary carriage 34 slides as a unit relative to the main carriage 36 by virtue of the parallel auxiliary slide bars 37a and 37b sliding in the collars 36g and 36i and action of the fluid pressure actuator 36j.
The earth grading means 31 is mounted to the auxiliary carriage to move outwardly much like the auxiliary carriage is mounted to the main carriage. Incorporated into the inside plate 37c and outside plate 37d are collars 37e which slidingly receive the trimmer slide bars 31a and 31b. The trimmer slide bars 31a and 31b are attached to the earth grading means 31 by suitable means such as brackets 31c, 31d, and clamping block 31e. The trimmer slide bar 31b is provided with flats 31x to slide in the clamping block 31e, so that the alignment of auxiliary bar 31b may be adjusted. The earth grading means 31 is moved outwardly by a fluid pressure actuator 37f which is attached to the auxiliary carriage between the inside plate 37c and the outside plate 37d.
As shown schematically in FIG. 7, 8 and 9, the earth grading means is arranged to extend laterally. In FIG. 7, both the fluid pressure actuators 36j and 37f are fully extended causing the earth grading means to be fully extended. In FIG. 8, the earth grading means 31 is retracted to the auxiliary carriage by retracting the actuator 36j. However, the auxiliary carriage 37 is still fully extended from the main carriage. The fluid actuators 36j and 37f are envisioned to be separately controlled by the operator so that lateral movement of the earth grading means is accomplished by operation of actuators 36j and 37f individually or at the same time. In FIG. 9, the earth grading means is in its fully retracted position wherein the earth grading means 31 and auxiliary carriage 37 would underlie the main carriage 36. In these figures it can be easily seen that outside rail 36d is positioned higher relative to the front and back rails 36a and 36b to form an archway. The archway allows for a more compact carriage where, as can be seen in the figures, the auxiliary carriage 37 is received between the front and back rails 36a and 36b.
In some instances, it may be desirable to concurrently mold and grade off the right side of the machine. To mount the trimmer to extend from the other side of the machine will require some reassembly of the trimmer apparatus. The fluid actuated cylinder connectors 40, 41 and 42 which are attached to the main frame by bolts 43b (FIG. 6), are repositioned to the opposite sides of the machine. The carriage 35 is reattached to extend from the other side. The earth grading means 31 is disconnected from the auxiliary carriage 37 at brackets 31c and 31d, turned around and reattached. The trimmer is therefore able to extend from each side of the construction apparatus as the job requires.
In the drawings and specification, a preferred embodiment of the invention has been illustrated and described, and although specific terms are employed, they are used in a generic and descriptive sense and not for purposes of limitation. | A construction apparatus with a trimmer connected by a three-point suspension wherein each of the three points is independently adjustable for adjusting the angle of the trimmer relative to the main frame in accordance with the desired slope or grade of the ground surface and to raise and lower the trimmer. The trimmer is also provided with an improved carriage for permitting the trimmer to be moved laterally outwardly of the construction apparatus to grade the ground surface alongside the construction apparatus. The construction apparatus preferably molds a paving material onto the ground immediately behind the trimmer so that concurrent grading and molding is accomplished in one pass of the construction apparatus. | 4 |
TECHNICAL FIELD
[0001] This disclosure relates to lighting systems, and particularly to artistic lighting systems for creating or enhancing a particular mood.
BACKGROUND AND PRIOR ART
[0002] Artistic lighting can create and enhance a particular mood in a particular environment. In the case of a single room, artistic lighting choices such as lighting color and intensity can create an atmosphere of calm, excitement, romance, etc.
[0003] One particular artistic lighting device is a gobo. A gobo (go between) is traditionally a metal disk with patterns cut out to let light pass through. A gobo is put into a holder and then placed in between a tight source and a surface onto which the pattern is to be projected. Gobos create stationary projections, but cannot create the impression of a dynamic environment.
SUMMARY
[0004] The present invention is an apparatus for providing dynamic, artistic lighting to a room. The apparatus comprises a cylindrical gobo functionally connected to a motor for rotating the cylindrical gobo. Light from a light source in the center of the cylindrical gobo passes through patterned openings in the gobo to form projected images on a surface.
[0005] The apparatus may also have color changing LEDs to further alter and enhance the effect created by the projected light patterns from the cylindrical gobo. Multiple devices may be connected together to project light patterns on a larger surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows a top sectional view of one embodiment of the present invention;
[0007] FIG. 2 shows a top view of the embodiment shown in FIG. 1 ;
[0008] FIG. 3 shows a rear view of the embodiment shown in FIG. 1 ;
[0009] FIG. 4 shows a side sectional view of the embodiment shown in FIG. 1 ;
[0010] FIG. 5 shows a side view of the embodiment shown in FIG. 1 ;
[0011] FIG. 6 shows a perspective view of the embodiment shown in FIG. 1 ;
[0012] FIG. 7 shows a environmental view of the embodiment shown in FIG. 1 ;
DETAILED DESCRIPTION
[0013] Reference will now be made in detail to the subject matter disclosed, which is illustrated in the accompanying drawings. The scope of the invention is limited only by the claims; numerous alternatives, modifications and equivalents are encompassed. For the purpose of clarity, technical material that is known in the technical fields related to the embodiments has not been described in detail to avoid unnecessarily obscuring the description.
[0014] Referring to FIG. 1 , one embodiment of an artistic lighting apparatus 100 according to the present invention includes a cylindrical gobo 108 . A gobo is a device known in the art for creating projected light patterns. Gobos are generally thin metallic structures with patterns cut into the surface to allow light to pass through. A user places a gobo between a light source and a surface onto which the user wishes the pattern projected. Gobos known in the art are flat metallic disks held in gobo holders. In the present invention, the cylindrical gobo 108 may be a metallic surface with patterns cut through the surface to allow light from a light source to pass through. The artistic lighting apparatus 100 may include an elongated light source 112 inside the cylindrical gobo 108 , such as a fluorescent tube or some other light emitting structure capable of illuminating the entire interior length of the cylindrical gobo 108 and projecting light onto a surface. The artistic lighting apparatus 100 may include a gobo rotating motor 104 . The gobo rotating motor 104 may be connected to one or more gobo rotating gears 102 , also connected to the cylindrical gobo 108 . The gobo rotating motor 104 may turn the gobo rotating gears 102 , and thereby turn the cylindrical gobo 108 about an axis defined by a centerline of the cylindrical gobo 108 . The artistic lighting apparatus 100 may include one or more color-changing LED lamps 110 , known in the art. Color-changing LED lamps 110 may project colored, unpatterned light onto a surface while the elongated light source 112 emits light through the cylindrical gobo 108 to project patterned light onto the same surface. The artistic lighting apparatus 100 may include a display control computer 106 , functionally connected to the gobo rotating motor 104 , the color-changing LED lamps 110 and the elongated light source 112 . The display control computer 106 may be programmed to operate the gobo rotating motor 104 , color-changing LED lamps 110 and elongated light source 112 according to a predetermined program. The display control computer may vary the speed of rotating of the cylindrical gobo 108 by varying the speed of rotation of the gobo rotating motor 104 ; it may vary the color and intensity of the color changing LED lamps 110 ; and it may vary the intensity of the elongated light source 112 .
[0015] Referring to FIG. 2 and FIG. 3 , the artistic lighting apparatus 100 may further include light obstructive housing 200 to define a direction for light emitted from the artistic lighting apparatus 100 to project onto a surface. The light obstructive housing 200 obstructs allows the user to position the artistic lighting apparatus 100 such that light may be projected onto a single surface and obscured form all other surfaces. The light obstructive housing 200 also provides a structure for mounting the gobo rotating motor 104 and the gobo rotating gears 102 . The light obstructive housing 200 also supports the cylindrical gobo 108 , because the cylindrical gobo 108 would be functionally connected to the gobo rotating gears 102 . The light obstructive housing 200 may also provide a housing for the color-changing LED lamps 110 , and support for the elongated light source 112 . The artistic lighting apparatus 100 may include a power input connector 202 such as a power cord, functionally connected to the display control computer 106 , and may include a pass-through power output connector 204 to connect a second artistic lighting apparatus.
[0016] Referring to FIG. 4 and FIG. 5 , the figures show a sectional view and side view of the artistic lighting apparatus 100 in operation. The light obstructive housing 200 obstructs light emanating from the elongated light source 112 and the color-changing LED lamps 110 except where the user has oriented the artistic lighting apparatus 100 to direct such light 400 toward a particular surface. The light obstructive housing allows the user to create a particular artistic affect, and contain the affect to a defined area.
[0017] Referring to FIG. 6 , in another embodiment, a user may connect a first artistic lighting apparatus 600 to an identical second artistic lighting apparatus 604 . In this embodiment, the first artistic lighting apparatus 600 may include a detachable power cord 602 . The detachable power cord 602 would be detached from the second artistic lighting apparatus 604 . The first artistic lighting apparatus may have a pass-through power output connector 204 (not shown), that would engage a receptacle where the detachable power cord 602 would have been attached, and thereby provide power to the second artistic lighting apparatus 604 .
[0018] Referring to FIG. 7 , the artistic lighting apparatus 100 projects an artistic light display 700 onto a surface. The light display 700 may include various colors to create or enhance a particular mood. The light display may also change as the cylindrical gobo 108 rotates within the artistic lighting apparatus 100 .
[0019] Although the disclosure has been described in terms of specific embodiments, one skilled in the art will recognized that various modifications may be made that are within the scope of the present disclosure. Therefore, the scope of the disclosure should not be limited to the foregoing description. Rather, the scope of the disclosure should be determined based upon the claims recited herein, including the full scope of equivalents thereof. | A device for creating and enhancing a mood is disclosed. The device includes a cylindrical gobo with a light source and a motor to rotate the gobo. The device may also include color-changing LEDs. Through variations in color, light source intensity and gobo design, a user may create or enhance a desired mood in a room. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/757,123, filed Jan. 26, 2013, the contents of which are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to fabrics, and more particularly to fabrics that degrade in strength, color, or other significant attributes, due to exposure to ultra-violet wavelengths of light, wherein the use of nanoparticles embedded within thin films mitigates degradation of the fabrics and increases the tear strength of such fabrics.
BACKGROUND OF THE INVENTION
[0003] Various fabrics are significantly adversely affected by exposure to ultraviolet light (“UV”). UV, as used herein, refers to wavelengths of light between about 280 nm and about 400 nm. Fabrics, which are woven of yarns known as aramids, or “aromatic” “polyamides,” are especially susceptible to UV exposure. Some exemplary product names for these fabrics are KEVLAR, PBI, and NOMEX. Aramid fabrics include, but are not limited to, meta-aramids and para-aramids. Aramid fabrics are typically used as “ballistic fabric” due to great tensile and great tear strength. Ballistic fabrics are used in the textile industry for making cables, ropes, pre-forms for composites, bulletproof vests, cut-resistant articles, firefighters' turnout gear, airbags for passenger cars, tendons for giant scientific balloons, and the like. However, exposure to solar UV light can greatly reduce the tear strength of these fabrics quite rapidly.
[0004] It is recognized that there is a need for a solution to this degradation of ballistic fabrics caused by UV light. Such a solution could extend the life of the fabric significantly. Currently, due to the deleterious effects of UV exposure, firefighters' turnout gear—jackets, pants, etc.—are often replaced every five years at a cost in excess of five thousand dollars per suit. The military, as well, spends large sums of money on premature replacement of body armor and many other items made in whole or in part of ballistic fabric. It is considered prudent to proactively scrap some gear prior to signs of failure rather than expose a soldier to the dangers resulting from gear failure.
[0005] Currently, one solution to shield fabric from UV wavelengths is to coat the fabric in a solid, highly-reflective film, such as thin aluminum. This is a flawed solution because it is necessary for many applications of aramid fabric that the fabrics pass vapor from the user to the external air, otherwise the wearer would suffer hyperthermic stress from excessive heat buildup. Thus, solid films are unsuitable for such applications. Similarly, covering the ballistic fabric with a lightweight, porous, UV-reflective fabric is insufficient, because it is the ballistic fabric that provides great strength and flame-resistance to the object and covering that fabric with another layer of fabric would defeat these benefits.
SUMMARY OF THE INVENTION
[0006] One aspect of the present invention is a method for treating fabrics to increase tear strength, comprising, forming an aqueous solution, comprising, nanoparticles that prevent more than 50% of UV light in the range of 280 nm to 400 nm from reaching the fabric; applying the aqueous solution to the fabric; and drying the fabric with heat at less than 110° C., thereby forming a coated fabric, wherein the appearance of the coated fabric will not be significantly altered in visible light.
[0007] One embodiment of the present invention is wherein the aqueous solution comprises ceramic nanoparticles. One embodiment of the present invention is wherein the aqueous solution comprises cerium oxide nanoparticles. One embodiment of the present invention is wherein the aqueous solution comprises zinc oxide nanoparticles.
[0008] One embodiment of the present invention is wherein the aqueous solution comprises cerium oxide and zinc oxide nanoparticles.
[0009] One embodiment of the present invention is wherein the nanoparticles have low thermal conductivity.
[0010] One embodiment of the present invention is wherein the nanoparticles prevent about 50% of UV light in the range of 320 nm to 400 nm. from reaching the fabric.
[0011] One embodiment of the present invention is wherein the tear strength of the coated fabric is increased by more than 10 percent. One embodiment of the present invention is wherein the tear strength of the coated fabric is increased by more than 40 percent.
[0012] One embodiment of the present invention is wherein the aqueous solution comprises nanoparticles with hydrophobic properties.
[0013] One embodiment of the present invention is wherein the aqueous solution further comprises an additive. One embodiment of the present invention is wherein the additive is a particle binder, a wax softener, a surfactant, a particle agglomeration preventer, a DWR, or a combination thereof.
[0014] One embodiment of the present invention is wherein the fabric is aramid-based.
[0015] One embodiment of the present invention is wherein the aqueous solution is applied by pad and mangle, knife over roller, or spraying. One embodiment of the present invention is wherein the aqueous solution is applied in solid form, a film, or a powder by transferring the solution to the fabric through the application of heat, pressure, or a combination thereof.
[0016] One embodiment f the present invention is further comprising sonicating the aqueous solution.
[0017] One embodiment of the present invention is wherein the coated fabric is non-flammable.
[0018] One embodiment of the present invention is wherein the nanoparticles absorb UV light in the range of 280 nm to 400 nm. One embodiment of the present invention is wherein the nanoparticles reflect UV light in the range of 280 nm to 400 nm.
[0019] One embodiment of the present invention is wherein the fabric comprises a plurality of individual yarns, and the coated fabric comprises a surface coating on the individual yarns, but does not bind the individual yarns to each other.
[0020] These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The foregoing and other objects, features, and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0022] FIG. 1 shows a UV-visible diffuse reflectance spectrum of CeO 2 particles.
[0023] FIG. 2 shows a UV-visible diffuse reflectance spectrum of ZnO particles.
[0024] FIG. 3 shows a model of “bridging” between fibers of the warp and the weft yarns of woven fabric.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Aramid fibers, or aromatic polyamides, are a class of heat-resistant, flame-resistant, and inherently strong, synthetic fibers. Aramid fibers have many applications including, but not limited to, aerospace and military applications, as firefighter turn-out gear, as ballistic rated body armor fabric, as ballistic composites, and as an element of FRP (fiber-reinforced plastic) in small-boat construction.
[0026] The chain molecules in aramid fibers are highly oriented along the fiber axis, so the strength of the chemical bond can be exploited. Some of the more common trade names of aramid fibers, as well as meta-aramids, are readily recognized, KEVLAR, TWARON, NOMEX, PBI/KEVLAR.
[0027] When aramids, para-aramids, meta-aramids, and the like are woven into fabric, the strength-to-weight ratios become very high. However, these fabrics readily degrade upon exposure to ultraviolet light, losing seventeen percent or more of their tear strength in a few hours. These fabrics are known to lose more than fifty percent of their tear strength after one hundred and twenty hours. The industry has made many attempts to provide a coating for these fabrics that would act as a shield against ultraviolet-induced degradation. Generally, this has taken the form of sol-gels of Zinc oxide or Titanium dioxide. However, the manner of application of the protective coating has caused a serious degradation in the tear strength of the fabric.
[0028] Previous attempts have been made to decrease the photo-degradation of aramids through the application of sol-gels of Titanium Dioxide (TiO 2 ) to the fabric. In contrast to conventional coating processes such as evaporation and sputtering, sol-gel coating can be done at room temperature and normal atmospheric pressure environment. Sol-gel coating has been used to create a transparent metal oxide film that adheres well to the fiber surface to improve textile properties such as abrasion resistance, electrical conductivity. UV protection, biocompatible properties and the like. However, sol-gel coating has not been successful in preserving the tear strength of aramid fabrics. In the thesis work of Dr. Lidan Song, a sol-gel, which deposited TiO 2 on aramid fabrics was studied. The sol-gel added significantly to the weight of the fabric as seen in Table 1 from Song's work:
[0000]
TABLE 1
Add-on weight of TiO 2 on coted NOMEX fabric
Original
Low concentration coating
High concentration coating
mass a
Masss a
Increase
Mass a
Increase
(g/m 2 )
(g/m 2 )
(%)
(g/m 2 )
(%)
A
183.9
196.2
6.7
200.8
9.2
B
196.5
207.9
5.8
212.2
8.0
C
254.8
264.0
3.6
272.4
6.9
[0029] As can be seen in Table 1, an 8-9% increase in weight of the fabric occurs with the application of the sol-gel. This is unacceptable, because the users of aramids firefighting, etc.—are looking for ways to save weight, not increase it.
[0030] In one embodiment of the present invention, the weight of a typical PBI/KEVLAR fabric was increased by 3.46 g per square meter. This is an increase of only 1.4%. See, Table 2, below.
[0000]
TABLE 2
Add-on weight of an solution of die
present invention on PBI/KEVLAR
Original Mass
After coating
(g/m 2 )
Mass(g/m 2 )
Increase (%)
242.79
246.25
1.4
[0031] The slight increase in weight by application of an embodiment of the present invention is more than compensated by the increase in tear strength. In independent tests, one embodiment of the present invention produced an increase in the tear strength of a PBI/KEVLAR fabric from 115 N to 223 N. In contrast, the use of sol-gel decreases the tear strength as seen in Table 3, below (from Dr. Song's work):
[0000]
TABLE 3
Breaking strength (n = 5) of original uncoated, low concentration
and high concentration sol-gel coated fabric C vs. light exposure.
Original
Low concen-
High concen-
Light
uncoated
tration
tration
exposure
Maximum
Maximum
Maximum
(AFU)
Load (N)
Load (N)
Load (N)
0
565.7
315.5
337.3
20
480.1
267.3
308.7
40
390.0
241.3
274.9
60
340.1
229.0
259.1
80
297.8
202.1
234.3
120
240.8
176.9
205.3
Original uncoated fabric C mass = 255 g/m 2
[0032] Note that the breaking strength drops from 565.7 N to 337.3 N (N=Newtons, a measure of force) just by applying the sol-gel. The fabrics' breaking strengths drop to about half of the original breaking strength after sol-gel coating both in high and low concentration sol solutions. In one example, the fabric had an initial breaking strength of 438.3 N and the breaking strength decreased to 262.2 N when coated with the low concentration sol-gel and 276.8 N after coating with the high concentration sol-gel.
[0033] According to Dr. Song, this loss of breaking strength may be explained in a couple of ways. First, the loss of breaking strength may be caused by the structural change of the fabric, because the film not only covers the fiber surface but also bridges the gaps between the individual, fibers. The fibers become stuck together by the inorganic TiO 2 thin film after sol-gel coating. The TiO 2 thin film decreases the flexibility of individual fibers. At the same time, the TiO 2 films increase the friction between single fibers. The inflexibility and the change in the fiber friction restrict the movement of the individual fibers. This reduction of the free movement prevents the readjustment of fibers when stressed, and therefore decreases the chance for fibers to join together to share the load when a load is applied. As a result, fibers of the sol-gel coated fabric tend to break at a lower load in comparison to original uncoated fabric while a load is applied. A second possible contributing factor to the loss of initial breaking strength is the combined effect of the presence of nitric acid HNO 3 in the TiO 2 sol solution and the heat treatment afterwards.
[0034] In one embodiment of the present invention, the coating on the individual fibers does not cover the gaps between individual fibers. In certain embodiments, added friction from the use of Cerium oxide (CeO 2 ) nanoparticles causes the fibers to work together without causing yarn bundles to bind. In certain embodiments of the present invention, strong acids and/or high heat are not used to bond the nanoparticles to the fabric.
[0035] Another aspect of the present invention uses CeO 2 , which has better absorbance in the UVA. In certain embodiments, ZnO is also used. In contrast, the sol-gel method applies TiO 2 , which has some gap in absorbance in the 380 nm to 400 nm range. Additionally, TiO 2 generates free radicals, which in turn increase the speed of photodegradation of the surface. CeO 2 , on the other hand, scavenges free radicals, even through the polymer coating, thus interrupting the degradation process. Another benefit of free-radical scavenging, is the inhibition of bacterial growth. In a recent study, coated CeO2 particles were tested against Pseudomonas aeruginosa, a common bacteria seen on infected medical devices. After 24 hours the growth of Pseudomonas aeruginosa was inhibited by over 50% in the presence of the polymer coated CeO 2 .
[0036] In one embodiment of the present invention a tough, micro-thin coating of nanoparticles is applied to Kevlar®, PBI/Kevlar, or other aramid, meta-aramid, or para-aramid ballistic fabrics to absorb, and/or reflect, greater than about 90% of the incident ultraviolet light in the 280 nm to 400 nm range. By absorbing or reflecting the UV light before it can strike the fabric, the useful life of ballistic fabric is greatly extended.
[0037] In one embodiment of the present invention, a highly UV-absorbent suspension of nanoparticles is applied to Kevlar®, PBI/Kevlar, or other aramid, meta-aramid, or para-aramid ballistic fabrics, and confers long-term protection against the degradation caused by ultraviolet light while also increasing the tear strength of the fabric.
[0038] Both Kevlar® and PBI/Kevlar® fabrics absorb most of the ultraviolet light (UV) striking them. Energy in UV wavelengths causes a rapid decline in fabric tear strength and ballistic resistance. As much as a seventeen percent loss in tear strength has been seen in only three hours of exposure to normal sunlight. An application of one embodiment of the present invention provides a tough, micro-thin coating of nanoparticles to the fibers of the ballistic fabric.
[0039] In certain embodiments, the nanoparticles absorb greater than about 90% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 10% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 20% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 30% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 40% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 50% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 60% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 70% of incident ultraviolet light in the 280 nm to 400 nm range. In certain embodiments, the nanoparticles absorb greater than about 80% of incident ultraviolet light in the 280 nm to 400 nm range.
[0040] In certain embodiments, the nanoparticles reflect greater than about 90% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 10% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 20% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 30% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 40% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 50% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 60% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 70% of incident ultraviolet light in the 250 nm to 400 nm range. In certain embodiments, the nanoparticles reflect greater than about 80% of incident ultraviolet light in the 250 nm to 400 nm range.
[0041] Data on % reflectance was obtained by photographing the treated fabric of the present invention in solar wavelengths filtered with an ultraviolet band pass filter (e.g., the PrecisionU made by UVROptics). Reflectance standards that reflect the same percentage of light in all wavelengths from 250 nm to 1150 nm are placed in the photos, as camera sensors typically only get down to about 320 nm. According to the standards, the CeO 2 +ZnO embodiment of the present invention reflects 7% of the ambient solar UV (between 320 nm and 400 nm—the camera sensor used did not record below 320 nm).
[0042] In one embodiment of the present invention, ZrO 2 nanoparticles are used and results in approximately 90% UV reflectance between 320 nm and 400 nm (the camera sensor used did not record below 320 nm).
[0043] The UV-visible diffuse reflectance spectrum of CeO 2 particles can be seen in FIG. 1 . The CeO 2 UV-visible diffuse reflectance spectrum when compared to the UV-visible diffuse reflectance spectrum of ZnO in FIG. 2 shows that the ZnO particles increase in percentage absorption of UV faster than the CeO 2 particles do; however, the CeO 2 particles absorbance begins sooner. Additionally, CeO 2 nanoparticles have other desirable properties, e.g., hardness, electrostatic dissipation, etc., which make them a nice choice for certain embodiments of the present invention.
[0044] Firefighter turnout gear treated with one embodiment of the present invention also reflects significantly more of the infrared (“IR”) wavelengths (e.g., from Near IR through Thermal IR) than the base fabric alone. This results in less heat penetration and therefore less stress for the wearer. In certain embodiments, the nanoparticles are ceramic and have low thermal conductivity; thus, they do not contribute to the wearer's heat load.
[0045] Friction between individual fibers in the ballistic fabric is beneficial, but friction between overlapping yarn strands is not. In FIG. 3 , a representation of “bridging” between the warp and the weft yarn in the fabric is shown. This is an explanation as to why the sol-gel approach decreases the tear strength of these fabrics.
[0046] In certain embodiments of the present invention, the particles are small (e.g., 10 nm to 50 nm in diameter). This is compared to a human hair, which is about 90,000 nm in diameter. In certain embodiments of the present invention, the binder is diluted; allowing a thin film to cover the individual fibers, but the film is too thin to bind the yarn strands to one another or cover gaps between yarn bundles (“bridge”). The friction between the fibers created by the nanoparticles and binder of the present invention is longitudinal, thus causing the fibers to move and work together rather than slipping over one another. This is, in part, what increases the tear strength of the fabrics treated in certain embodiments of the present invention.
[0047] For simplicity, the fabric herein is discussed in reference to aramid-based fabrics, but one of skill in the art would appreciate that the embodiments of this invention would be applicable to other fabrics. In one embodiment of the present invention, the fabric comprises a synthetic fiber. In one embodiment of the present invention, the fabric comprises a natural fiber. In one embodiment of the present invention, the fabric comprises an aramid. In one embodiment of the present invention, the fabric comprises a polyester. In one embodiment of the present invention, the fabric comprises a polyamide. In one embodiment of the present invention, the fabric comprises a polypropylene. In one embodiment of the present invention, the fabric comprises rayon. In one embodiment of the present invention, the fabric comprises a composite fiber.
[0048] Friction between a projectile and a ballistic fabric has a positive effect on fabric energy absorption by influencing the number of yarn strands that become involved in dispersing the energy. One embodiment of the present invention increases the friction between the projectile and fabric through the millions of nanoparticles adhering to the yarns; reducing slippage and increasing the likelihood of more yarn involvement in absorbing the projectile strike. Additionally, a 2003 U.S. Army sponsored study, found that the hardness of silica particles entrained in a Kevlar fabric contributed to the puncture and ballistic resistance of the fabric. The nanoparticles of present invention are significantly harder than the silica particles used in the study.
[0049] In one embodiment of the present invention, a very thin film is applied to the fabric such that it does not bind the yarns together, thus reducing the chance of yarns being torn during pullout. In certain embodiments, the film is on each fiber of the fabric but does not span the pores of the weave, and as such does not alter the breathability of the garment. In certain embodiments, the nanoparticles are electro-static dissipative, slowly bleeding any acquired static electricity rather than producing a dangerous spark.
[0050] It is understood that the embodiments of the present invention may be applied by knife-over-roller, pad and mangle, or other common textile treatment techniques. In certain embodiments of the present invention, the solution may be applied in a solid form including, but not limited to, a film, a solid, a powder and the like, where the solution is transferred to the fabric using heat, pressure, or both. In certain embodiments, the solution is applied with a hot iron. In certain embodiments of the present invention, high heat is not required to bond the nanoparticle film to the fabric as is common with sol-gels. In one embodiment of the present invention, the solution is water-based and non-toxic treatment with no volatile organic compounds (VOCs).
[0051] In certain embodiments of the present invention, durable water repellent or durable water resistant (“DWR”) compounds may be integrated with the nanoparticles in order to protect ballistic fabric from water absorption. It is understood that wet ballistic fabric loses much of its stopping power through yarn slippage.
[0052] It has been shown that fabric with a higher level of friction absorbs larger amounts of energy. In one study, Bazhenov investigated the effect of water on the ballistic performance of a rectangular laminate comprised of 20 layers of ARMOS fabric. The specimens were attached to a plasticine foundation and struck with projectiles possessing spherical tips. The dry laminate stopped the bullet while the wet laminate was perforated. It was observed that the impacted yarns in the wet laminate were not broken indicating that the yarns moved laterally and allowed the bullet to slide through the fabric. Based on this observation, Bazhenov surmised that the water served as a lubricant that decreased friction between the bullet and the yarns.
[0053] Experimental:
[0054] One embodiment of the present invention uses UV absorbent nanoparticles. The following mixture is an example of one embodiment of the fabric treatment of the present invention. The treatment was tested on KEVLAR and KEVLAR/PBI. The following table presents the relative weights of each of the ingredients and the relative percent of each component used in the fabric treatment.
[0000]
TABLE 4
(g)
%
(g)
Distilled water
90.0
~46.6%
90.0
Acrylic or urethane binder in Aqueous
60.0
~31.1%
60.0
suspension
Zinc Oxide NP in Aqueous Suspension
10.0
~5.2%
10.0
Wax Softener in Aqueous Suspension
3.0
~1.6%
3.0
Cerium Oxide NP in Aqueous Suspension
30.0
~15.5%
30.0
Total
193
NP = nanoparticles
[0055] The components in Table 4 were mixed thoroughly. In certain embodiments, sonication was used to avoid excessive aggregation. Some aggregation will occur, but it should not be visible. No agglomeration or flocculation should be present. The solution was warmed to 100° F before applying to the fabric. The solution was applied to the fabric with padding and mangle. The mangle was heated to 400° F. The ballistic fabric was immersed in warm water, passed through the heated mangle, immersed in the solution, and hung to drip. The coated fabric was then passed through the heated mangle several times. In a production environment, the fabric might be passed through a mangle once and then into a stenter for drying.
[0056] One embodiment of the present invention uses UV reflective nanoparticles. The following mixture is an example of one embodiment of the fabric treatment of the present invention. The treatment was tested on KEVLAR and KEVLAR/PBI. The following table presents the relative weights of each of the ingredients and the relative percent of each component used in the fabric treatment.
[0000]
TABLE 5
(g)
%
(g)
Distilled water
90.0
~46.6%
90.0
Acrylic or urethane binder in
60.0
~31.1%
60.0
Aqueous suspension (e.g. a DWR
in aqueous suspension, such as
NanoSphere by Schoeller)
Wax Softener in Aqueous Suspension
3.0
~1.6%
3.0
Magnesium Oxide NP in Aqueous
40.0
~20.7%
30.0
Suspension
Total
193
NP = nanoparticles
[0057] The components in Table 5 were mixed thoroughly. In certain embodiments, sonication was used to avoid excessive aggregation. Some aggregation will occur, but it should not be visible. No agglomeration or flocculation should be present. The solution was warmed to 100° F. before applying to the fabric. The solution was applied to the fabric with padding and mangle. The mangle was heated to 400° F. The ballistic fabric was immersed in warm water, passed through the heated mangle, immersed in the solution, and hung to drip. The coated fabric was then passed through the heated mangle several times. In a production environment, the fabric might be passed through a mangle once and then into a sterner for drying.
[0058] The nanoparticles of the present invention are from about 10 nm to about 50 nm. In certain embodiments, the nanoparticles are from about 13 nm to about 40 nm. In certain embodiments, the nanoparticles are from about 15 nm to about 30 nm. In certain embodiments, the nanoparticles are about 10 nm, about 12 nm, about 14 nm, about 16 m, about 18 nm, or about 20 nm. In certain embodiments, the nanoparticles are about 22 nm, about 24 nm, about 26 nm, about 28 nm, or about 30 nm. In certain embodiments, the nanoparticles are about 32 nm, about 34 nm, about 36 nm, about 38 m, or about 40 nm. In certain embodiments, the nanoparticles are about 42 nm, about 44 nm, about 46 nm, about 48 m, or about 50 nm.
[0059] In certain embodiments of the present invention, aggregates of the nanoparticles are less than about 100 nm.
[0060] In certain embodiments of the present invention, the nanoparticles are ceramic. In certain embodiments of the present invention, the nanoparticles are oxides. In certain embodiments of the present invention, the nanoparticles are non-oxides. In certain embodiments of the present invention, the nanoparticles are cerium oxide. In certain embodiments, the nanoparticles are zinc oxide. In certain embodiments of the present invention, the nanoparticles are zirconium oxide. In certain embodiments of the present invention, the nanoparticles are aluminum oxide. In certain embodiments of the present invention, the nanoparticles are magnesium oxide.
[0061] In one embodiment of the present invention, the nanoparticles are cerium oxide and are approximately 13 nm in size in an aqueous suspension combined with nanoparticles of zinc oxide that are approximately 20 nm in size in an aqueous suspension.
[0062] In certain embodiments, additives can be used with the nanoparticles. Some forms of additives can be an acrylic or urethane used as a particle binder, a stearate such as magnesium stearate to prevent particle agglomeration, a surfactant, a wax for softening, and/or a durable water repellent such as NanoSpheres from Schoeller.
[0063] Independent tests of the fabric treatments of the present invention demonstrate improved tear strength, as shown in Table 6, below, where the fabric tested was PBI/Kevlar. The fabrics were tested using the wing-rip method.
[0000]
TABLE 6
Treated
Untreated
Warp: 213 N
Warp: 115 N
Weft: 149 N
Weft: 100 N
[0064] As can be seen in Table 6, the tear strength of the ballistic fabric is improved in both the Warp and Weft directions. The tear strength in the Warp direction is nearly doubled, and the tear strength m the Weft direction is increased by nearly 50%.
[0065] As used herein “solution” is used for simplicity, but it is understood that solution represents a mixture and that mixture might be an emulsion, a suspension, a solution, a solid, and the like.
[0066] As used herein “fabric” means a product comprising fibers including, but not limited to, cloth that is woven, knitted, felted and the like; rope; cable; netting; webbing; and the like.
[0067] As used herein, an “aqueous” solution means a mixture comprising more than 10% water. In certain embodiments, the aqueous solution of the present invention will comprise other solvents or carriers including, but not limited to, alcohols.
[0068] While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention. | A system and method for treating fabrics to increase tear strength and to decrease UV exposure of the fabrics to help mitigate degradation in strength, color, or other significant attributes of the fabric. Nanoparticles are embedded within thin films and applied to the fabrics to increase the tear strength of such fabrics and minimize UV exposure. | 3 |
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a divisional application of U.S. application Ser. No. 14/207,179, which was filed Mar. 12, 2014, the disclosure of which is incorporated herein as if set forth in its entirety. U.S. application Ser. No. 14/207,179 claims priority from U.S. Provisional Application Ser. No. 61/780,621 filed Mar. 13, 2013, the disclosure of which is incorporated herein as if set forth in its entirety.
FIELD
[0002] Provided herein are processes for the preparation of an apoptosis-inducing agent, and chemical intermediates thereof. Also provided herein are novel chemical intermediates related to the processes provided herein.
BACKGROUND
[0003] 4-(4-{[2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-en-1-yl]methyl}piperazin-1-yl)-N-({3-nitro-4-[(tetrahydro-2H-pyran-4-ylmethyl)amino]phenyl}sulfonyl)-2-(1H-pyrrolo[2,3-b]pyridin-5-yloxy)benzamide (hereafter, “Compound 1”) is a potent and selective Bcl-2 inhibitor having, inter alia, antitumor activity as an apoptosis-inducing agent. Compound 1 has the formula:
[0000]
[0004] Compound 1 is currently the subject of ongoing clinical trials for the treatment of chronic lymphocytic leukemia. U.S. Patent Publication No. 2010/0305122 describes Compound 1, and other compounds which exhibit potent binding to a Bcl-2 family protein, and pharmaceutically acceptable salts thereof. U.S. Patent Publication Nos. 2012/0108590 and 2012/0277210 describe pharmaceutical compositions comprising such compounds, and methods for the treatment of neoplastic, immune or autoimmune diseases comprising these compounds. U.S. Patent Publication No. 2012/0157470 describes pharmaceutically acceptable salts and crystalline forms of Compound 1. The disclosures of U.S. 2010/0305122; 2012/0108590; 2012/0157470 and 2012/0277210 are hereby incorporated by reference herein in their entireties.
SUMMARY
[0005] Provided herein are processes for the preparation of Compound 1 of the formula:
[0000]
[0006] Also provided herein are compounds of the formulae:
[0000]
[0000] wherein R is C 1 to C 12 alkyl; and processes for their preparation.
DETAILED DESCRIPTION
[0007] Provided herein is a process for the preparation of Compound 1 of the formula:
[0000]
[0000] which comprises:
[0008] (a) combining a compound of formula (K):
[0000]
[0009] wherein R is C 1 to C 12 alkyl,
[0000] with a tert-butoxide salt, an aprotic organic solvent, and water to provide a compound of formula (L):
[0000]
[0010] (b) combining the compound of formula (L) with a compound of formula (N):
[0000]
[0000] and
1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDAC),
4-dimethylaminopyridine (DMAP), and an organic solvent to provide the compound of formula (1).
[0011] In some embodiments, R is C 1 to C 6 alkyl. In some embodiments, R is C 1 to C 4 alkyl. In some embodiments, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl. In some embodiments, R is tert-butyl.
[0012] In one embodiment, the process provided herein further comprises:
[0013] (c) combining a compound of formula (M):
[0000]
[0000] with (tetrahydro-2H-pyran-4-yl)methanamine, a tertiary amine base, and an organic solvent to provide the compound of formula (N).
[0014] In another embodiment, the process provided herein further comprises:
[0015] (d) combining a compound of formula (D):
[0000]
[0016] wherein R is C 1 to C 12 alkyl,
[0000] with a compound of formula (I):
[0000]
[0000] a source of palladium, a tert-butoxide salt, and a phosphine ligand in an aprotic organic solvent to provide the compound of formula (K).
[0017] In some embodiments, the phosphine ligand is a compound of formula (J):
[0000]
[0018] In another embodiment, the process provided herein further comprises:
[0019] (e) combining a compound of formula (B) with a compound of formula (C):
[0000]
wherein R is C 1 to C 12 alkyl,
and a tert-butoxide salt in an organic solvent to provide the compound of formula (D).
[0021] In another embodiment, the process provided herein further comprises:
[0022] (f) combining a compound of formula (A):
[0000]
[0000] with R 1 MgX in an aprotic organic solvent;
[0023] wherein R 1 is C 1 to C 6 alkyl; and X is Cl, Br or I;
[0024] (g) combining a C 1 to C 12 alkyl chloroformate or a di-(C 1 to C 12 alkyl)dicarbonate with the product of step (f), to provide the compound of formula (C).
[0025] In another embodiment, the process provided herein further comprises:
[0026] (h) combining a compound of formula (E):
[0000]
[0000] with DMF and POCl 3 to provide a compound of formula (F):
[0000]
[0027] (i) combining the compound of formula (F) with a source of palladium and 4-chlorophenylboronic acid in an organic solvent to provide a compound of formula (G):
[0000]
[0028] (j) combining the compound of formula (G) with BOC-piperazine and sodium triacetoxyborohydride in an organic solvent to provide a compound of formula (H):
[0000]
[0000] and
[0029] (k) combining the compound of formula (H) with hydrochloric acid to provide the compound of formula (I).
[0030] In one embodiment, the process comprises steps (a) through (d). In one embodiment, the process comprises steps (a) through (e). In another embodiment, the process comprises steps (a) through (g). In another embodiment, the process comprises steps (a) through (k).
[0031] In one embodiment, the process comprises steps (a), (b) and (d). In another embodiment, the process comprises steps (a), (b), (d) and (e). In another embodiment, the process comprises steps (a), (b), (d), (h), (i), (j) and (k). In another embodiment, the process comprises steps (a), (b), (c), (d), (h), (i), (j) and (k). In another embodiment, the process comprises steps (a), (b), (d), (f), (g), (h), (i), (j) and (k). In another embodiment, the process comprises steps (a), (b), (d), (e), (f), (g), (h), (i), (j) and (k).
[0032] In some embodiments, in step (a) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide. In some embodiments, in step (a) the tert-butoxide salt is sodium tert-butoxide. In some embodiments, in step (a) the tert-butoxide salt is potassium tert-butoxide.
[0033] In some embodiments, in step (a) the aprotic organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (a) the aprotic organic solvent is 2-methyltetrahydrofuran.
[0034] In some embodiments, in step (b) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (b) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (b) the organic solvent is dichloromethane.
[0035] In some embodiments, in step (c) the tertiary amine base is N,N-diisopropylethylamine
[0036] In some embodiments, in step (c) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (c) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (c) the organic solvent is acetonitrile.
[0037] In some embodiments, in step (d) the compound of formula (I) is first combined with a base prior to the combining of step (d). In some embodiments, the base is an inorganic base. In some embodiments, the base is an organic base. In some embodiments, the base is selected from the group consisting of K 3 PO 4 , Na 3 PO 4 , NaOH, KOH, K 2 CO 3 or Na 2 CO 3 . In some embodiments, the base is K 3 PO 4 . In some embodiments, in step (d) the compound of formula (I) is first combined with a base in one or more solvents prior to the combining of step (d).
[0038] In some embodiments, in step (d) the source of palladium is Pd 2 dba 3 or [(cinnamyl)PdCl] 2 . In some embodiments, in step (d) the source of palladium is Pd 2 dba 3 .
[0039] In some embodiments, in step (d) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide.
[0040] In some embodiments, in step (d) the tert-butoxide salt is anhydrous. In some embodiments, in step (d) the tert-butoxide salt is anhydrous sodium tert-butoxide.
[0041] In some embodiments, in step (d) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (d) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (d) the aprotic organic solvent is a mixture of THF and toluene.
[0042] In some embodiments, step (d) further comprises the following steps:
(1) combining the tert-butoxide salt with the compound of formula (I) in an aprotic organic solvent; (2) combining the source of palladium, the compound of formula (J), and the compound of formula (D) in an aprotic organic solvent; and (3) adding the mixture of step (1) to the mixture of step (2).
[0046] In some embodiments, in step (d) the mixture resulting from step (2) is filtered prior to step (3).
[0047] In some embodiments, step (d) is carried out under an atmosphere of nitrogen or argon.
[0048] In some embodiments, in step (d) a catalytic amount of the source of palladium is used relative to the amount of compound (I). In some embodiments, the source of palladium is Pd 2 dba 3 and the catalytic amount of Pd 2 dba 3 is from about 0.5 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of Pd 2 dba 3 is about 0.75 mole percent.
[0049] In some embodiments, in step (d) a catalytic amount of the compound of formula (J) is used relative to the amount of compound (I). In some embodiments, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 5 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 2 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is about 1 mole percent or about 2 mole percent.
[0050] In some embodiments, in step (e) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide. In some embodiments, in step (e) the tert-butoxide salt is sodium tert-butoxide. In some embodiments, in step (e) the tert-butoxide salt is potassium tert-butoxide.
[0051] In some embodiments, in step (e) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (e) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (e) the organic solvent is DMF.
[0052] In some embodiments, in step (f), R 1 is C 1 to C 4 alkyl. In some embodiments, R 1 is isopropyl.
[0053] In some embodiments, in step (f), R is methyl and the C 1 to C 12 alkyl chloroformate is methyl chloroformate. In some embodiments, R is ethyl and the C 1 to C 12 alkyl chloroformate is ethyl chloroformate. In some embodiments, R is tert-butyl and the di-(C 1 to C 12 alkyl)dicarbonate is di-tert-butyl dicarbonate.
[0054] In some embodiments, in step (f) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (f) the aprotic organic solvent is THF.
[0055] In some embodiments, in step (i) the source of palladium is Pd(OAc) 2 .
[0056] In some embodiments, in step (i) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (i) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (i) the organic solvent is acetonitrile.
[0057] In some embodiments, step (i) comprises combining tetrabutylammonium bromide with the compound of formula (F), a source of palladium and 4-chlorophenylboronic acid in the organic solvent.
[0058] In some embodiments, in step (j) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (j) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (j) the organic solvent is a mixture of THF and toluene. In some embodiments, the mixture of THF and toluene is about 1:1 by volume.
[0059] In some embodiments, step (j) further comprises producing the compound of formula (H) as a crystalline solid. In some embodiments, step (j) further comprises:
[0060] (1) adding an aqueous solution to the mixture of step (j) to produce an aqueous and an organic phase;
[0061] (2) separating the organic phase from the mixture of step (1);
[0062] (3) concentrating the organic phase; and
[0063] (4) adding an organic solvent to the mixture of step (3) to produce the compound of formula (H) as a crystalline solid.
[0064] In some embodiments of step (4) of step (j), the organic solvent is acetonitrile. In some embodiments of step (4) of step (j), the organic solvent is acetonitrile and the mixture is heated to about 80° C.
[0065] In some embodiments, step (4) of step (j) further comprises cooling the mixture to about 10° C. to about −10° C. In some embodiments, step (4) of step (j) further comprises cooling the mixture to about −10° C., and isolating the compound of formula (H) as a crystalline solid by filtering the mixture.
[0066] In some embodiments, the combining of step (k) is in an organic solvent. In some embodiments, the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the organic solvent is isopropanol.
[0067] In some embodiments, step (k) further comprises producing the compound of formula (I) as a crystalline solid. In some embodiments, the combining of step (k) is in an organic solvent, and step (k) further comprises isolating the compound of formula (I) as a crystalline solid by filtering the mixture.
[0068] In some embodiments, the combining of step (k) is in an organic solvent, and step (k) further comprises cooling the mixture to about 10° C. to about −10° C. to produce the compound of formula (I) as a crystalline solid.
[0069] In some embodiments, the combining of step (k) is in isopropanol, and step (k) further comprises cooling the mixture to about 10° C. to about −10° C. to produce the compound of formula (I) as a crystalline solid. In some embodiments, the combining of step (k) is in isopropanol, and step (k) further comprises cooling the mixture to about −5° C. to produce the compound of formula (I) as a crystalline solid, and isolating the compound of formula (I) as a crystalline solid by filtering the mixture.
[0070] Also provided herein is a process of preparing a compound of formula (C):
[0000]
wherein R is C 1 to C 12 alkyl,
which comprises
(a) combining a compound of formula (A):
[0000]
[0000] with R 1 MgX in an aprotic organic solvent; wherein R 1 is C 1 to C 6 alkyl; and X is Cl, Br or I; and
[0073] (b) combining a C 1 to C 12 alkyl chloroformate or a di-(C 1 to C 12 alkyl)dicarbonate with the product of step (a), to provide the compound of formula (C).
[0074] In some embodiments, R is C 1 to C 6 alkyl. In some embodiments, R is C 1 to C 4 alkyl. In some embodiments, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl. In some embodiments, R is tert-butyl.
[0075] In some embodiments, R 1 is C 1 to C 4 alkyl. In some embodiments, R 1 is isopropyl.
[0076] In some embodiments, the organic solvent of step (a) is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments the organic solvent of step (a) is THF.
[0077] In one embodiment, R is C 1 to C 6 alkyl.
[0078] In one embodiment, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl.
[0079] In one embodiment, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl; and R 1 is isopropyl.
[0080] In one embodiment, R is tert-butyl and R 1 is isopropyl.
[0081] In some embodiments, in step (b), R is methyl and the C 1 to C 12 alkyl chloroformate is methyl chloroformate. In some embodiments, R is ethyl and the C 1 to C 12 alkyl chloroformate is ethyl chloroformate. In some embodiments, R is tert-butyl and the di-(C 1 to C 12 alkyl)dicarbonate is di-tert-butyl dicarbonate.
[0082] Also provided herein is a process for the preparation of a compound of formula (D):
[0000]
[0083] wherein R is C 1 to C 1e alkyl,
[0000] which comprises:
[0084] (x) combining a compound of formula (B):
[0000]
[0000] with a compound of formula (C):
[0000]
[0000] and a tert-butoxide salt in an organic solvent to provide the compound of formula (D).
[0085] In one embodiment, R is tert-butyl.
[0086] In some embodiments, the process of preparing the compound of formula (D) further comprises steps (x′) and (x″):
[0087] (x′) combining a compound of formula (A):
[0000]
[0000] with R 1 MgX in an aprotic organic solvent; wherein R 1 is C 1 to C 6 alkyl; and X is Cl, Br or I;
[0088] (x″) combining a C 1 to C 12 alkyl chloroformate or a di-(C 1 to C 12 alkyl)dicarbonate with the product of step (x′), to provide the compound of formula (C).
[0089] In some embodiments, in step (x) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide.
[0090] In some embodiments, the organic solvent of step (x) is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the organic solvent of step (x) is DMF.
[0091] In some embodiments, in step (x′), R 1 is a C 1 to C 4 alkyl. In some embodiments, R 1 is isopropyl.
[0092] In some embodiments, in step (x″), the C 1 to C 12 alkyl chloroformate is methyl chloroformate. In some embodiments, the C 1 to C 12 alkyl chloroformate is ethyl chloroformate. In some embodiments, the di-(C 1 to C 12 alkyl)dicarbonate is di-tert-butyl dicarbonate.
[0093] In some embodiments, in step (x′) the aprotic organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (x′) the aprotic organic solvent is THF.
[0094] Also provided herein is a compound of the formula (2):
[0000]
[0095] In one embodiment, the compound of the formula (2) is prepared by the following steps:
[0096] (y) combining a compound of formula (B):
[0000]
[0000] with a compound of formula (C):
[0000]
[0000] wherein R is tert-butyl,
and a tert-butoxide salt in an organic solvent to provide the compound of formula (D):
[0000]
[0000] wherein R is tert-butyl; and
[0097] (z) combining the compound of formula (D), wherein R is tert-butyl;
[0000] with a compound of formula (I):
[0000]
[0000] a source of palladium, a tert-butoxide salt, and a phosphine ligand in an aprotic organic solvent.
[0098] In one embodiment, the phosphine ligand of step (z) is a compound of formula (J):
[0000]
[0099] In one embodiment, in step (z) the source of palladium is Pd 2 dba 3 .
[0100] In some embodiments, in step (z) the aprotic organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the aprotic organic solvent is a mixture of THF and toluene.
[0101] In some embodiments, in step (z), the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide.
[0102] In some embodiments, in step (z) the tert-butoxide salt is anhydrous sodium tert-butoxide or anhydrous potassium tert-butoxide.
[0103] In some embodiments, step (z) further comprises the following steps:
(1) combining the tert-butoxide salt with the compound of formula (I) in an aprotic organic solvent; (2) combining the source of palladium, the compound of formula (J), and the compound of formula (D) in an aprotic organic solvent; and (3) adding the mixture of step (1) to the mixture of step (2).
[0107] In some embodiments, in step (z) the mixture resulting from step (2) is filtered prior to step (3).
[0108] In some embodiments, step (z) is carried out under an atmosphere of nitrogen or argon.
[0109] In some embodiments, in step (z) a catalytic amount of the source of palladium is used relative to the amount of compound (I). In some embodiments, the source of palladium is Pd 2 dba 3 and the catalytic amount of Pd 2 dba 3 is from about 0.5 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of Pd 2 dba 3 is about 0.75 mole percent.
[0110] In some embodiments, when the phosphine ligand of step (z) is a compound for formula (J), a catalytic amount of the compound of formula (J) is used relative to the amount of compound (I). In some embodiments, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 5 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 2 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is about 1 mole percent or about 2 mole percent.
[0111] In another embodiment, provided herein are compounds of the formulae:
[0000]
[0112] In some embodiments, the processes described herein are improved methods for commercial chemical manufacturing of Compound 1. Without being bound to a particular theory or mechanism of action, the processes described herein significantly improve the overall efficiency and product yield of Compound 1. Previous processes (e.g., U.S. Patent Publication Nos. 2010/0305122 and 2012/0157470, and International Patent Publication Nos. WO 2011/15096 and WO 2012/071336) were found to lack feasibility for production of Compound 1 on a commercial scale. Thus, the processes provided herein represent improved methods for the synthesis of Compound 1 in quantities required for clinical and/or commercial development. Improvements relative to these previous processes include, but are not limited to, overall yield of Compound 1, overall process efficiency and economics, mild reaction conditions, practical isolation/purification procedures, and viability for commercialization.
[0113] The improved process provided herein involves a selective nucleophilic aromatic substitution reaction (“SnAr reaction”) of compounds (B) and (C), which can be carried out under milder conditions with a shorter reaction time when compared to previously described processes as found, for example, in U.S. Patent Publication Nos. 2010/0305122 and 2012/0157470, and International Patent Publication Nos. WO 2011/15096 and WO 2012/071336. Without being limited by theory, the improved SnAr reaction of compound (B) and (C) does not generate regioisomeric side products which necessitate further purification to remove the side products, as was the case in previously described processes. The SnAr reaction in the previous process also requires a longer reaction time and harsh reaction conditions which result in a low overall yield relative to the processes described herein. Furthermore, the previous processes also require tedious purification of the intermediates which is impracticable on a large, commercial scale process. The processes described herein are more convergent than prior processes, resulting in a highly efficient cross-coupling reaction of compound (D) and the free base of compound (I) in high yield. In some embodiments, the processes described herein utilize crystalline solid intermediates (H) and (I), which allow efficient purification by crystallization to remove impurities—advantages not available in previously described processes.
[0114] The following schemes illustrate one or more embodiments of the process provided herein. In some embodiments, the compound of formula (D) is prepared from compound (B) and compound (C) as shown in Scheme 1 below. The compound of formula (B) may be prepared by techniques known in the art, e.g., as shown in WO 2000/047212 and J. Am. Chem. Soc., 1959, 81: 743-747. The compound of formula (C) may be prepared by techniques known in the art, e.g., as shown in WO 2006/059801 and Tetrahedron Letters, 2008, 49(12), 2034-2037; or as shown in Scheme 2.
[0000]
[0115] The compound of formula (C) of Scheme 1 may prepared from commercially available compound (A) as shown in Scheme 2 below, wherein “R 1 MgX” represents a Grignard reagent wherein R 1 is an alkyl group, and X is Cl, Br or I. The electrophilic acetylating reagent of Scheme 2 can be, but is not limited to, methyl or ethyl chloroformate or BOC 2 O.
[0000]
[0116] An exemplary reaction according to Scheme 2 is shown below.
[0000]
[0117] In another embodiment, the compound of formula (I) is prepared from compound (E) as shown in Scheme 3 below. Compound (E) is commercially available or may be prepared by techniques known in the art, e.g., as shown in U.S. Pat. No. 3,813,443 and Proceedings of the Chemical Society, London, 1907, 22, 302.
[0000]
[0118] In another embodiment, the compound of formula (N) is prepared from compound (M) as shown in Scheme 4 below. Compound (M) is commercially available or may be prepared by techniques known in the art, e.g., as shown in GB 585940 and J. Am. Chem. Soc., 1950, 72, 1215-1218.
[0000]
[0119] In another embodiment, the compound of formula (1) is prepared from compound (D) and compound (I) as shown in Scheme 5 below. Compound (J) may be prepared by techniques known in the art, e.g., as shown in WO 2009/117626 and Organometallics, 2008, 27(21), 5605-5611.
[0000]
[0120] In some embodiments, the preparation of the compound of formula (K) from compound (D) and compound (I) is air and/or moisture sensitive, and is therefore performed under an inert atmosphere, e.g., using nitrogen or argon gas.
[0121] Without being bound to a particular theory, the use of compound (D) as an intermediate in the preparation of the compound of formula (1) as shown above in Schemes 1 to 5 is an improvement over previously described processes for the preparation of the compound of formula (1). In some embodiments, the improvements include higher product yields, shorter reaction times. In some embodiments, the improvements are provided when R is tert-butyl in compound (D).
[0122] Schemes 1 to 5 are non-limiting examples of the process provided herein. Solvents and/or reagents are known compounds and may be interchanged according to the knowledge of those skilled in the art.
[0123] Abbreviations used in Schemes 1 to 5 are as follows:
[0000]
Ac
acetyl
BOC
tert-butoxycarbonyl
dba
dibenzylidineacetone
DIEA
N,N-diisopropylethylamine
DMAP
4-dimethylaminopyridine
DMF
dimethylformamide
EDAC
1-ethyl-3-(3-dimethylaminopropyl)carbodiimide HCl
IPA
isopropanol
iPr
isopropyl
Me
methyl
n-Bu
n-butyl
tBu
tert-butyl
THF
tetrahydrofuran
[0124] Unless indicated otherwise, the temperatures at which a reaction of Schemes 1 to 5 is conducted is not critical. In certain embodiments, when a temperature is indicated in a reaction, the temperature may be varied from about plus or minus 0.1° C., 0.5° C., 1° C., 5° C., or 10° C. Depending upon which solvent is employed in a particular reaction, the optimum temperature may vary. In some embodiments, reactions are conducted in the presence of vigorous agitation sufficient to maintain an essentially uniformly dispersed mixture of the reactants.
[0125] In conducting a reaction provided herein, neither the rate, nor the order, of addition of the reactants is critical unless otherwise indicated. Unless otherwise indicated, reactions are conducted at ambient atmospheric pressure. Unless otherwise indicated, the exact amount of reactants is not critical. In some embodiments, the amount of a reactant may be varied by about 10 mole percent or about 10% by weight.
[0126] Unless otherwise indicated, the organic solvents used in the processes provided herein may be selected from those commercially available or otherwise known to those skilled in the art. Appropriate solvents for a given reaction are within the knowledge of the skilled person and include mixtures of solvents. Examples of organic solvents provided herein for use include but are not limited to: pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, tetrahydrofuran (THF), dimethylformamide (DMF), hexamethylphosphoramide (HMPA), N-methyl-2-pyrrolidinone (NMP), nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, methyl tert-butyl ether (MTBE), benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof
[0127] In some embodiments, an organic solvent used in the processes provided herein is an aprotic organic solvent. As provided herein, an aprotic solvent is a solvent that does not contain an acidic hydrogen atom or a hydrogen atom that is capable of hydrogen bonding (e.g., is not bound to an oxygen or a nitrogen atom). The aprotic organic solvent may be selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the aprotic organic solvent is THF. In some embodiments, the aprotic organic solvent is DMF. In some embodiments, the aprotic organic solvent is acetonitrile.
[0128] As provided herein, a “tertiary amine base” refers to an amine that is substituted with three alkyl groups, e.g., triethylamine or N,N-diisopropylethylamine
[0129] As provided herein, a “catalytic amount” refers to less than one molar equivalent of a reagent or reactant in a given reaction, as determined relative to another reagent or reactant in the reaction mixture. In some embodiments, a catalytic amount is described as a mole percent relative to another reagent or reactant in the reaction mixture.
[0130] As provided herein, a “source of palladium” refers to a source of palladium in a stable oxidation state, i.e., Pd(0), Pd(I), Pd(II) and/or Pd(IV). The palladium may be free metal, such as in a powder form, or may be bound to one or more ligands, e.g., PdCl 2 , Pd 2 dba 3 , PdCl 2 (PPh 3 ) 2 , Pd(PPh 3 ) 4 , Pd(OAc) 2 or [(cinnamyl)PdCl] 2 .
[0131] As provided herein, a “phosphine ligand” refers to a compound of formula PR′ 3 , wherein each R′ is independently selected from C 1 to C 6 alkyl or phenyl, wherein the aryl group is optionally substituted by C 1 to C 6 alkyl, phenyl, trialkylamino, alkoxy or halo.
[0132] As provided herein, unless otherwise defined, the term “about” means that the value or amount to which it refers can vary by ±5%, ±2%, or ±1%.
[0133] The products obtained by any of the processes provided herein may be recovered by conventional means, such as evaporation or extraction, and may be purified by standard procedures, such as distillation, recrystallization or chromatography
EXAMPLES
[0134] Compounds of the following examples are shown in Schemes 1 to 5 above and were named using Chemdraw® Ultra software. In addition to the abbreviations described above with respect to the schemes provided herein, the following abbreviations are used in the Examples:
[0135] “HPLC”=high pressure liquid chromatography; “IP”=in process; “ML”=mother liquor; “NLT”=no less than; “NMT”=no more than; “RB”=round bottom; “RT”=room temperature; “sm”=starting material.
[0136] Unless indicated otherwise, compounds were characterized by HPLC and 1 H NMR analysis and used in later reactions with or without purification. 1 H NMR analysis was performed at 400 MHz unless otherwise indicated. Unless specified otherwise, product yield/purity was determined by weight, qNMR, and/or HPLC analysis.
Example 1
Synthesis of tert-butyl 4-bromo-2-fluorobenzoate (Compound (C))
[0137] To a 100 ml jacketed reactor equipped with a mechanical stirrer was charged 4-bromo-2-fluorol-iodobenzene, “Compound (A)” (5 g, 1.0 eq) and THF (25 ml). The solution was cooled to −5° C. 2 M isopropyl magnesium chloride in THF (10.8 ml, 1.3 eq) was slowly added maintaining the internal temperature below 0° C. The mixture was stirred at 0° C. for 1 h. Di-tert-butyl dicarbonate (5.44 g, 1.5 eq) in THF (10 ml) was added. After 1 h, the solution was quenched with 10% citric acid (10 ml), and then diluted with 25% NaCl (10 ml). The layers were separated and the organic layer was concentrated to near dryness and chased with THF (3×10 ml). The crude oil was diluted with THF (5 ml), filtered to remove inorganics, and concentrated to dryness. The crude oil (6.1 g, potency=67%, potency adjusted yield=88%) was taken to the next step without further purification. 1 H NMR (DMSO-d 6 ): δ 1.53 (s, 9H), 7.50-7.56 (m, 1H), 7.68 (dd, J=10.5, 1.9 Hz, 1H), 7.74 (t, J=8.2 Hz, 1H).
Example 2
Synthesis of tert-butyl 2-((1H-pyrrolo[2,3-b]pyridin-5-yl)oxy)-4-bromobenzoate (Compound (D))
[0138] To a 3 L three-neck Morton flask were charged 1H-pyrrolo[2,3-b]pyridin-5-ol (80.0 g, 1.00 eq.), tert-butyl 4-bromo-2-fluorobenzoate (193 g, 1.15 eq.), and anhydrous DMF (800 mL). The mixture was stirred at 20° C. for 15 min. The resulting solution was cooled to about zero to 5° C. A solution of sodium tert-butoxide (62.0 g) in DMF (420 mL) was added slowly over 30 min while maintaining the internal temperature at NMT 10° C., and rinsed with DMF (30 mL). The reaction mixture was stirred at 10° C. for 1 hour (an off-white slurry) and adjusted the internal temperature to ˜45° C. over 30 min. The reaction mixture was stirred at 45-50° C. for 7 hr and the reaction progress monitored by HPLC (IP samples: 92% conversion % by HPLC). The solution was cooled to ˜20° C. The solution was stirred at 20° C. overnight.
[0139] Water (1200 mL) was added slowly to the reaction mixture at <30° C. over 1 hour (slightly exothermic). The product slurry was adjusted to ˜20° C., and mixed for NLT 2 hours. The crude product was collected by filtration, and washed with water (400 mL). The wet-cake was washed with heptane (400 mL) and dried under vacuum at 50° C. overnight to give the crude product (236.7 g).
[0140] Re-crystallization or Re-slurry: 230.7 g of the crude product, (potency adjusted: 200.7 g) was charged back to a 3 L three-neck Morton flask. Ethyl acetate (700 mL) was added, and the slurry heated slowly to refluxing temperature over 1 hr (small amount of solids left). Heptane (1400 mL) was added slowly, and the mixture adjusted to refluxing temperature (78° C.). The slurry was mixed at refluxing temperature for 30 min., and cooled down slowly to down to ˜−10° C. at a rate of approximate 10° C./hour), and mixed for 2 hr. The product was collected by filtration, and rinsed with heptane (200 ml).
[0141] The solid was dried under vacuum at ˜50° C. overnight to give 194.8 g, 86% isolated yield of the product as an off-white solid. MS-ESI 389.0 (M+1); mp: 190-191° C. (uncorrected). 1 H NMR (DMSO-d 6 ): δ 1.40 (s, 9H), 6.41 (dd, J=3.4, 1.7 Hz, 1H), 7.06 (d, J=1.8 Hz, 1H), 7.40 (dd, J=8.3, 1.8 Hz, 1H), 7.51 (t, J=3.4 Hz, 1H), 7.58 (d, J=2.6 Hz, 1H), 7.66 (d, J=8.3 Hz, 1H), 8.03 (d, J=2.7 Hz, 1H), 11.72 (s, 1H, NH).
Example 3
Synthesis of 2-chloro-4,4-dimethylcyclohexanecarbaldehyde (Compound (F))
[0142] To a 500 mL RB flask were charged anhydrous DMF (33.4 g, 0.456 mol) and CH 2 Cl 2 (80 mL). The solution was cooled down <—5° C., and POCl 3 (64.7 g, 0.422 mol) added slowly over 20 min @<20° C. (exothermic), rinsed with CH 2 Cl 2 (6 mL). The slightly brown solution was adjusted to 20° C. over 30 mM, and mixed at 20° C. for 1 hour. The solution was cooled back to <5° C. 3,3-Dimethylcyclohexanone (41.0 g, 90%, ˜0.292 mol) was added, and rinsed with in CH 2 Cl 2 (10 mL) (slightly exothermic) at <20° C. The solution was heated to refluxing temperature, and mixed overnight (21 hours.).
[0143] To a 1000 mL three neck RB flask provided with a mechanical stirrer were charged 130 g of 13.6 wt % sodium acetate trihydrate aqueous solution, 130 g of 12% brine, and 130 mL of CH 2 Cl 2 . The mixture was stirred and cooled down to <5° C. The above reaction mixture (clear and brown) was transferred, quenched into it slowly while maintaining the internal temperature <10° C. The reaction vessel was rinsed with CH 2 Cl 2 (10 mL). The quenched reaction mixture was stirred at <10° C. for 15 min. and allowed to rise to 20° C. The mixture was stirred 20° C. for 15 min and allowed to settle for 30 min. (some emulsion). The lower organic phase was separated. The upper aq. phase was back extracted with CH 2 Cl 2 (50 mL). The combined organic was washed with a mixture of 12% brine (150 g)—20% K 3 PO 4 aq. solution (40 g). The organic was dried over MgSO 4 , filtered and rinsed with CH 2 Cl 2 (30 ml). The filtrate was concentrated to dryness under vacuum to give a brown oil (57.0 g, potency=90.9 wt % by qNMR, ˜100%). 1 H NMR (CDCl 3 ): δ 0.98 (s, 6H), 1.43 (t, J=6.4 Hz, 2H), 2.31 (tt, J=6.4, 2.2 Hz, 2H), 2.36 (t, J=2.2 Hz, 2H), 10.19 (s, 1H).
Example 4
Synthesis of 2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-enecarbaldehyde (Compound (G))
[0144] To a 250 mL pressure bottle were charged 2-chloro-4,4-dimethylcyclohex-1-enecarbaldehyde (10.00 g), tetrabutylammonium bromide (18.67 g), and acetonitrile (10 mL). The mixture was stirred at 20° C. for 5 min. 21.0 wt % K 2 CO 3 aq. solution (76.0 g) was added. The mixture was stirred at room temperature (rt) for NLT 5 min. followed by addition of 4-chlorophenylboronic acid (9.53 g) all at once. The mixture was evacuated and purged with N 2 for three times. Palladium acetate (66 mg, 0.5 mol %) was added all at once under N 2 . The reaction mixture was evacuated and purged with N 2 for three times (an orange colored mixture). The bottle was back filled with N 2 and heated to ˜35° C. in an oil bath (bath temp ˜35° C.). The mixture was stirred at 30° C. overnight (15 hours). The reaction mixture was cooled to RT, and pulled IP sample from the upper organic phase for reaction completion, typically starting material <2% (orange colored mixture). Toluene (100 mL) and 5% NaHCO 3 -2% L-Cysteine aq. solution (100 mL) were added. The mixture was stirred at 20° C. for 60 min. The mixture was filtered through a pad of Celite to remove black solid, rinsing the flask and pad with toluene (10 mL). The upper organic phase was washed with 5% NaHCO 3 aq. solution-2% L-Cysteine (100 mL) once more. The upper organic phase was washed with 25% brine (100 mL). The organic layer (105.0 g) was assayed (118.8 mg/g, 12.47 g product assayed, 87% assayed yield), and concentrated to ˜⅓ volume (˜35 mL). The product solution was directly used in the next step without isolation. However, an analytical sample was obtained by removal of solvent to give a brown oil. 1 HNMR (CDCl 3 ): δ 1.00 (s, 6H), 1.49 (t, J=6.6 Hz, 2H), 2.28 (t, J=2.1 Hz, 2H), 2.38 (m, 2H), 7.13 (m, 2H), 7.34 (m, 2H), 9.47 (s, 1H).
Example 5
Synthesis of tert-butyl 4-((4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazine-1-carboxylate (Compound (H))
[0145] To a 2 L three neck RB flask provided with a mechanical stirrer were charged a solution of 4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-carbaldehyde (50.0 g) in toluene (250 mL), BOC-piperazine (48.2 g) and anhydrous THF (250 mL). The yellow solution was stirred at 20° C. for 5 min. Sodium triacetoxyborohydride (52.7 g) was added in portion (note: the internal temperature rose to ˜29.5° C. in 15 min cooling may be needed). The yellow mixture was stirred at ˜25° C. for NLT 4 hrs. A conversion of starting material to product of 99.5% was observed by HPLC after a 3 hour reaction time.
[0146] 12.5 wt % brine (500 g) was added slowly to quench the reaction. The mixture was stirred at 20° C. for NLT 30 min and allowed to settle for NLT 15 min. The lower aq. phase (˜560 mL) was separated (note: leave any emulsion in the upper organic phase). The organic phase was washed with 10% citric acid solution (500 g×2). 500 g of 5% NaHCO 3 aq. solution was charged slowly into the flask. The mixture was stirred at 20° C. for NLT 30 min., and allowed to settle for NLT 15 min. The upper organic phase was separated. 500 g of 25% brine aq. solution was charged. The mixture was stirred at 20° C. for NLT 15 min., and allowed to settle for NLT 15 min. The upper organic phase was concentrated to ˜200 mL volume under vacuum. The solution was adjusted to ˜30° C., and filtered off the inorganic salt. Toluene (50 mL) was used as a rinse. The combined filtrate was concentrated to ˜100 mL volume. Acetonitrile (400 mL) was added, and the mixture heated to ˜80° C. to achieve a clear solution. The solution was cooled down slowly to 20° C. slowly at rate 10° C./hour, and mixed at 20° C. overnight (the product is crystallized out at ˜45-50° C., if needed, seed material may be added at 50° C.). The slurry was continued to cool down slowly to ˜−10° C. at rate of 10° C./hours. The slurry was mixed at ˜−10° C. for NLT 6 hours. The product was collected by filtration, and rinsed with pre-cooled acetonitrile (100 mL). The solid was dried under vacuum at 50° C. overnight (72.0 g, 85%). MS-ESI: 419 (M+1); mp: 109-110° C. (uncorrected); 1 H NMR (CDCl 3 ): δ 1.00 (s, 6H), 1.46 (s, 9H), 1.48 (t, J=6.5 Hz, 2H), 2.07 (s, br, 2H), 2.18 (m, 4H), 2.24 (t, J=6.4 Hz, 2H), 2.80 (s, 2H), 3.38 (m, 4H), 6.98 (m, 2H), 7.29 (m, 2H).
Example 6
Synthesis of 1-((4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazine dihydrochloride (Compound (I))
[0147] To a 2.0 L three-neck RB flask equipped with a mechanical stirrer were charged the Boc reductive amination product (Compound (H), 72.0 g) and IPA (720 mL). The mixture was stirred at rt for 5 min, and 59.3 g of concentrated hydrochloride aq. solution added to the slurry. The reaction mixture was adjusted to an internal temperature of ˜65° C. (a clear and colorless solution achieved). The reaction mixture was agitated at ˜65° C. for NLT 12 hours.
[0148] The product slurry was cooled down to −5° C. slowly (10° C./hour). The product slurry was mixed at ˜−5° C. for NLT 2 hours, collected by filtration. The wet cake was washed with IPA (72 mL) and dried at 50° C. under vacuum overnight to give 73.8 g (95%) of the desired product as a bis-hydrochloride IPA solvate (purity >99.5% peak area at 210 nm). MS-ESI: 319 (M+1); 1 HNMR (D 2 O): δ 1.00 (s, 6H), 1.19 (d, J=6.0 Hz, 6H, IPA), 1.65 (t, J=6.1 Hz, 2H), 2.14 (s, br, 2H), 2.26 (m, 2H), 3.36 (br, 4H), 3.55 (s, br, 4H), 3.82 (s, 2H), 4.02 (septet, J=6.0 Hz, 1H, IPA), 7.16 (d, J=8.1 Hz, 2H), 7.45 (d, J=8.1 Hz, 2H; 1 HNMR (CDCl 3 ): δ 0.86 (s, 6H), 1.05 (d, J=6.0 Hz, 6H, IPA), 1.42 (t, J=6.1 Hz, 2H), 2.02 (s, br, 2H), 2.12 (m, 2H), 3.23 (m, 4H), 3.4 (s, br, 4H), 3.68 (s, 2H), 3.89 (septet, J=6.0 Hz, 1H, IPA), 7.11 (d, J=8.1 Hz, 2H), 7.41 (d, J=8.1 Hz, 2H).
Example 7
Synthesis of 3-nitro-4-(((tetrahydro-2H-pyran-4-yl)methyl)amino)—benzenesulfonamide (Compound (N))
[0149] To a 500 mL three-neck RB flask equipped with a mechanical stirrer were charged the 4-chloro-3-nitrobenzenesulfonamide, Compound M (10.0 g), diisopropylethylamine (17.5 g), (tetrahydro-2H-pyran-4-yl)methanamine (7.0 g) and acetonitrile (150 mL). The reaction mixture was adjusted to an internal temperature of 80° C. and agitated for no less than 12 hours.
[0150] The product solution was cooled down to 40° C. and agitated for no less than 1 hour until precipitation observed. The product slurry was further cooled to 20° C. Water (75 mL) was slowly charged over no less than 1 hour, and the mixture cooled to 10° C. and agitated for no less than 2 hours before collected by filtration. The wet cake was washed with 1:1 mix of acetonitrile:water (40 mL). The wet cake was then reslurried in water (80 mL) at 40° C. for no less than 1 hour before collected by filtration. The wet cake was rinsed with water (20 mL), and dried at 75° C. under vacuum to give 12.7 g of the desired product in 99.9% purity and in 91% weight-adjusted yield. 1 H NMR (DMSO-d 6 ): δ 1.25 (m, 2H), 1.60 (m, 2H), 1.89 (m, 1H), 3.25 (m, 2H), 3.33 (m, 2H), 3.83 (m, 2H), 7.27 (d, J=9.3 Hz, 1H), 7.32 (s, NH 2 , 2H), 7.81 (dd, J=9.1, 2.3 Hz, 1H), 8.45 (d, J=2.2 Hz, 1H), 8.54 (t, J=5.9 Hz, 1H, NH).
Example 8
Synthesis of tert-butyl 2-41H-pyrrolo[2,3-b]pyridin-5-yl)oxy)-4-(4-((44′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazin-1-yl)benzoate (Compound (K))
[0151] General Considerations:
[0152] this chemistry is considered air and moisture sensitive. While the catalyst precursors in their solid, dry form can be handled and stored in air without special precautions, contact with even small amounts of solvent may render them susceptible to decomposition. As a result, traces of oxygen or other competent oxidants (e.g., solvent peroxides) must be removed prior to combination of the catalyst precursors with solvent and care must be used to prevent ingress of oxygen during the reaction. Also, care must be taken to use dry equipment, solvents, and reagents to prevent formation of undesirable byproducts. The sodium t-butoxide used in this reaction is hygroscopic and it should be properly handled and stored prior to or during use.
[0153] To a 2.0 L three-neck RB flask equipped with a mechanical stirrer were charged the bis-hydrochloride salt (Compound (I), 42.5 g) and toluene (285 ml). 20% K 3 PO 4 (285 ml) was added and the biphasic mixture was stirred for 30 min. The layers were separated and the organic layer was washed with 25% NaCl (145 ml). The organic layer concentrated to 120 g and used in the coupling reaction without further purification.
[0154] NaOtBu (45.2 g) and Compound (I) in toluene solution (120 g solution-30 g potency adjusted) were combined in THF (180 ml) in a suitable reactor and sparged with nitrogen for NLT 45 min. Pd 2 dba 3 (0.646 g), Compound (J) (0.399 g), and Compound (D) (40.3 g) were combined in a second suitable reactor and purged with nitrogen until oxygen level was NMT 40 ppm. Using nitrogen pressure, the solution containing Compound (I) and NaOtBu in toluene/THF was added through a 0.45 μm inline filter to the second reactor (catalyst, Compound (J) and Compound (D)) and rinsed with nitrogen sparged THF (30 ml.).
[0155] The resulting mixture was heated to 55° C. with stirring for NLT 16 h, then cooled to 22° C. The mixture was diluted with 12% NaCl (300 g) followed by THF (300 ml). The layers were separated.
[0156] The organic layer was stirred with a freshly prepared solution of L-cysteine (15 g), NaHCO 3 (23 g), and water (262 ml). After 1 h the layers were separated.
[0157] The organic layer was stirred with a second freshly prepared solution of L-cysteine (15 g), NaHCO 3 (23 g), and water (262 ml). After 1 h the layers were separated. The organic layer was washed with 12% NaCl (300 g), then filtered through a 0.45 μm inline filter. The filtered solution was concentrated in vacuo to ˜300 mL, and chased three times with heptane (600 mL each) to remove THF.
[0158] The crude mixture was concentrated to 6 volumes and diluted with cyclohexane (720 ml). The mixture was heated to 75° C., held for 15 min, and then cooled to 65° C. over NLT 15 min. Seed material was charged and the mixture was held at 65° C. for 4 hours. The suspension was cooled to 25° C. over NLT 8 h, then held at 25° C. for 4 hours. The solids were filtered and washed with cyclohexane (90 ml) and dried at 50° C. under vacuum.
[0159] Isolated 52.5 g (88.9% yield) as a white solid. Melting point (uncorrected) 154-155° C. 1 H NMR (DMSO-d 6 ): δ 0.93 (s, 6H), 1.27 (s, 9H), 1.38 (t, J=6.4 Hz, 2H), 1.94 (s, 2H), 2.08-2.28 (m, 6H), 2.74 (s, 2H), 3.02-3.19 (m, 4H), 6.33 (dd, J=3.4, 1.9 Hz, 1H), 6.38 (d, J=2.4 Hz, 1H), 6.72 (dd, J=9.0, 2.4 Hz, 1H), 6.99-7.06 (m, 2H), 7.29 (d, J=2.7 Hz, 1H), 7.30-7.36 (m, 2H), 7.41-7.44 (m, 1H), 7.64 (t, J=6.7 Hz, 1H), 7.94 (d, J=2.7 Hz, 1H), 11.53 (s, 1H).
Example 9
Synthesis of 2-41H-pyrrolo[2,3-b]pyridin-5-yl)oxy)-4-(4-04′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazin-1-yl)benzoic acid (Compound (L))
[0160] Solution preparation: 10% KH 2 PO 4 (aq):KH 2 PO 4 (6 g) in water (56 g); 2:1 heptane/2-MeTHF:heptane (16 mL) in 2-MeTHF (8 mL).
[0161] Compound (K) (5.79 g), potassium tert-butoxide (4.89 g), 2-methyltetrahydrofuran (87 mL), and water (0.45 mL) were combined in a suitable reactor under nitrogen and heated to 55° C. until reaction completion. The reaction mixture was cooled to 22° C., washed with the 10% KH 2 PO 4 solution (31 g) twice. The organic layer was then washed with water (30 g).
[0162] After removal of the aqueous layer, the organic layer was concentrated to 4 volumes (˜19 mL) and heated to no less than 50° C. Heptane (23 ml) was slowly added. Alternatively, after removal of the aqueous layer, the organic layer was concentrated to 5 volumes and heated to no less than 70° C. and 5 volumes of heptane were slowly added. The resulting suspension was cooled to 10° C. Solids were then collected by vacuum filtration with recirculation of the liquors and the filter cake washed with 2:1 heptane/2-MeTHF (24 ml). Drying of the solids at 80° C. under vacuum yielded 4.0 g of Compound (L) in approximately 85% weight-adjusted yield. 1 H NMR (DMSO-d 6 ): δ 0.91 (s, 6H), 1.37 (t, J=6.4 Hz, 2H), 1.94 (s, br, 2H), 2.15 (m, 6H), 2.71 (s, br, 2H), 3.09 (m, 4H), 6.31 (d, J=2.3 Hz, 1H), 6.34 (dd, J=3.4, 1.9 Hz, 1H), 6.7 (dd, J=9.0, 2.4 Hz, 1H), 7.02 (m, 2H), 7.32 (m, 2H), 7.37 (d, J=2.6 Hz, 1H), 7.44 (t, J=3.0 Hz, 1H), 7.72 (d, J=9.0 Hz, 1H), 7.96 (d, J=2.7 Hz, 1H) & 11.59 (m, 1H).
Example 10
Synthesis of 4-(4-{[2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-en-1-yl]methyl}piperazin-1-yl)-N-({3-nitro-4-[(tetrahydro-2H-pyran-4-ylmethyl)amino]phenyl}sulfonyl)-2-(1H-pyrrolo[2,3-b]pyridin-5-yloxy)benzamide
(Compound (1))
[0163] Solution preparation prior to reaction: 10% Acetic Acid:Acetic Acid (37 mL) in water (333 g); 5% NaHCO 3 :NaHCO 3 (9 g) in water (176 g); 5% NaCl:NaCl (9 g) in water (176 g).
[0164] Compound (N) (13.5 g), DMAP (10.5 g), EDAC (10.7 g) and dichloromethane (300 mL) were combined in a suitable reactor and agitated at 25° C. In a second suitable reactor was charged the Acid (Compound (L), 25 g), Et 3 N (8.7 g) and dichloromethane (120 mL). The resulting Acid (Compound (L)) solution was slowly charged to the initial suspension of Compound (N) and agitated until reaction completion. N,N-dimethylethylenediamine (9.4 g) was then charged to the reaction mixture with continued agitation. The reaction mixture was warmed to 35° C. and washed with 10% Acetic acid solution (185 mL) twice. The lower organic layer was diluted with more dichloromethane (75 mL) and methanol (12.5 mL). The organic, product layer was then washed with 5% NaHCO 3 solution (185 mL) and then washed with 5% NaCl solution (185 mL) at 35° C. The lower, organic layer was separated and then concentrated to 8 vol (—256 mL) diluted with methanol (26 mL) and warmed to 38° C. Ethyl Acetate (230 mL) was slowly charged. The resulting suspension was slowly cooled to 10° C. and then filtered. The wet cake was washed twice with a 1:1 mix of dichloromethane and ethyl acetate (˜2 vol, 64 mL). After drying the wet cake at 90° C., 32 g (84%) of Compound (1) was isolated. 1 H NMR (DMSO-d 6 ): δ 0.90 (s, 6H), 1.24 (m, 2H), 1.36 (t, J=6.4 Hz, 2H), 1.60 (m, 2H), 1.87 (m, 1H), 1.93 (s, br, 2H), 2.12 (m, 2H), 2.19 (m, 4H), 2.74 (s, br, 2H), 3.06 (m, 4H), 3.26 (m, 4H), 3.83 (m, 2H), 6.17 (d, J=2.1 Hz, 1H), 6.37 (dd, J=3.4, 1.9 Hz, 1H), 6.66 (dd, J=9.1, 2.2 Hz, 1H), 7.01 (m, 2H), 7.31 (m, 2H), 7.48 (m, 3H), 7.78 (dd, J=9.3, 2.3 Hz, 1H), 8.02 (d, J=2. 61 Hz, 1H), 8.54 (d, J=2. 33 Hz, 1H), 8.58 (t, J=5.9 Hz, 1H, NH), 11.65 (m, 1H).
[0165] All references cited herein are incorporated by reference in their entirety. While the methods provided herein have been described with respect to the particular embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope as recited by the appended claims.
[0166] The embodiments described above are intended merely to be exemplary, and those skilled in the art will recognize, or will be able to ascertain using no more than routine experimentation, numerous equivalents of specific compounds, materials, and procedures. All such equivalents are considered to be within the scope of the invention and are encompassed by the appended claims. | Provided herein is a process for the preparation of an apoptosis-inducing agent, and chemical intermediates thereof. Also provided herein are novel chemical intermediates related to the process provided herein. | 2 |
FIELD OF INVENTION
[0001] The subject matter disclosed herein relates generally to the field of elevator systems, and more particularly, to a safety circuit for an elevator system.
BACKGROUND
[0002] Elevator systems may include safety circuits to control operation of the elevator systems in a predefined manner. U.S. Pat. No. 5,407,028 discloses an exemplary elevator safety circuit that employs a number of relays to provide power to an elevator brake and elevator motor. Existing safety circuits employ forced guided relays to apply or interrupt power to elevator components, such as a brake or motor. Forced guided relays have contacts that are mechanically linked, so that all contacts are ensured to move together. Forced guided relays are typically more expensive than other relays lacking a mechanical connection between relay contacts. Also, forced guided relays are typically larger than other relays lacking a mechanical connection between relay contacts.
BRIEF SUMMARY
[0003] According to an exemplary embodiment, an elevator safety circuit includes a plurality of relays; safety logic for monitoring status of the plurality of relays, the safety logic generating an output signal in response to the status of the plurality of relays; and a processor controlling operation of an elevator drive in response to the output signal; wherein at least one of the relays is a forced guided relay and at least one of the relays is other than a forced guided relay.
[0004] Other aspects, features, and techniques of embodiments of the invention will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Referring now to the drawings wherein like elements are numbered alike in the FIGURES:
[0006] FIG. 1 depicts an elevator safety circuit in a standstill condition in an exemplary embodiment; and
[0007] FIG. 2 depicts a drive unit including the safety circuit of FIG. 1 in an exemplary embodiment.
DETAILED DESCRIPTION
[0008] FIG. 1 depicts an elevator safety circuit 10 in an exemplary embodiment. Elevator safety circuit 10 applies or interrupts power to an elevator brake 12 (e.g., on an elevator car or drive unit) and an elevator drive 14 . Elevator drive 14 provides power (e.g., 3 phase power) to elevator motor 16 to impart motion to an elevator car.
[0009] Elevator safety circuit 10 includes a brake relay 20 that applies or interrupts power to brake 12 . Brake relay 20 is other than a forced guided relay. Elevator safety circuit 10 includes a drive relay 30 that applies or interrupts power to drive 14 . Drive relay 30 is other than a forced guided relay. Elevator safety circuit 10 includes a safety relay 40 . Safety relay 40 includes three contacts, 42 , 44 and 46 , connections to which are described in further detail herein. Safety relay 40 is a forced guided relay, meaning that contacts 42 , 44 and 46 are mechanically linked to move together.
[0010] Brake relay 20 includes a contact 22 connected to a first contact 42 of safety relay 40 . Power to the brake 12 is applied through contact 22 and first contact 42 . Drive relay 30 includes a contact 32 connected to a second contact 44 of safety relay 40 . Power to the drive 14 is applied through contact 32 and second contact 44 . Third contact 46 of safety relay 40 is connected to a reference voltage V 1 , which may be a ground, logic one (e.g., 5 volts), etc.
[0011] The states of brake relay 20 , drive relay 30 and safety relay 40 are monitored in order to determine if the system is in a proper state to operate an elevator car. Safety logic 50 receives monitoring signals from each of the brake relay 20 , drive relay 30 and safety relay 40 . A connection 24 is provided from a location in brake relay 20 to safety logic 50 . The connection 24 may include a coupler 26 , convert the voltage of a brake relay monitoring signal from brake relay 20 (e.g., 48 volts) to a level suitable for safety logic 50 (e.g., 5 volts). Coupler 26 may be an opto-coupler or other known type of device. In operation, when contact 22 is closed, the brake relay monitoring signal will indicate this state to the safety logic 50 (e.g., a 5 volt signal is provided to safety logic 50 ). When contact 22 is open, the brake relay monitoring signal is not provided to safety logic 50 .
[0012] A connection 34 is provided from a location in drive relay 30 to safety logic 50 . The connection 34 may include a coupler 36 , convert the voltage of a drive relay monitoring signal from drive relay 30 (e.g., 22 volts) to a level suitable for safety logic 50 (e.g., 5 volts). Coupler 36 may be an opto-coupler or other known type of device. In operation, when contact 32 is closed, the drive relay monitoring signal will indicate this state to the safety logic 50 (e.g., a 5 volt signal is provided to safety logic 50 ). When contact 32 is open, the drive relay monitoring signal is not provided to safety logic 50 .
[0013] A connection 48 is provided from a location in safety relay 40 to safety logic 50 . At standstill, when contact 46 is closed, a safety relay monitoring signal will indicate this state to the safety logic 50 (e.g., a reference voltage V 1 signal is provided to safety logic 50 ). This indicates that contact 42 and 44 are opened. When contact 46 is open, the safety relay monitoring signal is not provided to safety logic 50 .
[0014] Safety logic 50 receives the brake relay monitoring signal, drive relay monitoring signal and safety relay monitoring signal and generates an output signal. The safety logic 50 may include logic gates (e.g., AND, OR, NOR) to generate a three-bit output signal that is provided to a processor 60 . Processor 60 controls operation of the elevator system based on the output signal from the safety logic 50 . For example, processor 60 may prevent starting of motor 16 if one of brake relay 20 , drive relay 30 or safety relay 40 has not closed. Further, processor 60 may prevent starting of motor 16 if one of brake relay 20 , drive relay 30 or safety relay 40 has not opened after an elevator run.
[0015] Safety logic 50 may also be placed into a test mode so that test signals may be applied to the safety logic 50 , and the resultant output signal monitored. FIG. 1 depicts test signals 70 applied to safety logic 50 . The output of the safety logic 50 can then be checked to ensure proper operation. This may be performed periodically (e.g., once a year) as part of an inspection process.
[0016] FIG. 2 depicts a drive unit 100 including the safety circuit 10 of FIG. 1 in an exemplary embodiment. Drive unit 100 includes a power board 102 and a control board 104 . Power board 102 includes drive 14 that controls a converter 106 . Converter 106 includes switches that convert DC power from battery 108 to AC power to drive motor 16 in motoring mode. Conversely, converter 106 converts AC power from motor 16 to DC power to charge battery 108 in regenerative mode.
[0017] Safety circuit 10 is located on control board 104 . Brake relay 20 , drive relay 30 and safety relay 40 are represented as a safety chain on control board 104 . Safety logic 50 is also positioned on control board 104 , along with couplers 26 and 36 . Brake relay contact 22 , drive relay contact 32 , and safety relay contacts 42 , 44 and 46 are also on control board 104 . As described above with reference to FIG. 1 , safety logic 50 uses the brake relay monitoring signal, drive relay monitoring signal and safety relay monitoring signal to enable and disable operation of the drive unit 100 .
[0018] Several advantages are provided by using relays other than forced guided relays. Brake relay 20 and drive relay 30 are smaller in physical size than safety relay 40 , reducing the overall size of the safety circuit 10 , as compared to safety circuits employing all forced guided relays. Brake relay 20 and drive relay 30 may be surface mount devices. Further, the cost of safety circuit 10 is reduced, as compared to using all forced guided relays.
[0019] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. While the description of the present invention has been presented for purposes of illustration and description, it is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications, variations, alterations, substitutions, or equivalent arrangement not hereto described will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. Additionally, while the various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as being limited by the foregoing description, but is only limited by the scope of the appended claims. Features shown with one embodiment may be used with any other embodiment even if not described with the other embodiments. | An elevator safety circuit includes a plurality of relays; safety logic for monitoring status of the plurality of relays, the safety logic generating an output signal in response to the status of the plurality of relays; and a processor controlling operation of an elevator drive in response to the output signal; wherein at least one of the relays is a forced guided relay and at least one of the relays is other than a forced guided relay. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
In patent application Ser. No. 401,954 which has issued as U.S. Pat. No. 3,884,370 for "System for Sorting and Processing Articles Including Flat Mail Pieces" by Robert S. Bradshaw et al, there is described a system which may be used to sort and process mail pieces known as flats which cannot be processed on letter mail equipment. Mechanical carriers are used to support the flats during the processing cycle. A monorail conveyor distribution system provides transport, storage, and switching of the carriers. The present diverter gate may be advantageously utilized in conjunction with the conveyor and carriers of the patented system. The aforementioned patent is assigned to the same assignee as the present application.
BACKGROUND OF THE INVENTION
As illustrated and described in the reference patent, the carriers which support the items being processed are generally transported on straight runs by a horizontal timing belt. They may however, be directed to a desired destination by gating onto a vertical belt which provides turns in a horizontal plane, and then returned to another horizontal belt. In this arrangement, the vertical elevation of the vertical belt with respect to that of the horizontal belt must be carefully controlled. For example, in a gated transfer from a horizontal to a vertical belt, the vertical belt must approach the transfer area at a vertical elevation less than that of the horizontal belt, but within the transfer area assume an elevation which equals and then surpasses the elevation of the horizontal belt. The horizontal displacement of the two belts in the transfer area is an important design consideration.
While the gating arrangements described hereinbefore are highly satisfactory in an actual operative environment, it should be noted that current emphasis on energy saving techinques and design simplicity have prompted interest in systems which substitute, wherever possible, gravity force for powered transport. The diverter gate of the present invention falls within the scope of such a system.
SUMMARY OF THE INVENTION
In accordance with the present invention, a gate is provided for use in an item transport system wherever gravity may be successfully utilized in the conveyance of the items being processed. It should be noted that the gating and switching techniques taught in the reference patent and mentioned hereinbefore may also be used in the same system. It is therefore assumed that the carrier will be compatible for either powered or gravity movement.
In operation, the carrier is transported by a belt having its surface in a horizontal plane. This horizontal belt runs in a "U" channel in which one edge of the channel serves as a guide rail to retain the carrier on the belt. The gate of the present invention substitutes a flexible element for a portion of the guide rail, and positions the element in substantial alignment with the remainder of the rail. The carrier head is designed to envelop the rail. Attached to the gate element is a bar which is capable of limited rotation about a pivot. Means are provided for selectively causing rotation of the bar about the pivot. This results in a deflection of one end of the gate member about its mounting point.
If the gate is in a non-diverting position, the carrier moves past the gate and is unaffected thereby. However, if the gate is in a diverting position, the carrier is caused to move sideways on the plane of the horizontal belt for a given distance, while the carrier head is permitted to remain in driving contact with the belt. Subsequently, the carrier head pivots about the horizontal belt and the carrier drops onto the inclined portion of the gate. At the end of the latter portion, an inclined rail or like means provides a gravity path for the carrier to transport it to its destination. The gate is returned to its non-diverting position as soon as the carrier has moved off of its inclined portion. It is to be noted that the entire gating operation is accomplished with minimum design complexity and high reliability.
Other features and advantages of the present invention will become apparent in the detailed description appearing hereinafter.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of the present gate shown in a non-diverting position.
FIG. 2 is a section view taken along lines 2--2 of FIG. 1 illustrating the relationship of a carrier, such as that disclosed in the reference patent, to the horizontal timing belt and the gate of FIG. 1.
FIG. 3 illustrates the tooth-like structures on the underside of the carrier head.
FIG. 4 depicts in plan view, the present gate in a diverting position.
FIG. 5 is a front elevation of the diverter gate illustrating specifically the inclined portion thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The structure and mode of operation of the present gate are best appreciated by considering the non-diverting and diverting gate positions. The former is shown in FIG. 1; the latter, in FIG. 4.
In the plan view of the gate 10 in FIG. 1, there is shown a portion of a horizontal timing belt 12 carried in a "U" channel 14, the latter having at least one edge which serves as a guide rail 16. A carrier 18, has its head portion 20 positioned on the surface of the moving belt 12 and enveloping the guide rail 16. In the desired transfer or gating area, the guide rail 16 is absent. The gate 10 comprises a flexible member 22 which occupies the transfer area and in the non-diverting mode is substantially coplanar with the vertical portions of the guide rails 16 appearing on either side thereof. One end of the flexible member 22 is fixed in relation to rail 16, such as at point 15 in FIG. 1, where it is assumed that a portion of the member has been bonded to the rail. Attached to the member 22 is one end of a bar 24 which is capable of limited rotation about a pivot 26. The extremities of a link 28 are pivotally connected to the respective opposite end of bar 24 and to the plunger 30 of a solenoid 32.
The top edge of member 22 is collinear with the top of the guide rail 16 for a distance "x", beyond which the gate member has a portion 22a which is inclined to the horizontal by a predetermined angle. This is clearly shown in FIG. 5. Although in the non-diverting gate position of FIG. 1, no guide means are present for the length of the inclined portion 22a, the distance is relatively short and friction forces prevent carrier 18 from slipping off the belt 12.
In the non-diverting position of FIG. 1, the carrier 18 is depicted as being transported on the powered moving flat belt 12 in the direction of arrow 34 and approaching the gate 10. The solenoid 32 is not energized and its plunger 30 is extended in the direction of the arrow 36, thereby permitting the gate member 22 to reside in substantial alignment with the guide rail 16. The gate member thus appears to the carrier 18 as an extension of the rail 16, and belt 12 drives the carrier past the gate to its destination.
Before proceeding with a description of the energized condition of solenoid 32 and the establishment of the diverting condition, as seen in FIG. 4, it is believed helpful to examine briefly the structure of the carrier 18. It should be observed that the particular carrier configuration described herein has been chosen solely for purposes for illustrating the gate operation and is not limitative of the invention. Moreover, a detailed description of the carrier and its relationship to both horizontally and vertically oriented belts may be found in the referenced patent.
With reference to FIG. 2, the carrier 18 is comprised of a T-shaped head section 20, which may be assymetrical as shown in the drawing, and a lower clamping section 38. The head section 20 and the lower clamping section 38 are connected to each other by hanger 45. The lower clamping section 38 is comprised of a moveable jaw 40 adapted to pivot at point 42 and to contact an item, such as a document (not shown), positioned adjacent a stationary jaw 44. Jaw 40 is attached to a moveable member 46 by a link 48. A compressed spring 50 normally pushes upward against the upper portion of member 46, causing jaw 40 to rotate about point 42 in a direction to grasp the document being transported. Release of the document when required is effected by downward pressure upon the upper portion of member 46 in opposition to the spring force. The latter causes jaw 40 to pivot away from stationary jaw 44.
With continued reference to FIG. 2, and additional reference to FIG. 3 which depicts the underside of the carrier head 20, the carrier is shown being transported on belt 12, disposed in a channel 14 and having a guide rail 16. The underside of the carrier head 20 comprises along the long portion thereof, tooth sections 52 adapted to mesh with the teeth in horizontal belt 12. Along the short portion of carrier head 20, tooth sections 54 appear. While the latter sections do not play a specific role in the operation of the diverter gate of the present invention, they are adapted to engage the teeth in a vertically disposed belt to implement a powered turn. This operation, mentioned briefly hereinbefore, is described fully in the reference patent.
FIG. 4 depicts in plan view, the gate 10 in a diverting position. It is again assumed that the carrier 18 is being transported in the direction of arrow 34 by belt 12 and has not yet reached the gate 10. It is further assumed that the carrier is to be removed from belt 12 and directed to an alternate gravity controlled path. A signal is sent to solenoid 32 by means, not illustrated, to cause the energization thereof. This signal may be initiated by an operator or may be derived automatically by a device which senses the need for carrier gating. In either event, the energization of solenoid 32, causes its plunger 30 to be retracted in the direction of arrow 36. Link 28 is drawn in the same direction as plunger 36, causing bar 24 to rotate about pivot 26. The flexible member 22 of the gate is deflected like a cantilever beam and rotates outward, away from the guide rail 16, making an angle α therewith. In an actual embodiment α is approximately fifteen degrees. The rotation of gate member 22 is completed prior to the carrier 18 arriving at the gate.
With continued reference to FIG. 4 and additional reference to FIG. 5, as the carrier 18 contacts the gate member 22, it is moved sideways on the plane of the drive belt 12 for a distance "x". This permits the carrier head 20 to move partially off the drive belt 12, but to still remain in driving contact with it. At this point, additional driving from the belt 12, not only drives the carrier head sideways, but allows the carrier to drop onto the inclined portion 22a of gate member 22. It is apparent that in order for the carrier to drop onto the incline, the carrier head must pivot about the belt 12. This results from the driving motion of the belt, coupled with the kinetic energy of the carrier. The incline, represented by the angle β, may be of the order of ten degrees, although the actual angle will be dictated by system conditions, including the material of which the gate member is made. The ten degree incline assumes a material having a low coefficient of friction. Materials such as UHMW-Polymer, NYLATRON and ZYTEL are a few of many materials which possess low friction coefficients and also, the ability to be flexed for a large number of cycles without damage or fatigue. The gate member 22 may also be made of metal, but the higher coefficient of friction associated with the metallic surface, requires that the inclined portion 22a of the gate be designed to provide a steeper incline, that is, a larger angle β. An inclined wire or rail 56 mates with the inclined portion 22a of the active gate member 22. The surface 58 (FIGS. 2 and 3) under the carrier head 20 lying between the sets of tooth sections 52 and 54, initially contacts the inclined portion 22a of gate member 22 and subsequently rail 56 as the carrier slides downward, maintaining nevertheless, its substantial vertical alignment. It is apparent that the tooth sections 52, surface 58 under the carrier head, and hanger 45/moveable member 46 cooperate in forming a trough or groove across the lower surface of carrier head 20. The radius of curvature which may be assumed by the flexible gate member 22 when it is in a diverting position is directly proportional to the length of the last mentioned groove and the thickness of the material of which the gate member 22 is made, and is inversely proportional to the width of the groove. Depending upon system requirements, the rail 56 may assume a variety of configurations, for example, the paths provided for the carrier may be straight, curved to the right or left, or spiraled.
Immediately after the carrier has moved off the inclined portion 22a of the gate, the solenoid 32 is deenergized. A return spring 60 causes the gate member 22 and the associated linkages to assume the positions illustrated in FIG. 1.
The diverter gate of the present invention has general utility in the referenced flat sorting system. One application for which it is suited involves the return of the empty carriers to a plurality of induction stations as they are needed to initiate a new sort cycle. Thus, the empty carriers circulating on a powered belt may be selectively diverted to the induction stations. The absence of a carrier in the station may be sensed, such as by photocell means, and a signal sent to a gate solenoid to divert the next available carrier to that station.
In conclusion, it is submitted that the diverter gate described herein offers an economical and reliable means of increasing the flexibility and overall economy of a conveyor system of the type described and claimed in the referenced patent. Changes and modifications of the gate may be needed to fit particular requirements. Such variations as are within the skill of the mechanical designer, and which do not depart from the true scope and spirit of the invention are intended to be covered by the following claims. | The present disclosure describes an improved gate for selectively diverting item-supporting carriers from a transport path on a powered conveyor to their ultimate destination via an alternate path. More specifically, the gate finds application in a mail-handling system which requires the routing of carriers during the processing operation. In this regard, selected carriers may be diverted from the conveyor belts on which they are being transported onto a gravity turn effected by the gate itself, and then permitted to continue unaided to their destination by means of an inclined rail or similar structure. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to the field of in-vivo implants for biomedical applications. More specifically, the present invention provides a means for obtaining permanent atraumatic access to otherwise inaccessible biological tissues which are protected or covered by hardened bone structures. This invention allows cancellous bone and marrow as well as organs surrounded by hardened cortical bone to be accessed repeatably from the same site with minimal surgical trauma and morbidity.
BACKGROUND
In the field of bone and mineral research, it is important to be able to access metabolic tissue for the purpose of diagnosis or determining the pathogenesis of disease and efficacy of treatment. Access to osseous tissue is complicated by traumatic surgical intervention. Therefore, previously available data from hard tissue samples has been susceptible to wide variance due to the adverse impacts of surgical procedures and sampling instrumentation.
An effective bone sampling instrument must be capable of removing a sample without undue alteration of the morphology of the tissue. Further, the apparatus must be biocompatible, evoking no foreign body responses while it is implanted in the bone tissue. In addition, bone-implant interference and chemical adhesions must be of such a nature that the apparatus becomes a permanent fixture in the bone.
The required level of fixation or integration has been demonstrated with materials such as commercially pure titanium, titanium alloys, and titanium coatings. Titanium has the advantages of high strength, light weight, machinability and biocompatible corrosion behavior. U.S. Pat. No. 4,330,891 issued to Branemark is directed to a method for forming a titanium oxide material which is inert when placed in bone. Prior investigations both in the United States and abroad indicate that implants of titanium in bone become osseointegrated within weeks or months. Titanium and titanium alloys have been used for constructing oral prostheses, cardiac pacemaker housings, and fasteners for reconstructive surgery.
To date, there has been no teaching in the prior art of an effective apparatus for removing a sample of living bone tissue without undue destruction of the bone morphology. The analytic bone implant device of the present invention, as described in greater detail hereinbelow, overcomes the difficulties related to prior bone sampling techniques by providing a means for a permanent atraumatic access to otherwise inaccessible biological tissues. Tissues of interest include cancellous bone and marrow, cells, and physiologic fluids.
SUMMARY OF THE INVENTION
The Analytic Bone Implant (ABI) of the present invention provides a means for obtaining a significant sample of cancellous tissue for histologic and morphometric analysis. This bone implant device provides samples of cancellous bone and access to the medullary space. The provision for repeated accesses to the medullary compartment of bone is a significant and unique feature of the ABI.
Briefly, the Analytic Bone Implant of the present invention comprises a generally cylindrical housing having a predetermined length and an inner chamber for collecting the sample of bone tissue. The outer surface of the housing is provided with a plurality of threads for securing the ABI into bone tissue. The housing is further provided with a plurality of openings to allow bone tissue to grow into a collecting means in the interior of the housing for subsequent removal. In the preferred embodiment of the ABI, the access ports comprise arched slots in the housing which are alignable with complementary arched slots in a basket assembly. The arched slots on the basket assembly are provided with sharp edges which serve as cutting blades to facilitate the removal of the bone sample. In an alternate embodiment, the access ports are a plurality of generally circular apertures in a spaced geometric pattern in the housing.
In the preferred embodiment, the collection means is in the form of a generally cylindrical basket assembly which is received in the interior of the housing. In the alternate embodiment of the invention, the collection means is a "cup" assembly which is defined by a disk having a diameter approximately the same as the interior of the implant housing. The disk is secured in the housing by a shaft which is attached to the cap of the implant. When the cap of the implant is removed, the disk is pulled though the housing to force the tissue sample out of the inner chamber of the housing.
The various embodiments of the Analytic Bone Implant of the present invention provide at least ten novel features and advantages over the sampling devices of the prior art. First, access trauma is minimized because the cap of the chamber can be accessed by a small surgical incision. Second, bone access ports allow communication between the core of the device and the medullary space for the transmission of mechanical stresses and physiologic substances. Third, chamber volume can be varied to optimize bone growth. Fourth, the housing protects the bone sample and facilitates bone removal. Fifth, the inner volume provides a large sample for histomorphometric studies and could accommodate small devices or drug deliver systems. Sixth, bone marrow access is provided once the cap and the core are removed. Seventh, sampling is facilitated by a cutting blade which engages during cap removal shearing the bone at the internal aspect of the access ports. Eighth, small size which allows implantation in a variety of species and sites. Ninth, biocompatibility which is achieved by the use of titanium or titanium alloy with a clean and sterile surface. Tenth, tissue may be obtained for in vitro studies, including isolation of bone cell populations and osteotropic factors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevated perspective view of the analytic bone implant of the present invention.
FIG. 2 is a cross-sectional view of the analytic bone implant of the present invention in-situ in a portion of bone tissue.
FIG. 3a is a cross-sectional side view of the housing of preferred embodiment of the analytic bone implant showing the geometric placement of the bone access slots.
FIG. 3b is a top view of the housing of the preferred embodiment showing the placement of the insertion slots therein.
FIG. 4a is an elevational side view of the tissue sampling basket with cutters of the preferred embodiment of the analytic bone implant.
FIG. 4b is a top view of the tissue sampling basket of the preferred embodiment of the analytic bone implant.
FIG. 5a is an elevational side view of the cap with mandrel of the analytic bone implant.
FIG. 5b is an elevational top view of the cap with mandrel of the analytic bone implant.
FIG. 6a is a elevational side view of the alternate embodiment of analytic bone implant housing showing details relating to the placement of bone access ports therein.
FIG. 6b is a top view of the alternate embodiment of analytic bone implant housing showing the geometric placement of the bone access ports and insertion slots.
FIG. 7a is an cross-sectional side view of the cap of the alternate embodiment of analytic bone implant housing.
FIG. 7b is a top view of the cap of the alternate embodiment of analytic bone implant housing.
FIG. 7c is a side view of the cap of the alternate embodiment of the analytic bone implant housing.
FIG. 8a is an elevational side view of the alternate embodiment of tissue sampling cup of the analytic bone implant.
FIG. 8b is an top view of the alternate embodiment of tissue sampling cup of the analytic bone implant.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in more detail, and to the elevational perspective view of FIG. 1 in particular, a conceptual illustration of the Analytic Bone Implant 10 (hereinafter sometimes called "ABI") of the present invention is shown. The implant is broadly comprised of a housing 12, a cap assembly 14, and a removable insert assembly (sample collecting means), described in greater detail below. The housing serves as a mount and achieves this function through osseointegration or fixation in the surrounding bone tissue. Specifically, the housing 12 is formed of an appropriate titanium alloy, discussed below, that has biocompatiblity properties which facilitate the growth of bone tissues into the threads 16 in the outer surface of the housing 12. The housing 12 is provided with a plurality of access ports, illustrated generally by reference number 15, which provide a path for growth of bone tissue into the collecting means in the interior of the housing.
Referring to the cross-sectional view of FIG. 2, a conceptual view is shown of the ABI embedded in a portion of bone 11. The ABI is positioned in the bone such that the access cap 14 is external to the bone and the periosteum, but below the epidermis. The threads 16 of the housing 12 are tightly held in the surrounding bone tissue. In the position shown in FIG. 2, the upper threads of the housing are embedded in cortical bone 11a, while the lower threads are embedded in medullary tissue 11b. The ABI has a length of approximately eight millimeters and a diameter of approximately eight millimeters.
The cross-sectional side view of FIG. 2 depicts a generalized conceptual embodiment of the ABI insert assembly and is shown for the purposes of illustration only. However, this figure shows many of the features of the alternate embodiment of the present invention and thus it will be described briefly to aid in the understanding of the invention. Briefly, the collecting means of this embodiment is an insert assembly which includes a vertical shaft 20 having a threaded portion 22 which is received in a threaded central bore 22 in the cap 14 of the ABI. The lower end of the shaft 20 is attached to a disk 24 having an outer diameter approximately equal to the inner diameter of the housing 12. Bone tissue grows into the inner chamber 26 of the ABI via a plurality of openings 15 in the housing 12. In addition, in the embodiment of the ABI shown in FIG. 2, bone tissue enters the chamber 26 also via a plurality of apertures 28 in the lower disk 24. The volume of the chamber 26 can be varied by inserting various combinations of collars into the inner chamber 26, for example, the collars 30 and 32 shown in FIG. 2.
In order to understand the advantages offered by the present invention, it is important to have a general understanding of bone growth kinetics. When the ABI inserted into a site in the patient's bone, an "injury" condition is created. The injury created by the insertion of the implant is similar to that of an uncomplicated fracture site. Healing of the site is a continuous process involving three phases: (1) organization of thrombus; (2) procallous to callous or fibrocartilage formation; and (3) formation of osseous callous and remodeling. There are concurrent histologic, ultrastructural, systemic responses and biochemical events at the healing site. The bone that ultimately forms in the ABI chamber is identical to that which results from stimulation of osseogenesis under a variety of conditions in humans. Qualitative and quantitative data on the status of the bone-healing process can be acquired by analyzing samples from the ABI chamber. Once new bone is sampled from the chamber, a fresh endosseous wound (fracture) site is created and the healing process is restarted.
Details relating to the housing of the preferred embodiment of the ABI can be seen by referring to FIGS. 3a and 3b. In the embodiment shown in FIG. 3a, the housing 12a comprises a plurality of arch-like slots 40 which provide a path for bone growth into a sampling chamber on the interior of the housing 12a. Each of the slots 40 is provided with a cutting edge which aids in the removal of an undamaged sample of bone tissue. Referring to FIG. 3b, it can be seen that the preferred embodiment of the housing contains a total of four arch-like slots 40, although the exact number of slots can be varied depending on the specific application of the implant. The four slots of the preferred embodiment are placed at 90 degree intervals around the perimeter of the housing.
The outer surface of the housing 12a is provided with a plurality of threads 16, FIG. 3a, for securing the housing in bone tissue. The lower edge 17a of the housing is tapered and the lower threads are tapered also to provide a means for self-tapping insertion of the ABI housing into the sampling site. The upper portion of the housing is provided with a slot 42a for receiving an insertion tool which is used to rotate the housing to cause the threads to engage the bone tissue. To place the ABI into the bone it is necessary to first create a bore having a coarsely threaded inner surface. This can be accomplished through the use of any number of commonly available medical threading devices which are well known in the art. Once this coarsely threaded bore has been established, the ABI housing can be threaded into the bore by inserting an appropriate tool into the slot 42a in the upper portion of the housing and turning the housing to cause the threads 16 on the outer surface to engage the coarse threads on the inner surface of the insertion site. After the housing has been threaded into the bore, bone tissue will migrate into the threads 16 to secure the housing more firmly.
A tissue sampling basket 46 of the preferred embodiment is illustrated in FIGS. 4a and 4b. The outer diameter of the sampling basket is chosen to allow the basket to be received within the housing 12a, FIG. 3a. As can be seen in FIG. 4a, the basket 46 is provided with a plurality of arch-like slots 40a which are alignable with the slots 40 in the housing 12a of FIG. 3a. Furthermore, each of the slots 40a is provided with cutting edges which cooperate with the edges of the slots 40 in the housing 12a to cut the sample of bone tissue when the sampling basket is removed from the housing. The lower portion of the basket 46 is provided with a plate 47, FIG. 4b, having a threaded aperture 48 which is adapted to receive complimentary threads 52 on the lower end of the shaft 54 of a cap 14a, shown in FIG. 5a.
Referring now to FIGS. 5a and 5b, the cap 14a also has a threaded portion 56 which is engagable with threads 44 in the inner surface of the housing 12a, shown in FIG. 3a, to secure the cap and basket assembly within the housing. The threads of the aperture 52 and the threads 56 on the cap 14a have opposite inclines so that the basket 46, FIG. 4a, is turned by the cap 14a to perform the cutting off of the bone sample when the cap is removed from the housing.
Details relating to a housing 12b of an alternate embodiment of the ABI can be seen by referring to FIGS. 6a and 6b. The housing 12b has many of the features discussed above in connection with the housing of the preferred embodiment. However, bone access in the alternate embodiment is provided by a plurality of apertures 41 which are in a spaced geometric pattern in the housing. In the alternate embodiment of the ABI a total of twelve apertures are used to provide a path for bone migration into the inner chamber of the housing. The upper portion of the housing 12b is provided with a slot 48b which is adapted to receive an appropriate tool, as discussed above in connection with the preferred embodiment.
FIG. 7a is a cross-sectional view of the assembled ABI of the alternate embodiment. As discussed above, the collecting means of this embodiment is an insert assembly which includes a vertical shaft 20 having a threaded portion 21 which is received in a threaded central bore 22 in a cap 14b. The lower end of the shaft 20 is attached to a disk 24 having an outer diameter approximately equal to the inner diameter of the housing 12b, FIG. 6a. Bone tissue grows into the inner chamber 26 of the ABI via the plurality of apertures 41 in the housing 12b. In addition, bone tissue enters the chamber 26 via a plurality of apertures 28 in the lower disk 24, also seen in FIG. 8b. The volume of the chamber 26 can be varied by inserting various combinations of collars into the inner chamber 26, for example, the collars 30 and 32 shown in FIG. 7a.
The housings of both embodiments are designed with sufficient surface area to promote tissue-device adhesion while allowing bone, cells, vessels and other tissues to enter the devices' core through apertures or slots in the housing. The cap serves several purposes: (1) access to the core of the device, (2) fixation mount for core assembly, and (3) prevention of connective tissue encroachment into the ABI chamber. In all applications, the insert allows removal of tissues from the ABI chamber.
Once the bone has grown into the ABI chamber, removal of the cap facilitates sample removal. In the preferred embodiment of the ABI, the act of unscrewing and removing the cap will shear the tissue entering the chamber through the entry ports providing a structurally intact sample of consistent volume. When the insert-cap assembly is disassembled, a cylinder of bone with a hole down its longitudinal axis can be removed. The tissue sample obtained from the preferred embodiment of the ABI is approximately 0.01 cubic inches.
Although the Analytic Bone Implant of the present invention has been described in connection with its preferred embodiment, it is not intended to be limited to the specific forms set forth herein, but, on the contrary, it is intended to cover such modifications, alternatives and equivalents as can reasonably be included within the scope and spirit of the invention as defined by the appended claims. | A analytic bone implant includes a cylindrical housing with an inner chamber designed for collecting sample of bone tissues. The outer surface of the housing is provided with a plurality of threads for securing the implant into bone tissue. The housing is further provided with a plurality of openings to allow new bone tissue to grow into a collecting basket. The openings in the housing are alignable with complementary openings in the basket. The openings on the basket are provided with sharp edges which serve as cutting blades to facilitate the removal of the bone sample. The implant includes provision for repeated access to the medullary compartment for obtaining sample of cancellous tissue for histologic and morphometric analysis. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority pursuant to 35 U.S.C. 119(e) to U.S. Provisional Application No. 60/871472 filed 19 Jan. 2007, which application is incorporated herein by reference in its entirety including incorporated material.
RELATED PATENTS AND APPLICATIONS
[0002] U.S. Pat. No. 5,907,404 by Marron, et al. entitled “Multiple wavelength image plane interferometry” issued May 25, 1999;
[0003] U.S. Pat. No. 5,926,277 by Marron, et al. entitled “Method and apparatus for three-dimensional imaging using laser illumination interferometry” issued Jul. 20, 1999;
[0004] U.S. patent application Ser. No. 10/893,052 filed Jul. 16, 2004 entitled “Object imaging system using changing frequency interferometry method” by Michael Mater;
[0005] U.S. patent application Ser. No. 10/349,651 filed Jan. 23, 2003 entitled “Interferometry method based on changing frequency” by Michael Mater;
[0006] U.S. patent application Ser. No. 11/181,664 filed Jul. 14, 2005 by inventors Jon Nisper, Mike Mater, Alex Klooster, Zhenhua Huang entitled “A method of combining holograms”;
[0007] U.S. patent application Ser. No. 11/194,097 filed Jul. 29, 2005 by inventor Mike Mater et. al entitled “Method for processing multiwavelength interferometric imaging data”.
[0008] U.S. patent application Ser. No. 11/194,092 filed Jul. 29, 2005 by inventor Mike Mater et. al entitled “A statistical method of generating a synthetic hologram from measured data”.
[0009] U.S. patent application Ser. No. 11/194,103 filed Jul. 29, 2005 by inventor Michel Mater et. al entitled “Method for processing multiwavelength interferometric imaging data”.
[0010] A U.S. patent application Ser. No. 11/301,320 entitled “Optical fiber delivered reference beam for interferometric imaging” filed Dec. 12, 2005.
[0011] A U.S. patent application Ser. No. 11/299,548 entitled “Optical fiber delivered reference beam for interferometric imaging” filed Dec. 12, 2005.
[0012] A U.S. patent provisional application 60/868,120 filed Dec. 1, 2006.
[0013] A U.S. patent provisional application 60/868,547 filed Dec. 5, 2006.
[0014] A U.S. patent provisional application 60/868,734 filed Dec. 6, 2006.
[0015] A U.S. patent provisional application 60/946772 filed 6 Jul. 2007.
[0016] A U.S. patent provisional application 60/946610 filed 12 Jul., 2007.
[0017] A U.S. patent provisional application 60946629 filed 27 Jun., 2007.
[0018] The above identified patents and patent applications are assigned to the assignee of the present invention and are incorporated herein by reference in their entirety including incorporated material.
FIELD OF THE INVENTION
[0019] The field of the invention is the field of vibration isolation and stabilization of mechanically supported objects.
OBJECTS OF THE INVENTION
[0020] It is an object of the invention to produce a stabilized vibration isolation platform which does not roll or pitch if additional weight is added to or removed from the platform.
SUMMARY OF THE INVENTION
[0021] In a first embodiment, a plurality of tension elements is attached to a platform, wherein each of the plurality of tension elements such as cables pulls the platform in approximately the same direction as the gravitational pull on the platform. The platform is supported against the pull of gravity and the tension of the cables by one or more non-rigid or compliant supports such as pressurized pistons, air bags, or elastomeric elements which change dimensions to support more or less force from the platform as weight is added to the platform. Each tension element is attached at one point to a tension producing device pulling at the tension elements, so that the tension producing device produces a tension force equal to the sum of the tensions forces of the plurality of tension elements. In a second embodiment, a torsion device transfers vertical force from one part of the platform to another to keep the table from pitching or rolling as the load on the table is changed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a sketch of an embodiment of the invention.
[0023] FIG. 2 is a sketch of an embodiment of the invention.
[0024] FIG. 3 is a sketch of an embodiment of the invention.
[0025] FIG. 4 is a sketch of plan view of an embodiment of the invention shown in FIG. 3 .
[0026] FIG. 5 is a sketch of an embodiment of the invention.
[0027] FIG. 6 is a sketch of plan view of an embodiment of the invention shown in FIG. 5 .
[0028] FIG. 7 is a sketch of an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] It is common to mount sensitive optical and other equipment on vibration isolation tables to isolate the equipment from vibrations transmitted through the ground or the base of the table, or to damp out vibrations transmitted through the air to the equipment.
[0030] Vibration isolation tables are effective at damping out high frequency vibrations, but low frequency vibrations are often reduced by mounting the table on air pistons, so that air pressure in the pistons holds the table up, and low frequency vibrations are not transmitted effectively through the air.
[0031] The pistons are usually attached to a source of pressurized air, and a feedback mechanism is used to discharge or introduce air out and into the piston. When a weight is added to the table, the table will pitch and/or roll and the feedback system adjusts the air pressures to bring back the table to the set position. The set position is usually to have the table surface level, but this is not necessary for the operation of the present invention.
[0032] Unfortunately, the time taken for the stabilization of the system is of the order of tens of seconds. For measurements which must be made on objects which are added and then removed from the table, and which must be made in tens of seconds, this time is too long. The present invention shows a number of embodiments which stabilize the table in pitch and roll, and control “rocking” motions which affect heavy optical or other apparatus mounted with center of gravity high above the table. The vertical motion of the table is not restricted, and the table moves vertically as weight is added or subtracted.
[0033] FIG. 1 shows a sketch of a preferred embodiment of the invention. A stabilized vibration isolation platform 10 is supported against gravity by one or more supports 11 . In the most preferred embodiments of the invention, the mounts are pistons filled with a gas such as compressed air, but could be pistons filled with any compressible fluid in fluid communication with a device to set and regulate pressure. In other embodiments, the supports 11 are elastomeric elements, compressible fluid filled elements or other elements for which force supporting the platform is changed as weight is added or subtracted from the table and the dimensions of the element change. The platform is attached by cables 12 at points 13 . Tension is applied to the cables by attaching the cables to or near to the same point 14 of a tension producing device 15 . In FIG. 1 , a weight is shown providing the tension. The tension forces transmitted through the cables 12 are changed in direction by pulleys 16 . The angle formed by the two cables 12 at attachment point 14 is exaggerated in FIG. 1 for clarity, and the respective pulleys 16 should be as close together as possible. A turnbuckle 17 is used to adjust the relative lengths of the cables to change the relative tension in cables ensure, for example, that the platform 10 is level.
[0034] In operation, the platform is set to a particular position by adjusting the supports 11 and/or the turnbuckle 17 . When a weight is added off center to the platform, the added weight depresses the support 11 on one side of the platform and reduces the tension of one of the cables 12 . The entire tension from the tension producing device 15 is now transmitted to the other of cables 12 , and the increased tension depresses the other side of the platform against the other support 11 , so the platform sinks and the relative heights of the attachment points 13 changes little, so that the table 10 remains level.
[0035] In a feedback mode, the air pressure in supports 11 will be changed to increase the pressure, and move the platform back to its original position. If supports 11 are elastomeric elements, the increased weight will compress the elements until the added weight is compensated, and the platform motion will stop with the platform at a lower position than the original position. In both cases, the tensions in the cables 12 will be different from the original tensions, but the tensions in each cable will sum to the force produced by the tension producing device 15 .
[0036] A preferred device 15 of the invention is a spring 25 attached between the cables 15 and a stable point such as the floor, the ground, or a base 18 , as shown in FIG. 2 .
[0037] Other preferred embodiments of the invention include a pneumatically operated piston 35 which is controlled to adjust the height of the platform 10 .
[0038] In all cases, the supports 11 supporting the platform must offer sufficient support for the weight of the platform and the weights which the platform will carry, as well as the tension forces of the cable 12 . Clearly, the pressure in supports 11 can be different, as can the tensions in cables 12 , and the balance of the support forces and the tension forces can be set to adjust the position of the platform within wide limits.
[0039] In the prior art, a number three or more of supports 11 would normally be used to support the platform. A feedback mechanism would normally be used to raise and lower pressure in each support until each support drives the table to a predetermined height at the position of the support, so that the entire table is level. Note that controllers, feedback electronics, and separate valves for each support are needed. In the present invention, a single support 70 is sufficient, as is shown by FIG. 7 . The level of the platform 10 is then determined only by the balance of tensions in the cables 12 . In addition, if a number of supports 11 are used, a single air supply can feed each support, so the air pressure in each piston is equal, and the differing tensions in the cables 12 compensate for the differing weight distributions of the objects loaded on the table. The cost of the cables and pulleys and weights or torsion bars is expected to be less that the costs of the extra apparatus needed in the prior art.
[0040] While cables are shown as the tension elements in FIGS. 1-3 , other tension elements such as chains, short segments of rod, etc, are anticipated by the inventors as parts of a system to transmit tensile forces to the platform 10 .
[0041] In addition, vibration damping elements (not shown) may be added to the various springs, weights, pistons, and supports.
[0042] While FIGS. 1-3 show a side elevation of a platform with two cables which stabilize the platform from rotating about one axis parallel to the top of the platform, addition of a third cable will provide stabilizing the platform about a second axis parallel to the top of the platform, as is shown in FIG. 4 . Obviously, more than 3 cables may be provided for more control and security.
[0043] FIGS. 5 and 6 show the most preferred embodiment of the invention. A torsion bar 50 runs through torsion bar supports 52 to an arm 60 , which connects in turn to a member 54 attached to the table 10 . Devices 56 such as ball joints which allow member 54 to rotate slightly with respect to table 10 , and bearings 58 , ensure that the vertical motion of the table pressing down one member 54 is smoothly transmitted to the other member 54 to pull down the table by an equal amount, so that the table remains level.
[0044] While FIGS. 5 and 6 show for simplicity only one torsion bar for stabilizing the table in one rotational axis, clearly a second torsion bar can be added at an angle to the first to ensure that the table remains level whenever a load is placed.
[0045] In the preferred embodiments of the invention, the table 10 floats freely on the supports 11 , and low frequency vibrations are not transmitted from the ground or from the base 18 to the ground. As objects are loaded or unloaded from the table 10 , that table may move vertically, but is prevented from rolling or pitching. (Yaw is a rotation around the vertical axis, and is not treated herein.) Limiting means (not shown) may be used to limit the vertical excursion of the table so that the table may return quickly to the equilibrium height as one weight is replaced by an equal weight. Alternatively, or in addition, the feedback system regulating the air pressure in the support members 11 may be turned off as the weights are removed and replaced, so that the table returns quickly to the equilibrium position.
[0046] 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, the invention may be practiced otherwise than as specifically described. | A vibration isolation platform having supports such as air pistons to damp out low frequency vibrations is equipped with a means for restricting pitch and roll motion as the weight distribution is changed and the vibration isolation platform exhibits vertical motion. The preferred means for restricting are torsion bars and tension means which transfer force from one part of the platform to the other. | 5 |
RELATED APPLICATION
This is a nonprovisional application claiming the priority benefit of provisional application Ser. No. 61/213,359, filed Jun. 2, 2009, hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention is generally directed to warning devices and particularly to warning devices to scare or divert birds away from structures subject to bird collision such as overhead power lines, guy wires, etc.
SUMMARY OF THE INVENTION
The present invention provides a diverter for diverting birds away from overhead lines, comprising a plastic plate substrate having an upper portion and a lower portion. The upper portion is narrower than the lower portion such that its center of gravity is lower. The substrate includes a central portion and triangular-shaped left and right edge portions. The triangular portions are narrow to wide from top to bottom. The central portion includes an opening at an upper portion thereof for attachment to a ring. The central portion includes front and rear flat surfaces each having an upper area and a lower area. One of the front flat surface upper and lower areas includes a first fluorescent retroreflective sheet. One of the rear flat surface upper and lower areas includes a second fluorescent retroreflective sheet. The first and second fluorescent retroreflective sheets having respective contrasting colors. Another one of the front flat surface upper and lower areas and another one of the rear flat surface upper and lower areas includes a luminescent material.
The substrate is preferably trapezoidal-shaped for a lowered center of gravity. It has a central portion which is substantially rectangular. The luminescent material may be embedded within the substrate. The luminescent material is preferably a sheeting material adhesively attached to lower portions of the front and rear surfaces. The fluorescent orange retroreflective sheet and the fluorescent yellow-green retroreflective sheet are preferably adhesively attached to the substrate. The triangular edge portions are turned at an angle relative to the plane of the substrate in the same direction. The angle is preferably about 45°. The fluorescent orange retroreflective sheet occupies substantially one-half of the front surface. The fluorescent yellow-green retroreflective sheet occupies substantially one-half of the rear surface. The luminescent material is preferably a sheet that occupies substantially one-half of the front or rear surfaces. The several sheets are substantially rectangular. The opening has a wall having with a crown to minimize friction with the attaching ring, thereby affording greater looseness and movement to the substrate in the wind. The substrate is attached to a ring through the opening and a swivel is attached to the ring to allow vertical rotation of the substrate. The first fluorescent retroreflective sheet is orange and the second fluorescent retroreflective sheet is yellow-green.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a diverter made in accordance with the present invention.
FIG. 2 is a perspective view of the diverter shown in FIG. 1 .
FIG. 3 is a front elevational view of the diverter shown in FIG. 2 .
FIG. 4 is a cross-sectional view taken along line 4 - 4 in FIG. 3 .
FIG. 5 is a bottom end view of FIG. 3 .
FIG. 6 is a perspective view of another embodiment of a diverter made in accordance with the present invention.
FIG. 7 is an enlarged detail A showing a crown in the opening.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of a diverter 2 made in accordance with the present invention is disclosed in FIG. 1 . The diverter 2 is attached to an overhead power line 4 through a conventional clamp 6 and a standard swivel assembly 8 . The diverter 2 uses light through reflectance and refraction, and motion through rotation, oscillation and vibration to divert birds away from the power line and other structures on which birds typically perch or against which birds may collide.
The diverted 2 is made of a rigid plastic plate substrate 3 , such as acrylic translucent plastic, preferably ultraviolet light (u.v.) resistant to withstand typical outdoor environment. The translucent plastic absorbs stray light in low light conditions and will not break down under natural sunlight exposure. This type of plastic advantageously magnifies and enhances the fluorescent material that is applied to the surface of the substrate, as will be discussed below.
The substrate 3 is preferably substantially trapezoidal-shaped, as shown in FIGS. 2 and 3 , for a lowered center of gravity. Opposing triangular-shaped left and right edge portions 10 and 12 act as wings to increase rotation and improve aerodynamics of the diverter 2 in the wind. The left and right edge portions 10 and 12 are narrower at the top and wider at the bottom. The edge portions 12 and 10 are turned in the same direction relative to the plane of the substrate central portion 14 , as shown in FIG. 5 , at an angle 20 , preferably at about 45°. Wind tunnel testing has shown that the diverter 2 begins rotation and vibration during periods of 3-5 mph wind in the outside environment. The trapezoidal shape makes the substrate 3 narrower at the top and wider at the bottom to advantageously lower the center of gravity of the diverter 2 . A lower center of gravity allows the diverter 2 to maintain its vertical orientation for greater visibility to the birds.
The substrate 3 central portion 14 is substantially rectangular with front and rear flat surfaces 16 and 18 , as shown in FIGS. 4 and 5 . Fluorescent sheeting materials 22 and 24 , preferably rectangular, are adhesively attached to the upper front and rear upper surfaces 16 and 18 , as shown in FIGS. 3 and 4 . The sheeting materials 22 and 24 advantageously refract and reflect ambient light to make the diverter 2 visible to the birds. Since the substrate 3 is translucent, light can enter within the plastic material and emerge out through the sheeting materials 22 and 24 to help brighten the fluorescent colors. The sheeting materials 22 and 24 each occupies substantially one-half of the respective front and rear surfaces 16 and 18 .
Birds utilize refracted light in their feathers for communication and courtship display (e.g. iridescent colors in peacock feathers are refracted light not pigments in the feather structure). The diverter 2 refracts natural sunlight similar to the sunlight refracting from the bird's own feathers. This makes the diverter 2 a man-made feather in reality. Birds can see the diverter 2 and will not sit within about 25 foot radius when the u.v. index is greater than 2.0 (as calculated by the EPA for each city in the USA) and the diverter 2 is rotating or vibrating in the wind.
The sheeting material 22 is preferably fluorescent orange that refracts natural and artificial light. Light is refracted light in the 590 nm range within the spectrum of visible white light. An example of this material is available from 3M, called Fluorescent Orange Prismatic Work Zone Sheeting, described in Product Bulletin 3924S (October 2007), herein incorporated by reference. The sheeting material 22 consists of prismatic lenses formed in a transparent resin, sealed and backed with a pressure-sensitive adhesive and poly liner. The sheeting material 22 is retroreflective. The sheeting material 22 provides the prism or rainbow effect that refracts the spectrum of white light to make the diverter 2 visible to the approaching bird.
The sheeting material 24 is preferably fluorescent yellow-green that refracts natural and artificial light. Light is refracted light in the 570 nm range within the spectrum of visible white light. This material is mounted on the opposite side of the orange material 22 on the substrate 3 . An example of this material is available from 3M called Diamond Grade™ Fluorescent VIP Reflective Sheeting, described in Product Bulletin 3980 (September 2005), herein incorporated by reference. The material is a visible-activated fluorescent wide angle prismatic lens reflective sheeting. The sheeting material 24 provides the prism or rainbow effect that refracts the spectrum of white light to make the diverter 2 visible to the approaching bird.
By mounting these different colors on both sides of the diverter 2 , the contrast of the colors during rotation, oscillation, and/or vibrations is enhanced to approaching birds and bats and thereby causing the wildlife to avoid collisions with wires and other man-made objects that have been marked with the diverter 2 . The sheeting materials 22 and 24 are advantageously mounted on the upper portions of the substrate 3 to place them closer to the wire 4 on to which the diverter 2 is attached. This location is effective in preventing the birds from perching on or near the clamp 6 and covering the sheeting materials with bird droppings.
Fluorescent orange and yellow-green reflective materials advantageously provide daylight (diurnal) peak color to the passing or roosting birds. Research on avian vision has shown that birds in general see 5 times the concentration of fluorescent color than humans. The translucent acrylic plastic substrate 3 enhances the visibility to marked wires to birds and bats during the low-light conditions found during sunrise and sunset periods.
The diverter 2 incorporates tetra chromatic avian vision properties found in bird feathers. Humans utilize only tri-chromatic vision—red, green, and blue colors. Birds utilize tetra (4) chromatic vision—red, green, blue, and ultra violet. Ultra-violet color is invisible to the human naked eye, but visible to birds which have UV rods and cones within their retinas. Humans have no such UV rods and cones. The fluorescent orange and yellow-green sheeting materials 22 and 24 reflect UV-A (long wave) and UV-B (shortwave) sunlight, causing the perching bird to remain at a hazing distance of about 25 feet from the diverter 2 .
Luminescent sheeting materials 26 and 28 , preferably rectangular, are adhesively attached to the lower front and rear upper surfaces 16 and 18 , as shown in FIGS. 3 and 4 . The sheeting materials 26 and 28 each occupies substantially one-half of the respective front and rear surfaces 16 and 18 . The sheeting materials 26 and 28 advantageously absorb UVA and UVB at 360 nm and below during the daytime and provides light (phosphorescence; glow in the dark) during the nighttime in the 540 nm range. An example of this material is available from 3M, called Luminous Film 6900, describe in Product Bulletin 6900 (June 2002), herein incorporated by reference. The sheeting materials have pressure-sensitive adhesive.
The phosphors in the sheeting materials 26 and 28 absorb UVA and UVB at 360 nm and reflect sunlight by the shiny crystalline structure of zinc sulfide used. Birds can see this as a violet color. This color is not visible to the human eye which cannot see below 400 nm of the visible spectrum of sunlight. The luminescent sheeting materials 26 and 28 are visible to both diurnal and nocturnal bird migration over the marked wires. The phosphorescence of the sheeting materials 26 and 28 advantageously extends visibility to 10-12 hours after sundown to the diverter-marked wires.
Glow crystals 30 , such as zinc sulfide and doped strontium aluminate, may be imbedded within the manufactured acrylic plastic substrate 3 , as shown in FIG. 6 , instead of being applied as a sheeting material on the surface of the substrate 3 . After sundown, the translucent acrylic plastic substrate 3 with the embedded glow crystals glows in the dark for 10-12 hours to alert passing birds of an obstruction ahead on the marked wire. The glow in the dark natural crystals absorb and emit purple ultraviolet light visible to the birds as violet but appears as white to humans.
The diverter 2 advantageously makes the wire look larger in diameter to the birds by means of the reflective peak colors during the day and emitting afterglow light in low light, fog, and night time.
The diverter 2 has an opening 32 through its upper end portion through a longitudinal centerline 34 which passes through the center of gravity. The opening 32 is preferably reinforced with raised ridge 35 for durability. The opening 32 is loosely attached to a ring 36 , which is loosely attached to a swivel 38 that allows 360 degree rotation in the vertical axis. The swivel 38 is further loosely attached to another ring 40 , which is loosely attached to the clamp 6 . The opening 32 has a crown 37 in the opening wall to minimize friction between the ring 36 and the opening wall, to promote looseness and freedom of movement of the substrate 3 in the wind.
The swivel 38 allows for rotation about the centerline 34 to give increased contrast to migrating birds and bats by the alternating patterns of yellow-green and orange fluorescent colors given by the sheeting materials 22 and 24 on the opposite sides of the substrate 3 . The triangular edge portions 10 and 12 are acted upon by the wind to rotate the diverter 2 like a bullet about the centerline 34 .
The loose interconnection of the diverter 2 to the clamp 6 allows for oscillation back and forth movement (wiggling action) in natural wind conditions, increasing visibility to migrating bats and birds approaching diverter-marked wires and structures. The diverter 2 wiggles back and forth about the rings 36 and 40 , flashing at approaching birds during windy days.
The diverter 2 when mounted by removable conventional spring-loaded clamp 6 on wires, such as power lines, tower guy wires, and other tensioned wires, vibrates to alert migrating birds and bats to wire collision hazards. The vibration comes from the natural vibration of power lines typically tensioned at 32 lbs per square inch. Research has shown that birds can see very small movement of objects at much greater extent than human beings.
The diverter 2 has been shown to cause a change in flight behavior when applied to power line and other wires suspended in the air. Approaching birds begin to change flight behavior up to ¼ of a mile from the diverter-marked wires, thereby avoiding collisions and injury or death to the birds.
The diverter can be safely applied to energized power line conductor wire up to 115 kV with no coronal emission problems or radio and TV interference. Materials used in the diverter are rated to withstand the natural elements for long periods of time without degradation, typically 5-10 years. The diverter provides visibility in both daylight (diurnal) and nighttime (nocturnal) light conditions. The diverter can be applied by electrical lineman crews on energized wires without having to turn off the power grid during marking of the wires. The diverter is several times more visible to migrating birds and bats, and the diverter can be spaced a greater distance compared to prior art devices, reducing time and cost of installation. Stainless steel material is utilized for all moving parts of the swivel assembly to make them resistant to rust and corrosion by the elements.
While this invention has been described as having preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims. | A diverter for diverting birds away from overhead lines includes a plastic plate substrate having an upper portion and a lower portion. The upper portion is narrower than the lower portion such that a center of gravity is lower. The substrate includes a central portion and triangular-shaped left and right edge portions. The triangular portions are narrow to wide from top to bottom. The central portion includes an opening at an upper portion thereof for attachment to a ring. The central portion includes front and rear flat surfaces each having an upper area and a lower area. One of the front flat surface upper and lower areas includes a first fluorescent retroreflective sheet. One of the rear flat surface upper and lower areas includes a second fluorescent retroreflective sheet. The first and second fluorescent retroreflective sheets having respective contrasting colors. Another one of the front flat surface upper and lower areas and another one of the rear flat surface upper and lower areas includes a luminescent material. | 0 |
TECHNICAL FIELD
The present invention relates to a method of producing 2-(isopropylamino)ethanol, which is a compound useful as a raw material for a drug, an agricultural chemical, or the like.
BACKGROUND ART
Known methods of producing 2-(isopropylamino) ethanol are as follows:
(1) a method involving allowing acetone to react with 2-aminoethanol and hydrogen at from 1 to 2 atm in the presence of a platinum oxide catalyst in ethanol to produce 2-(isopropylamino) ethanol (Non Patent Literature 1); and
(2) a method involving allowing acetone to react with a mixture of 2-aminoethanol and hydrogen at 4.5 MPa in the presence of a palladium-carbon catalyst in methanol to produce 2-(isopropylamino)ethanol (Patent Literature 1).
PRIOR ART DOCUMENTS
Patent Literature
[PTL 1] JP 2009-173553 A
Non Patent Literature
[NPL 1] Organic Syntheses, 1946, Vol. 26, p. 38
SUMMARY OF INVENTION
Technical Problem
As described above, there has been reported a method involving allowing acetone to react with 2-aminoethanol and hydrogen under increased pressure in the presence of a platinum oxide catalyst or palladium-carbon catalyst in an alcohol solvent to produce 2-(isopropylamino)ethanol. However, there has yet to be a report of a method involving subjecting acetone, 2-aminoethanol, and hydrogen to a vapor-phase catalytic reaction in the presence of a noble metal-containing catalyst to produce 2-(isopropylamino)ethanol. Accordingly, it has been desired to develop a method of industrially producing 2-(isopropylamino)ethanol with high efficiency through a vapor-phase catalytic reaction.
Solution to Problem
The inventor of the present invention has made intensive studies in view of such circumstances. As a result, the inventor has found that 2-(isopropylamino)ethanol is obtained with high efficiency by subjecting acetone, 2-aminoethanol, and hydrogen to a vapor-phase catalytic reaction in the presence of a noble metal-containing catalyst. Thus, the inventor has completed the present invention.
That is, the present invention relates to a method of producing 2-(isopropylamino)ethanol, including subjecting acetone, 2-aminoethanol, and hydrogen to a vapor-phase catalytic reaction in presence of a noble metal-containing catalyst.
Advantageous Effects of Invention
According to one embodiment of the present invention, 2-(isopropylamino)ethanol can be obtained in a large amount and with high efficiency through the vapor-phase catalytic reaction. Therefore, the method of the present invention is industrially useful as a method of producing 2-(isopropylamino)ethanol.
DESCRIPTION OF EMBODIMENTS
The present invention is described in detail below.
According to one embodiment of the present invention, there is provided a method of producing 2-(isopropylamino)ethanol, including subjecting acetone, 2-aminoethanol, and hydrogen to a vapor-phase catalytic reaction in the presence of a noble metal-containing catalyst.
A reaction temperature in the present invention is generally from 80 to 250° C., preferably from 100 to 150° C., more preferably from 125 to 135° C. The reaction is performed under normal pressure or under increased pressure. The mode of the reaction is not particularly limited. The reaction is performed in a fixed bed, a fluidized bed, or a moving bed, and any one of the batch and continuous modes may be adopted.
The amount of acetone to be used is generally 0.5 mol or more, preferably from 2 to 6 mol with respect to 1 mol of 2-aminoethanol.
Purchased 2-aminoethanol may be used as it is for the reaction, or an aqueous solution or organic solvent solution of 2-aminoethanol may be used. When the aqueous solution or organic solvent solution is used, its concentration is not particularly limited and may be appropriately determined depending on the scale of the reaction.
As the noble metal-containing catalyst, a known one may be used, and the noble metal-containing catalyst is preferably a catalyst containing one or more kinds of palladium, platinum, and ruthenium, more preferably a catalyst containing one or more kinds of palladium and platinum.
The noble metal-containing catalyst may contain an element other than those described above as a second component in addition to the noble metal. Examples of the element include rhenium, tellurium, bismuth, antimony, gallium, indium, sulfur, phosphorus, selenium, and germanium.
The noble metal-containing catalyst may be used by being supported on a support. The support may be any support that is generally used as a support for a catalyst. Specific examples of the support include alumina, silica, silica-alumina, silicon carbide, zirconium oxide, magnesium oxide, cerium oxide, titanium oxide, and various zeolites. Of those, alumina or silica is preferred, and alumina is particularly preferred. The support has a surface area of generally from 40 to 500 m 2 /g, preferably from 100 to 350 m 2 /g. The amount of the noble metal to be supported on the support is not particularly limited, but is generally from 0.5 to 5 wt %, preferably from 0.5 to 2 wt %, more preferably from 0.5 to 1 wt % with respect to the support.
Specific examples of the noble metal-containing catalyst include a platinum-alumina catalyst, a platinum-carbon catalyst, a platinum-black catalyst, a palladium-alumina catalyst, a palladium-carbon catalyst, a palladium-black catalyst, a ruthenium-alumina catalyst, a ruthenium-carbon catalyst, and a ruthenium-black catalyst. Preferred specific examples of the catalyst include a palladium-alumina catalyst and a platinum-alumina catalyst.
A method of preparing the noble metal-containing catalyst is not particularly limited. Examples of the method of preparing the noble metal-containing catalyst include a kneading method, an impregnation method, and a coprecipitation method. The shape of the noble metal-containing catalyst is, for example, a shape prepared by extrusion or by tableting into an arbitrary shape. In addition, the shaped noble metal-containing catalyst may be used after being fired under an atmosphere of an arbitrary gas such as nitrogen at from 150 to 500° C.
The noble metal-containing catalyst is preferably used for the reaction after being subjected to reduction treatment. A reducing agent to be used for the reduction treatment is not particularly limited, but is preferably hydrogen. A method of reducing the noble metal-containing catalyst is not particularly limited, but is preferably heat treatment under a hydrogen flow. The flow rate of hydrogen in the reduction treatment is generally SV=100 to 500/hr, preferably SV=200 to 400/hr. The hydrogen may be diluted with an inert gas such as nitrogen or argon. A temperature at which the reduction with hydrogen is performed is generally from 50 to 400° C., preferably from 100 to 150° C., more preferably from 125 to 135° C.
At the time of the reaction, it is preferred to flow hydrogen at the same time as 2-aminoethanol and acetone are flowed, because in this case, the yield of 2-(isopropylamino) ethanol is improved. The amount of hydrogen to be used in that case is generally from 1 to 20 mol, preferably from 5 to 12 mol with respect to 1 mol of 2-aminoethanol.
2-Aminoethanol and acetone are generally mixed before being introduced into a reactor. The space velocity of the mixture in the reactor is generally from 0.01 to 2 (g/cc-catalyst·h), preferably from 0.1 to 1 (g/cc-catalyst·h) in terms of liquid hourly space velocity (LHSV).
The reaction is performed in the presence or absence of a diluent. Any diluent may be used without any particular limitation as long as the diluent is inert to the reaction. Specific examples of the diluent that may be used include: an inert gas such as nitrogen or argon; an aliphatic hydrocarbon such as hexane, heptane, octane, nonane, decane, or undecane; and a halogenated aliphatic hydrocarbon such as dichloromethane or 1,2-dichloroethane. One kind of those diluents may be used alone, or two or more kinds thereof may be used as a mixture.
The 2-(isopropylamino) ethanol generated through the reaction may be collected by general means such as cooling of a reacted gas to be obtained or absorption of the reacted gas into water or a solvent after the completion of the reaction. The collected 2-(isopropylamino)ethanol may be isolated/purified by general purification means such as distillation.
EXAMPLES
Next, the present invention is specifically described by way of Examples. However, the present invention is by no means limited to Examples below. It should be noted that analysis by gas chromatography in Examples was performed under the following conditions.
Conditions for Gas Chromatography Analysis
Gas chromatograph: GC-2010 manufactured by Shimadzu Corporation
Column: manufactured by J&W Scientific Incorporated, HP-1, 50 m,
inner diameter: 0.32 mm, film thickness: 1.05 μm
Temperature: 50° C.→(10° C./min)→250° C.
In addition, the conversion rate and yield were calculated according to the following definitions.
Conversion rate (o)=reacted 2-aminoethanol (mol)/2-aminoethanol supplied for reaction (mol)×100
Yield (%)=produced 2-(isopropylamino)ethanol (mol)/2-aminoethanol supplied for reaction (mol)×100
Example 1
A reaction tube having an inner diameter of 20 mm was filled with 520 ml of 1 wt % palladium-alumina pellets (manufactured by N.E. CHEMCAT Corporation, cylindrical shape measuring 3.2 mm in diameter by 3 mm in height) as a catalyst, and was filled with a 100-cm length each of Carborundum on and below the catalyst. The reaction tube was heated to a temperature of from 128 to 132° C., and a mixture of hydrogen at 1 l/min and nitrogen at 1 l/min was flowed from an upper portion for 1 hour to perform pretreatment of the catalyst. After the completion of the pretreatment of the catalyst, a mixture of 2-aminoethanol, acetone, and hydrogen (mixing molar ratio: 2-aminoethanol:acetone:hydrogen=1:4:9) was flowed through the reaction tube at LHSV=0.5 g/cc-catalyst·hr (mixture of 2-aminoethanol and acetone) from an upper portion to perform a reaction at from 128 to 132° C. A reacted gas discharged from the reaction tube was absorbed into cooled water, and then the absorption liquid was analyzed by gas chromatography. Between 95 to 99 hours after the initiation of the reaction, the average conversion rate of 2-aminoethanol was 100% and the average yield of 2-(isopropylamino)ethanol (based on 2-aminoethanol) was 96.0%.
Example 2
A reaction was performed in the same manner as in Example 1 except that: 0.5 wt % platinum-alumina pellets (manufactured by N.E. CHEMCAT Corporation, cylindrical shape measuring 3.2 mm in diameter by 3 mm in height) were used as the catalyst; the molar ratio was set to 2-aminoethanol:acetone:hydrogen=1:3:9; and the LHSV was set to 0.58 g/cc-catalyst·hr (mixture of 2-aminoethanol and acetone). Between 77 to 93 hours after the initiation of the reaction, the average conversion rate of 2-aminoethanol was 100% and the average yield of 2-(isopropylamino)ethanol (based on 2-aminoethanol) was 95.7%.
Comparative Example 1
A reaction was performed in the same manner as in Example 1 except that copper oxide/zinc oxide Actisorb (trademark) 301 (manufactured by Süd-Chemie, extruded product having a diameter of 1.5 mm) was used as the catalyst. As a result, the yield of 2-(isopropylamino)ethanol was 5% or less.
Comparative Example 2
A reaction was performed in the same manner as in Example 1 except that γ-alumina (manufactured by Sumitomo Chemical Company, Limited, spherical shape having a diameter of from 2 to 4 mm) was used as the catalyst. As a result, the yield of 2-(isopropylamino)ethanol was 5% or less.
Comparative Example 3
A reaction was performed in the same manner as in Example 1 except that stabilized nickel (manufactured by JGC Catalysts and Chemicals Ltd., cylindrical shape measuring 2.8 mm in diameter by 2.8 mm in height) was used as the catalyst. As a result, the yield of 2-(isopropylamino)ethanol was 5% or less.
INDUSTRIAL APPLICABILITY
According to one embodiment of the present invention, 2-(isopropylamino)ethanol can be obtained in a large amount and with high efficiency by subjecting acetone, 2-aminoethanol, and hydrogen to a vapor-phase catalytic reaction in the presence of a noble metal-containing catalyst. | The present invention relates to a method of producing 2-(isopropylamino)ethanol, including subjecting acetone, 2-aminoethanol, and hydrogen to a vapor-phase catalytic reaction in the presence of a noble metal-containing catalyst. According to the present invention, 2-(isopropylamino)ethanol can be industrially obtained in a large amount and with high efficiency through the vapor-phase catalytic reaction of acetone, 2-aminoethanol, and hydrogen. 2-(Isopropylamino)ethanol is a compound useful as a raw material for a drug, an agricultural chemical, or the like. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application takes the benefit of the filing date of U.S. patent application Ser. No. 60/027,927, filed Oct. 9, 1996 and further is a continuation-in-part of copending U.S. patent application Ser. No. 08/555,598, filed on Nov. 9, 1995 now U.S. Pat. No. 5,749,419.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of this invention relates to techniques for well completions and more particularly to the use of plugs during underbalanced well completions.
2. Background of the Prior Art
One of the primary goals during drilling and completion operations of wells is to protect the producing formations from damaging effects associated with fluids lost into the formation during the drilling and completion operations. A secondary goal is to eliminate excessive losses of expensive drilling and completion fluids.
Most wells currently are completed conventionally using kill-weight fluids which might impair the formation. Even if a well is drilled underbalanced (formation pressure greater than wellbore pressure), the well typically is exposed to damaging fluids during completion operations. This process defeats the principle purpose of underbalanced drilling which is to avoid impairment of the formation.
In situations using prior art apparatus and techniques, particularly those involving deviated wellbores, the initial portion of the well is drilled and a casing is set. The casing is then cemented. After the cement sets, the deviated portion of the wellbore is drilled. Prior designs have involved running a liner string into the wellbore after completion of the drilling of the deviation in the wellbore beyond the cemented casing. An inflatable packer has been inserted through the liner string to isolate the formation while the bottomhole assembly is assembled into the wellbore above an inflatable bridge plug. Certain problems, however, have developed in particular applications with the use of through-tubing inflatable bridge plugs. For one thing, the ability of the through-tubing inflatables to hold particular differentials can be problematic, especially if there are irregularities in the sealing surface where the plug is inflated. Additionally, due to the compact design required in certain applications, the through-tubing inflatable element cannot expand far enough to reliably hold the necessary differential pressures that might exist across the inflated bridge plug. Finally, there could also be difficulties in retrieval of the through-tubing inflatable bridge plug back through the string from which it was delivered.
The flexible nature of the through-tubing inflatable design could also create problems if it was decided simply not to retrieve the plug after putting together the bottomhole assembly above it. The slender design of the through-tubing inflatable plug could create advancement problems if the plug were to be merely pushed to the bottom of the hole with the production tubing. If any washouts in the deviated portion of the wellbore were encountered by the bottomhole assembly with the deflated through-tubing plug at the front, then the entire assembly might get stuck prior to its being advanced to the bottom of the wellbore for proper positioning. Generally, the through-tubing designs have not provided a circulation passage therethrough to facilitate advancement of a deflated plug into the uncased portion of a wellbore using circulation.
To prevent formation damage and fluid loss and to maximize productivity of a well, the well needs to be drilled and completed underbalanced. The method and apparatus of the present invention address many of the problems associated with conventional completion techniques by providing a downhole tool such as an inflatable bridge plug which can be set at the desired location to isolate a portion of the wellbore. The tool is securely positioned to enable it to withstand substantial differentials. After the tool is positioned, the bottomhole assembly can be put together in the wellbore above the tool where the wellbore is isolated from the producing formation. The invention accomplishes the objective of removing the plugging device from the path by deactivating it and moving it within the wellbore. By carrying the plug with it within the wellbore, the deactivating apparatus gets the benefit of additional structural rigidity which allows it to advance to the bottom of the hole with less chance of hangups in washouts.
Other advantages of the apparatus and method include a physical support (anchor) for the plug to facilitate its being enveloped after it is deactivated. The design also facilities flow of circulation fluid through the deactivation tool and encapsulated plug as it is being moved to the bottom of the hole.
Another embodiment of the present invention is an inflatable swab valve that is installed as a part of the casing. During operation, the swab valve is inflated inwardly to seal the well. The seal is deactivated for later operations and downhole apparatus pass through the cavity formerly occupied by the inflated membranes of the swab valve.
SUMMARY OF THE INVENTION
A completion apparatus and method are illustrated that use a plug in the wellbore to isolate one section of a well from another, such as an open-hole section that has been drilled underbalanced, to safely hold back the formation without impairing it while completion or other equipment is run downhole. One embodiment of the plug works in conjunction with a deactivation tool which can be run on the bottom of a downhole apparatus such as a completion liner. This provides a method to run the downhole apparatus downhole without having to expose the formation to possibly damaging fluids. After the open-hole section is drilled, the plug is run in the hole on coiled tubing and set. Heavy fluids are then circulated above the plug without its being applied to the open-hole formation. The liner for the open-hole section is run in the well with a deflation tool, which ultimately engulfs the deflated plug using the mechanical support associated with the plug to facilitate the enveloping procedure. After envelopment, setdown weight releases the anchor for the plug and the assembly is run in the hole with circulation through the plug to facilitate advancement. A second embodiment of the invention is an inflatable swab valve that is installed in the casing and inflates inwardly to seal off the inside of the well. It can later be deflated to allow the passage of downhole apparatus through the casing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a plug of the present invention being positioned in the wellbore.
FIG. 2A is the plug of FIG. 1 after it has been set and activated in the wellbore.
FIG. 2B is the plug of FIG. 1 after it has been deactivated and engulfed by a deactivation tool.
FIG. 3 illustrates the plug of the present invention in use with a completion liner and deflation tool.
FIG. 4 illustrates the plug of FIG. 3 enveloped and pushed to the bottom of the open-hole portion of the wellbore.
FIGS. 5A-5D show the run-in position for the apparatus and method of the present invention in a sectional elevational view.
FIG. 6A-6D show the tool of FIG. 5, with the plug in the inflated position and the anchoring mechanism in a set position.
FIGS. 7A-7D illustrate the insertion of the deflation tool with the inflatable element in a deflated condition and prior to release of the anchor.
FIGS. 8A-8D are the view of FIGS. 7A-7D, illustrating the opening of the flowpath through the tool to allow circulation when the deflated tool is advanced toward the bottom of the open hole.
FIG. 9A-9D illustrate the release of the anchoring mechanism to allow the forward advance of the assembly with the deflation tool already having spanned over the deflated element as shown separately on FIGS. 8A-8D.
FIG. 10 is another embodiment showing release of the anchor assembly by moving the cone out from under the slip.
FIG. 11A is a side view of another preferred embodiment showing an inflatable swab valve.
FIG. 11B is a cross-sectional top view of the swab valve of FIG. 11A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As seen in FIG. 1, a wellbore W is depicted schematically having an upper cased section 10, which has a casing 11 cemented into place prior to drilling an open hole portion 12 of the wellbore W. In FIG. 1 and FIG. 2A-B, the open hole portion 12 is shown as deviated with respect to the cased section 10. Other configurations, however, are also within the purview of the present invention. Coiled tubing 14, with a running tool 16 at its lower end, is used to insert a plug P into the cased section 10 of the wellbore W, as shown in FIG. 1. While the preferred plug P is an inflatable bridge plug, other types of obstruction devices such as packers and swab valves, for example, are intended to be within the scope of the invention.
Upon the setting and activation of the plug P, as shown in FIG. 2A, the wellbore W is divided into two zones, an upper zone U and a lower zone L.
FIG. 2B illustrates the plug P after it has been deactivated and engulfed by a deactivation tool D which has been run downhole on coiled tubing 14. The plug P contains a body 188, an inflatable element 86 and an anchoring mechanism 123 which are described below.
FIG. 3 illustrates the plug P in its activated position within the wellbore W. With the plug P activated, other apparatus, such as a completion liner 18 which is also shown in FIG. 3, can be run in the hole without having to kill the well. This avoids the possibility of formation damage due to kill fluids. It should be noted that typically these types of wells have been drilled in an underbalanced state where the wellbore pressure is less than the formation pressure. This is a common technique, particularly with coiled tubing drilling. As shown in FIG. 2A and FIG. 3, the coiled tubing 14 shown in FIG. 1 has been removed and the upper zone U of the wellbore W at this time can be circulated with heavy fluid (not shown) wherein the pressure from that fluid is not applied to the well or lower portion L of the wellbore W due to the presence of plug P in an inflated condition.
FIG. 2B ill shows the plug P in a deflated condition and engulfed by the deflation tool 20, with the entire completion liner 18 (liner assembly) advanced into the open-hole 12 or lower zone L of the wellbore W. The liner assembly 18 attached above the deflation tool 20 does not constitute a portion of this invention and can be any one of a number of different bottomhole configurations for liners being advanced into a wellbore. It is the details of the plug P and the deactivation tool D and how they interact to accomplish the advancement illustrated in FIG. 4 which will be described in FIG. 5(A-D) through FIG. 9(A-D).
FIG. 5(A-D) is a detailed diagram of the running tool 16 which is used in combination with the plug P. The plug P has a latch mandrel 22 (FIG. 5A) which is initially secured to the running tool 16 by virtue of a shear pin 24 extending through a piston 26. One or more collets 28 are part of the running tool 16. The piston 26 has a surface 30 which traps the collets 28 into a groove 32 in the latch mandrel 22. The running tool 16 has a ball sleeve 34 which holds a spring-loaded flapper valve 36 open in the run-in position. Also shown in FIG. 5A is a ball 38 which can engage the ball sleeve 34 in the event emergency release is required as will be explained below. Normal release of the running tool 16 from the latch mandrel 22 occurs through a port 40. Access to the port 40 is through an inlet 42 which is not blocked by the ball 38 if the ball 38 is to be used and landed against the ball sleeve 34. Pressure is built up in a cavity 44 which is sealed by seals 46, 48 and 50. Seals 48 and 50 are on the piston 26.
The latch mandrel 22 and the rest of the components which make up the plug P, as will be described below, have a variety of flowpaths therethrough. After the running tool 16 and the plug P are run into the wellbore W, as shown in FIG. 1 and 5A-5D, and positioned within the cased section 10 of the wellbore W, the plug P is inflated. This is accomplished by applying hydraulic pressure through an actuation flowpath 52 which communicates with a passage 54, as shown in FIGS. 5A-5B. The passage 54 extends longitudinally through a crossover 56. A separate, transverse circulation flowpath 58 provides access into the longitudinal extending portion of a circulation flowpath 60. The crossover 56 separates flowpaths 52 and 60.
As shown in FIG. 5D, the flowpath 60 is initially obstructed with a stopper 62, which is secured by a shear pin 64 to an inner sleeve assembly 66. The inner sleeve assembly 66 is made up of several components, one of which is a connector 68 (FIG. 5B). The connector 68 has a series of transverse openings 70 which provide flow communication to an annular space 72 as shown in FIG. 6B. During the run-in position, shown in FIG. 5A-D, fluid pressure without the presence of the ball 38 is directed against the crossover 56 and then through the longitudinal flowpath 54 and ultimately into the annular space 72, which in turn communicates with openings 70. Fluid pressure through the openings 70 ultimately goes through openings 74 (FIG. 5B) where a poppet 76 is pushed against a spring 78. When a predetermined pressure has been exceeded and the poppet 76 is displaced, flow can proceed through openings 80 and through an annular passage 82. The poppet design is known in the art as a way to retain inflation pressure. The annular passage 82 communicates with a port 84 to allow inflation of the element 86 to take place by increasing the pressure and hence the volume of a cavity 88 (FIG. 6C). The poppet 76 has inner and outer seals 90 and 92 (FIG. 5B) which effectively prevent bypass flow around the poppet 76 until the poppet 76 is moved sufficiently to compress the spring 78 in response to flow of pressure where the outer seal 92 clears contact with a sleeve 94. The sleeve 94 is part of the outer portion of the body 188 of the plug P as shown in FIG. 5B. The sleeve 94 also has the transverse circulation flowpath 58 extending therethrough. It should be noted that seals 96 and 98 help separate the circulation flowpath 58 from the passage 54 which ultimately continues into the annular space 72. Seals 100 and 102 also help separate the annular flowpath 72 from the annular passage 82.
As the internal pressure in actuation flowpath 52 builds up, a cavity 104 (FIG. 6D), which is in fluid communication with the annular passage 82, also experiences a pressure buildup. The cavity 104 communicates with a cavity 106 through a port 108. In the run-in position shown in FIG. 5D, a shear pin 110 secures a ring 112 to a nose 114. The ring 112 is connected to a slip assembly 116. The slip assembly 116 includes a series of slips 118 with rough edges 120 which bite into the inside surface of the casing 11 of the cased portion 10 of the wellbore W, as shown in FIG. 6D. This is accomplished by using a cone 122 (FIG. 5D) with a sloping surface 124. The nose 114 is connected to an inner sleeve 126 which has a tooth pattern 128 on an outer side 127. The slip assembly 116 has a similar tooth pattern 130 with a different orientation. In between is a lock ring 132, which allows the slip assembly 116 to advance up or away from the nose 114 in response to a build up in pressure in the cavity 106, which ultimately breaks the shear pin 110. While the slips 118 are being set, the cone 122 is held to the sleeve 126 by a shear pin 165. The shear pin 165 ultimately is broken when it is time to release the set slips 118 as will be explained below. The structure of the slips 118 and the related structure around the cone 122 comprise the anchoring mechanism 123 for the plug P. The element 86 (FIG. 6B) is the sealing mechanism which isolates the upper zone U from the lower zone L, as shown in FIG. 2A, upon inflation.
At this point, the significant components in running and setting and releasing from the running tool 16 have been described. The sequence of events will now be reviewed to fully understand the operation of the plug P. As previously stated, coiled tubing 14 (FIG. 1) is used to run in the plug P in combination with the running tool 16. When the plug P is positioned in the desired location in the cased section 10 of the wellbore W, pressure is applied through the coiled tubing 14 and the running tool 16 into flowpath 52 (FIG. 6A). Eventually the pressure builds up to the point where the poppet 76 (FIG. 6B) is displaced against the spring 78. When that occurs, a flowpath is established from the passage 54 through the crossover 56 into the annular space 72, through openings 70 and 74, around the poppet 76, and through openings 80 into the annular passage 82. The element 86 is inflated through the port 84 against the casing 11, by increasing the volume of the cavity 88. Ultimately, additional pressure builds up to break the shear pin 110 (FIG. 5D). At that time the slip assembly 116 advances over the cone 122 and locks into position via the lock ring 132, as shown in FIG. 6D. With the element 86 set (FIG. 6B) and the slips 118 (FIG. 6D) secured against the cased portion 10 of the wellbore W, the pressure continues to build until the shear pin 24 (FIG. 5A) breaks. When that occurs, the piston 26, which is part of the running tool 16, moves downwardly, thus removing support for the collets 28. An upward pull on the coiled tubing 14 (FIG. 1), which is attached to a housing 136 (FIG. 5A), brings up the running tool 16, leaving behind only the latch mandrel 22 which is part of the body 188 of the plug P (shown in FIG. 6A). It should b-loaded flapper 36, which then springs downwardly as shown in FIG. 6A. In effect, the flowpath 52 is closed when the spring-loaded flapper 36 goes into its closed position, as shown in FIG. 6A. If for any reason the element 86 (FIG. 6B-6C) suffers a failure which could prevent pressure buildup to a sufficient level in the flowpath 52 to allow the running tool 16 to release from the latch mandrel 22, then the ball 38 (FIG. 5A) can be dropped to completely close off the flowpath 52 while leaving access through the inlet 42 to build pressure against the piston 26 for a release of the running tool 16 from the latch mandrel 22 in the manner previously described. It should also be noted that the inflated state of the element 86 (FIG. 6B-6C) is secured via the spring 78, which recloses the poppet 76 when the pressure is reduced in the coiled tubing 14 (FIG. 1). This occurs when the running tool 16 disengages from the latch mandrel 22. The pressure reduction seen in the flowpath 52 then allows the spring 78 to bias the poppet 76 back to the position shown in FIG. 6B to ensure the retention of the inflation pressure in the cavity 88 (FIG. 6C).
The lock ring 132, in effect, holds the slips 118 firmly against the cone 122, as shown in FIG. 6D. The plug P is now set and operations as illustrated previously in FIG. 3 can now take place without killing the well.
The liner assembly 18 with the deflation tool 20 is run into position in the wellbore W as shown in FIG. 3 and FIG. 4. FIGS. 7A-7D illustrate the preferred deflation tool 20. The bottom of a liner 18 could also be configured to act as a deflation tool 20. The deflation tool 20 comprises an elongated sleeve 138 (FIG. 7A) with a lock ring 140 adjacent to the upper end of the sleeve 138. The lock ring 140 operates on a similar principal as the lock ring 132 (explained above) when the lock ring 140 ultimately engages a serrated surface 142 (FIG. 7B) on an upper deflation sleeve 144. The upper deflation sleeve 144 is connected to a lower deflation sleeve 146, which in turn is secured to the sleeve 138 of the deflation tool 20 by a shear pin 148. The upper deflation sleeve 144 has a taper 150, which ultimately engages a taper 152 on a sleeve 94. As the assembly of the sleeve 138 with the upper sleeve 144 and the lower sleeve 146 is advanced over the latch mandrel 22 (FIG. 7A), the lower sleeve 146 eventually contacts an outer sleeve 154 (FIG. 5B). The outer sleeve 154 sealingly spans over openings 156, using seals 155 and 157, and is initially held in that position by a shear pin 158. When the lower deflation sleeve 146 strikes over the sleeve 154, as shown in FIG. 7B, it breaks the shear pin 158, making the sleeve 154 translate downwardly. The pressure in the cavity 88 (FIG. 6C), which is holding the element 86 (FIG. 6B-6C) against the cased portion 10 of the wellbore W, can now be vented out through openings 84, back into the annular passage 82, back through openings 80 and out through openings 156. Accordingly, FIG. 7C shows the element 86 in the deflated condition with the slips 118 (FIG. 7D) still set. The lower deflation sleeve 146 now becomes trapped against the sleeve 94 due to a split ring 180 (FIG. 7B), as will be described below. Slips 118 remain set to support the body 188 of the plug P for the subsequent operations as will be described.
After deflation of the element 86 the next operation is to move the deflation tool 20 over the deflated element 86 with the tubularly shaped sleeve 138. To do this, weight is set down from the surface which ultimately breaks the shear pin 148 (FIG. 7B). When the shear pin 148 breaks, the sleeve 138 can advance as shown in comparison between FIG. 7B and 8B. A ring 160 sits at the bottom of the sleeve 138 and has a taper 162 which ultimately bottoms on a taper 164 as shown in FIG. 8C. Once the tapers 162 and 164 have made contact, weight can be applied to the sleeve 126 (FIG. 8D) through the sleeve 138. Application of weight to the sleeve 126 allows the shear pin 165 to break. When the shear pin 165 breaks, a spring 166 supported by a ring 168 drives the cone 122 upwardly, as shown by comparing the cone position in FIG. 8D with 9D. In FIG. 9D, the spring 166 has expanded, thus pulling the cone 122 out from under the slips 118. While this is happening, a shoulder 170 on sleeve 126 contacts a shoulder 172 on the slip assembly 116. Accordingly, setting down weight with tapers 162 and 164 in contact break the shear pin 165, to allow the spring 166 to pull the cone 122 out from under the slips 118, while at the same time downward movement of the sleeve 126 brings shoulders 170 and 172 together which pushes the slips 118 out from over the cone 122. The end result is that there is a release of the slips 118 to allow fuller progress of the liner assembly 18 such as is illustrated in FIG. 3, with the deflation tool 20 to carry the plug P forward to the bottom of the hole as shown in FIG. 4.
The deactivation tool D is bottomed on a guide ring. However, slacking off weight to release the anchor might not be available due to the use of a smaller workstring (like coiled tubing) used for releasing. FIG. 10 shows the preferred arrangement for use with a coiled tubing workstring. A latch 173 on the bottom of the deflation tool 20 engages a profile 175 on the top end of the cone assembly. Applying tension to the workstring after the latching as shown in FIG. 10 will now shear the screws in the cone, releasing the anchor slip. A body lock ring 177 can be added in the cone assembly to prevent any downward movement of the cone after release. After defeating the anchor, the assembly can be run into the openhole section.
To facilitate the advancement of the liner assembly 18 with the plug P, fluid pressure is applied through the deflation tool 20, which ultimately, through the flowpath 58, communicates with the plug P through the flowpath 60 as shown in FIG. 8B. Seals 174 and 176 facilitate the application of fluid pressure through the completion liner assembly 18 and the deflation tool 20 all the way down to the stopper 62 which is in the nose 114. Ultimately, the shear pin 64 (FIG. 6D) breaks and the stopper 62 is displaced beyond openings 178, which are generally oriented laterally of the rounded nose segment 114. Thus with the displacement of the stopper 62, the entire assembly 199 (FIG. 4) (the downhole tool 20 and the deflated plug P) can be advanced to the bottom of the uncased wellbore in the lower zone L with fluid circulation through openings 178. The rounded pr W during advancement of the assembly 199 downhole.
What has now been described is the tube or sleeve 138 advancing over the deflated element 86, with weight being set down to release the slips 118. However, prior to the release of the slips 118, it is important for the deflation tool 20 to grip the body 188 of the plug P so that when the slips 118 are released, the plug P is retained by the deflation tool 20 and does not drop downhole. To accomplish this, the split ring 180 (FIG. 7B) is supported between the upper deflation ring 144 and the lower deflation ring 146 as the deflation tool 20 is advanced. The split ring 180, which has internal teeth 182, is spread over the sleeve 94, which itself has a series of jagged teeth 184. As the sleeve 138 is advanced, the split ring 180 is forced open and into engaging contact with the sleeve 94 based on the interaction between teeth 182 and teeth 184. At this time the split ring 180 locks the deflation tool 20 to sleeve 94 because the split ring 180 cannot move up and it thereby traps the lower deflation sleeve 146. Ultimately, when the sleeve 138 of the deflation tool 20 is advanced forward after the shear pin 148 is broken, the lock ring 140 at the top of the sleeve 138 engages the serrated surface 142 on the upper deflation ring 144, and the position of the sleeve 138 shown in FIG. 8B is now fully locked in. When the split ring 180 effectively locks the lower deflation sleeve 146 to the sleeve 94, the operator at the surface knows that the element 86 should have deflated due to the displacement of outer sleeve 154. At that time the weight can be set down to move the sleeve 138 over the now-deflated element 86 and ultimately lock the sleeve 138 into position with the lock ring 140.
As shown in FIG. 6C, there is a vent port 186 toward the lower end of the element 86. The vent port 186 is in fluid communication with the annular passage 82 such that when the outer sleeve 154 is pushed over, thus exposing openings 156 (FIG. 6B), the element 86 can deflate by venting pressure at its upper end through ports 84 as well as through the lower end through openings or ports 186. This helps to ensure that the element 86 is fully deflated with minimal trapped fluid due to elimination of pockets so that the sleeve 138 of the deflation tool 20 can move over element 86 smoothly without snagging.
As shown in FIG. 8B, the split ring 180 secures the assembly of the upper deflation sleeve 144 and the lower deflation sleeve 146 to the sleeve 94, such that when pressure is applied through the flowpath 58 to displace the stopper 62 (FIG. 8D), the deflation tool 20 is firmly anchored to the plug P. As previously stated, the position of the sleeve 138 when it washes over the element 86 is secured to the serrated surface 142 on the upper deflation sleeve 144. With the sleeve 138 secured through the use of the lock ring 140, the overall structure gains significantly in rigidity. For example, the sleeve 138 can be made of 7"casing while the body 188 of the plug P can be in the order of 27/8" which is considerably more flexible. The additional strength delivered by moving down the sleeve 138 prevents sag in the assembly over its length. The more rigid the assembly (the completion liner 18 in combination with the deflation tool 20 spanning over plug P, as shown in FIG. 4), the less likely it is that the entire assembly upon advancement downhole will sink into washed out sections in the uncased portions of the wellbore W. FIG. 4 illustrates an area of washout 190 in the uncased portion of the wellbore W. When washouts occur and an attempt is made to advance the assembly as shown in FIG. 4, the lack of longitudinal rigidity causes the front end to sag into the washed out portion. If the leading end of the liner assembly 18 is too flexible, it can easily be caught in the washout 190. To reduce this possibility, the nose 114 is rounded to help it over or out of small washouts. It is more important, however, that the additional structural rigidity (created in the assembly after the sleeve 138 is brought over the deflated element 86) ensures that the sag is kept to a minimum and that the assembly can advance, even over a washed out segment, by merely keeping true to its line of travel without sagging into washouts in the uncased portions of the wellbore W. The structure is akin to a cantilevered beam which can sag at its free end if it is not sufficiently rigid.
The assembly of the slips 118, as previously described, provides additional support of the plug P when the element 86 is inflated. Additionally, it provides continuing support for the body 188 of the plug P when the element 86 is deflated. This additional continuing support after deflation helps to make it possible to advance the sleeve 138 over the deflated element 86 to increase the longitudinal rigidity and thus minimize sag in the assembly upon subsequent advancement. The design also features a flowpath all the way to the nose 114 through outlets 178 so that circulation can be maintained while the assemblies advance as shown in FIG. 4. Circulation while advancing facilitates the advancement of the assembly to the position shown in FIG. 4.
Proper deflation of the element 86 is more likely in view of the vent ports 84 (FIG. 6B) and 186 (FIG. 6C) at the upper and lower ends of the cavity 88, respectively. With the deflation occurring through ports 84 and 186, the likelihood of trapped fluid within the cavity 88 when outer sleeve 154 is displaced is greatly reduced. That means the sleeve 138 can then more dependably go over the deflated element 86 at a time when the element is fully deflated and will not impede the progress of the advancing sleeve 138.
The spring-loaded flapper 36 covers over the passage 52 after removal of the running tool 16, as shown in FIG. 7A. In that position, pressure directed through the completion liner assembly 18, when fully latched to the plug P as shown in FIGS. 8A-8B, will force any pressure through the flowpath 58 for initially breaking loose the stopper 62, thus clearing the flowpath 178 and the nose 114. With the spring loaded valve 36 in the closed position, the passage 54 (FIG. 8B) is closed off so that applied pressure within the completion liner assembly 18 cannot communicate with the flowpath 52 or the passage 54.
When the completion liner assembly 18 is advanced to the position shown in FIG. 4, production in the known manner can begin from the uncased portion of the wellbore W.
While the preferred embodiment comprises the sleeve 138 coming over the plug P, stiffening the plug P or other downhole tool in other ways is a part of the invention. The sleeve 138 can be of differing construction and can cover all or part of the plug P. The plug P can be stiffened after deflation by adding rigidity to its body, internally as opposed to externally, using the sleeve 138 or by other equivalent techniques.
A second preferred embodiment the sealing device 250 is shown in FIG. 11A-11B. This device 250 includes an internally inflatable seal member (swab or plug) 200 and an anchor mechanism 202. The device 250 may be designed to be fitted into the casing before it is deployed in the wellbore to form the cased section or retrievabley installed in an existing wellbore as described below. FIGS. 11A-11B show the device 250 installed in the casing 11. The swab valve or plug 200 is fitted into the casing 11 before the casing 11 is positioned within the wellbore W to form the cased section 10, as shown in the partial cross-sectional side view of FIG. 11A. The plug 200 has an outer sleeve 202 which is the anchoring mechanism 123 that holds the valve 200 in position within the wellbore W and the conduit for the transmission of inflating medium (not shown), such as hydraulic oil or wellbore fluid. The outer sleeve 202 is attached to an inner sleeve 204 having an inflation port and check valve 206 that provides a passageway between the outer sleeve 202 and a flexible element 208 fitted to the inside of the inner sleeve 204.
The purpose of the element 208 is to seal the upper zone U of the wellbore W from the lower zone L similar to the element 86 of the inflatable bridge plug P described above, although the operation is different. The swab valve has a through opening 205 which is sufficiently large to allow the passage therethrough of the desired completion string. Instead of having a single element that expands outwardly to form a seal as described above, the inflatable swab valve 200 has two or more inflatable membranes 210 which expand from the inside of the inner sleeve 204 towards the center of the swab valve 200 or the wellbore axis.
As pressure is applied to the inflatable membranes 210 via the valve 206, the membranes 210 expand to fill the inside area 205 of the swab valve 200, as shown in FIG. 11B. The membranes 210 urge against each other at a juncture or intersection 214 along the length d of the flexible member 208. This however leaves axial areas 220a and 220b through which fluid may leak between the upper (U) and lower (L) wellbore sections. Compliant spacers or seal guides 218a and 218b having suitable sealing profiles and preferably made from a stiff material such as steel are disposed along the length of segments 218a and 218b respectively. When the membranes 210 are expanded or inflated, they sealingly urge against each other along the intersection 214 and also against each the compliant spacers 220a and 220b, thereby completely sealing the upper (U) and lower (L) sections of the wellbore W. After obtaining the desired seal, the pressure is locked in place, effectively sealing the wellbore W into the desired upper and lower zones U and L, respectively. Pressure can then be applied using an inflation tool (not shown) run in to the bore of the tool (not shown) or, alternatively, via a control line run down the outside of the coiled tubing 14 above the tool. Other methods could also be used to control the tool. Ribs 212, as shown in FIG. 11A, could be fitted within the inner sleeve 204 of the inflatable swab valve 200 to operate with the membranes 210 to provide additional strength to the membranes 210 after inflation.
Alternatively, the anchor mechanism 202 may be designed so that the swab valve 200 may be conveyed in the wellbore W and installed in place at a desired location. A mechanism also is provided to unlatch and retrieve the swab 200 from within the wellbore also is provided. Such anchoring mechanisms and retrieving devices are known in the art and are thus not described herein. An advantage of the retrievable device is that it can be installed in preexisting casings and may be reused. An advantage of the swab valve that is preinstalled installed in the casing 11 is that it can be integrated into the casing 11 at the surface, which can be a relatively simple operation and avoids a trip into the wellbore.
In either types of the configurations of the swab valve 200, it is set in the wellbore at a suitable location. The inflatable seal membranes are inflated to isolate the upper and lower sections of the wellbore W, which leaves the upper section U at a relatively low pressure. The desired tool string, such as tool string 18 of FIG. 3 carried by a wireline or a coiled tubing is then run into the upper section U. A seal is maintained around the wireline or the coiled tubing as is commonly known in the art. The tool string then deflates membranes 210, which collapse to their initial position as shown in FIG. 11A. The tool string is then moved through the opening 205 to a desired location in the lower section L to perform the desired operation. This preferred embodiment of the inflatable swab valve 200 can be used for the deployment of tools (such as drilling BHAs, slotted liners, screens and perforating guns, for example) in a live well for underbalanced application.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, might be made without departing from the spirit of the invention. | Completion method for avoiding formation impairment in the completion of a wellbore by anchoring and activating a plug at a selected position in the wellbore to seal off a selected portion of the wellbore from other portions of the wellbore. The plug is positioned at the selected position in the wellbore and anchored at that position. A seal in the plug is then activated such that fluid cannot pass the plug. Other parts of the wellbore can then be operated at different pressures than the isolated part of the wellbore without impairment of the formation resulting from the loss of well fluids into the formation. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/234,627, filed Sep. 23, 2005, which claims priority of British Patent Application No. 0421149.6, filed Sep. 23, 2004, the entirety of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a process for preparing oxycodone having low levels of impurities. In particular, the process is useful for preparing oxycodone with low levels of α,β-unsaturated ketones.
BACKGROUND OF THE INVENTION
[0003] Oxycodone is a narcotic analgesic having the structure (I):
[0004] Oxycodone can be manufactured from the natural product thebaine (II) by a well-known process as disclosed in U.S. Pat. No. 6,090,943:
Thebaine (II) or a salt thereof is reacted with hydrogen peroxide in isopropanol, water and formic acid, producing 14-hydroxycodeinone (III). The double bond in the 14-hydroxycodeinone (III) is reduced by reaction with hydrogen in the presence of a Pd/BaSO 4 catalyst, providing oxycodone (I).
SUMMARY OF THE INVENTION
[0005] Recently there has been a concern about the presence of α,β-unsaturated ketone impurities in pharmaceutical products. 14-hydroxycodeinone (III) is an α,β-unsaturated ketone, and unsurprisingly, small quantities of this compound may be found in oxycodone (I). The present inventors have sought to provide a method for preparing oxycodone having low levels of impurities and in particular, low levels of α,β-unsaturated ketone impurities, preferably below 10 ppm.
[0006] In one aspect, the invention provides a method of purifying oxycodone or a salt thereof, including the steps of:
[0007] a) preparing a solution including the oxycodone or salt thereof in a solvent, the solution having a pH less than 6, and;
[0008] b) maintaining the solution at a temperature of at least 55° C. for a period of at least 1 hour;
[0000] wherein the step of maintaining is performed in the absence of hydrogenation reagents.
[0009] In another aspect, the invention provides a method of purifying oxycodone or a salt thereof, including the steps of:
[0010] a) preparing a solution including the oxycodone or salt thereof in a solvent, the solution having a pH less than 6, and;
[0011] b) maintaining the solution at a temperature of at least 55° C. for a period of at least 1 hour;
[0000] wherein the solution includes, after the maintaining step, a level of 14-hydroxycodeinone that is higher than a level of 14-hydroxycodeinone before the maintaining step.
[0012] In yet another aspect, the invention provides crystalline oxycodone hydrochloride including less than 2 ppm of 14-hydroxycodeinone.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The mixture comprising oxycodone and a solvent can be prepared by a number of methods. In a first method, oxycodone base or a salt of oxycodone, prepared and isolated using any of the methods known to those skilled in the art, is mixed with a solvent to form the mixture. In a second method, 14-hydroxycodeinone is hydrogenated in a solvent using known hydrogenation reagents, thereby providing a mixture comprising oxycodone and a solvent. In a third method, a mixture comprising thebaine and a solvent is subjected to oxidation conditions (e.g. hydrogen peroxide in formic acid and water), followed by hydrogenation conditions, thereby providing a mixture comprising oxycodone and a solvent. Other methods of preparing a mixture comprising oxycodone and a solvent may be known to those skilled in the art.
[0014] The pH of the mixture is adjusted to less than 6, suitably less than 5, more suitably less than 3 and preferably about 1. The pH is suitably adjusted by the addition of a strong acid such as concentrated hydrochloric acid to the mixture. Preferably at least one equivalent of acid is added to the mixture.
[0015] The solvent in the mixture is suitably an organic solvent such as isopropanol, ethanol or SD3A (a 95:5 mixture of ethanol:methanol). Preferably the mixture further comprises water.
[0016] After the pH is adjusted, the mixture is suitably heated to a temperature of at least 55° C., preferably at least 60° C. and most preferably about 70-75° C. The temperature is suitably not higher than the boiling point of the solvent. The mixture is suitably heated for a period of at least 1 hour, preferably at least 3 hours and most preferably between 5-10 hours.
[0017] Suitable hydrogenation reagents are well known to the skilled person and typically include a hydrogenation catalyst and either hydrogen or a hydrogen transfer reagent, such as sodium hypophosphite. Preferred hydrogenation catalysts are precious metal catalysts such as palladium or platinum dispersed on a support material such as carbon or barium sulfate. In a preferred embodiment, a precious metal catalyst is added to the mixture and hydrogen is passed through the mixture at a pressure of 10 psi or more (162 kPa or more). The hydrogenation step is suitably carried out at a temperature of at least ambient, preferably at a temperature between room temperature and 70° C. The temperature should be sufficient to dissolve the solids in the mixture, thereby providing a solution. The mixture is exposed to the hydrogenation reagents for at least 1 hour, suitably at least 2 hours and preferably about 6 hours.
[0018] The product of step (b) is a mixture comprising oxycodone and a solvent. Hydrogenation catalysts may be removed by filtering the mixture. A purified oxycodone salt may be obtained from the mixture by reducing the temperature, and allowing the salt to crystallise out. For example, if hydrochloric acid was used in step (a), the hydrochloride salt of oxycodone will be produced. Alternatively, oxycodone base may be provided by adding a base such as sodium hydroxide to the mixture and allowing the mixture to cool.
[0019] If precious metal catalysts are used in the hydrogenation step, it is possible that unacceptable levels of the metals will remain in the final product (desirably the heavy metal content of the final product is less than 20 ppm). In one embodiment of the present invention, the oxycodone or oxycodone salt produced in step (b) is subjected to a further process wherein a mixture comprising the oxycodone or oxycodone salt and a solvent is treated with charcoal. Suitably the mixture is heated to a temperature of approx. 60-65° C., the charcoal is added, the mixture is stirred at 60-65° C. for 5 to 10 hours and the hot mixture is filtered to remove the charcoal. Cooling the hot mixture provides the oxycodone salt or oxycodone. Suitably the weight ratio of oxycodone or oxycodone salt to charcoal is between 20:1 and 1:1, preferably about 5:1. The charcoal is suitably a charcoal such as Darco® G-60 (Norit, USA).
[0020] Oxycodone or an oxycodone salt produced according to the process of the invention has low levels of α,β-unsaturated ketones and is advantageously incorporated into pharmaceutical products.
EXAMPLES
[0021] The following examples are illustrative but not limiting of the invention.
Preparation of Oxycodone Base: Route A
[0022] Thebaine (15.94 g) was added to a 250 ml flask. Water (18 ml) was added and the mixture was stirred at room temperature. Formic acid (42 ml) was added over 3 minutes and then the mixture was cooled in an ice bath. Hydrogen peroxide (30%, 6.7 g) was added and the mixture was stirred for 1 hour. The mixture was removed from the ice bath, allowed to warm to room temperature and then heated to 48° C. for 2 hours. The mixture was transferred to a hydrogenation bottle. A 5wt % palladium on carbon catalyst (2 g) was added and hydrogen was passed through the mixture at approximately 20 psi for 15 hours. The catalyst was removed by passing the mixture through a pad of celite and rinsing the filtered solid with water/formic acid (3:1, 8 ml). The mixture was cooled in an ice bath and 25% sodium hydroxide (109 ml) was added dropwise over 50 minutes to increase the pH to 9-10. The mixture was stirred for 1 hour and 15 minutes and the solid product was filtered, rinsed with cold water and dried under vacuum pump for 3 hours. The product was oxycodone base (14.152 g, 87.7% yield) and contained 178 ppm of the α,β-unsaturated ketone impurity, 14-hydroxycodeinone.
Preparation of Oxycodone Base: Route B
[0023] Thebaine (100.0 g dry weight) was dissolved in 85% formic acid (252.3 g). 30% Hydrogen peroxide (43.6 g) was added over a period of about two hours. The mixture was stirred for three hours. Ammonium hydroxide solution was added to the mixture to increase the pH to 8-9. The solid precipitate was filtered and washed with water and ethanol. The solid was dried on the filter and in an oven. The product was 14-hydroxycodeinone (150.52 g damp, 75.32 g dry weight, 75% yield).
[0024] The 14-hydroxycodeinone (39.45 g of the damp solid) was dissolved in water (81.13 ml) and 80% acetic acid (16.17 ml). 10 wt % palladium on carbon catalyst (0.33 g wet weight, 0.16 g dry weight) was added and hydrogen was passed through the mixture for about 6 hours at about 12 psi. The mixture was filtered to remove the catalyst. An ammonium hydroxide solution was added to the mixture up to pH 9. The solid precipitate was washed with water and with ethanol, and was dried. The product was oxycodone (18.8 g, 79% yield).
Comparative Example 1
Heating and Recrystallisation of Oxycodone
[0025] 13.257 g of oxycodone prepared via Route A was added to a 250 ml flask. An ethanol/methanol mixture (70 ml) was added to the flask and the mixture was stirred at room temperature, heated to reflux (78° C.) for 1 hour, cooled to room temperature and then stirred at room temperature. The mixture was cooled in an ice bath for 30 minutes and the solid product was filtered and rinsed with an ethanol/methanol mixture. The solid was dried under vacuum for 3 hours. The product was oxycodone base (11.393 g, 85.95%) and contained 210 ppm of the α,β-unsaturated ketone impurity, 14-hydroxycodeinone.
[0026] Dissolving the oxycodone, heating to 78° C. for 1 hour and recrystallising did not reduce the amount of 14-hydroxycodeinone in the oxycodone.
Comparative Example 2
Heating and Recrystallisation of Oxycodone
[0027] 11 g of the oxycodone product from comparative example 1 was added to a 250mi flask. An ethanol/methanol mixture (55 ml) was added to the flask and the mixture was stirred at room temperature, heated to reflux (78° C.) for 1 hour, cooled to room temperature and then stirred at room temperature. The mixture was cooled in an ice bath for 35 minutes and the solid product was filtered and rinsed with an ethanol/methanol mixture. The solid was dried under vacuum overnight. The product was oxycodone base (10.682 g, 97.1%) and contained 165 ppm of the α,β-unsaturated ketone impurity, 14-hydroxycodeinone.
[0028] A second step of dissolving the oxycodone, heating to 78° C. for 1 hour and recrystallising did not significantly reduce the amount of 14-hydroxycodeinone in the oxycodone.
Example 1
Preparation of Oxycodone Hydrochloride Having Low Level of Impurities
[0029] 5 g of oxycodone product from comparative example 2 was added to a 100 ml flask. Water (10 ml) and isopropanol (10 ml) were added and the mixture was stirred. Concentrated hydrochloric acid (2.64 ml) was added. The mixture was heated to 75° C. for 10 hours and stirred at ambient temperature overnight. The mixture was transferred to a hydrogenation bottle and was heated to 45° C. 5wt % palladium on carbon catalyst (0.5 g) was added to the mixture and hydrogen was passed through the mixture at about 12 psi for 6.5 hours. The mixture was warmed to 55° C., passed through a filter paper, cooled to room temperature and then placed in an ice bath for 30 minutes. The solid product was filtered, rinsed with cold isopropanol and dried overnight under a vacuum pump. The product was oxycodone hydrochloride (5.533 g, 99.2%) and contained less than 2 ppm 14-hydroxycodeinone (measured by HPLC and MS-SIM (mass spectrometry with selected ion monitoring)).
Example 2a
Preparation of Oxycodone Base Having Low Level of Impurities
[0030] 1.2 g of crude oxycodone prepared via Route A was added to a 50 ml flask. Water (3.6 ml), isopropanol (3.6 ml) and formic acid (4.8 ml) were added. Concentrated hydrochloric acid (0.24 ml) was added. The mixture was heated to. 75° C. and stirred at 75° C. for 10 hours. The mixture was cooled to room temperature and stirred. HPLC showed that the level of 14-hydroxycodeinone in the oxycodone increased during the heating step. Treatment with acid and heating does not prepare oxycodone with a low level of impurities.
[0031] The mixture was transferred to a hydrogenation bottle. 5 wt % palladium on carbon catalyst (120 mg) was added to the mixture and hydrogen was passed through the mixture at room temperature and about 12 psi for 24 hours. The mixture was passed through a pad of celite and then placed in an ice bath. 50% sodium hydroxide (5.3 ml) was added dropwise over 17 minutes to a pH of 9-10. The mixture was stirred at 0-5° C. for 1 hour and 10 minutes. The solid product was filtered, rinsed with cold water and dried under a vacuum pump for four hours. The product was oxycodone base (1.072 g, 89.33%) and contained approximately 3 ppm 14-hydroxycodeinone (measured by MS-SIM).
Example 2b
Preparation of Oxycodone Hydrochloride Having Low Level of Impurities
[0032] 0.8 g of oxycodone base produced in Example 2a was added to a 50 ml flask. Water (1.6 ml) and isopropanol (3.76 ml) were added. Concentrated hydrochloric acid (0.32 ml) was added and the mixture was heated to 73° C. After 5 minutes at 73° C. the mixture was cooled to room temperature and was then stirred at room temperature for 1 hour. The mixture was placed in an ice bath and stirred for 1.5 hours. The solid product was filtered, rinsed with cold isopropanol and dried under a vacuum pump overnight. The product was oxycodone hydrochloride (0.892 g) and contained approximately 5 ppm 14-hydroxycodeinone (measured by MS-SIM).
Example 3
Preparation of Oxycodone Hydrochloride Having Low Level of Impurities
[0033] 18.8 g oxycodone prepared via Route B was added to a flask containing ethanol (43.9 ml) and water (10.14 ml). Ethanol (5.71 ml) and concentrated hydrochloric acid (7.37 ml) were mixed and then added to the flask, providing a mixture with a pH of 1. The mixture was heated at 75° C. for 5 hours and was then cooled to 65° C. The mixture was hydrogenated at 10-12 psi for six hours using a 10 wt % palladium on carbon catalyst (175.6 mg wet weight, 88 mg dry weight). The mixture was filtered to remove the catalyst and cooled. The solid product was filtered and washed with ethanol. The product was oxycodone hydrochloride (20.13 g, 75.3%) and contained approximately 0 ppm 14-hydroxycodeinone.
Comparative Example 3a
Hydrogenation of Oxycodone
[0034] 3 g of crude oxycodone prepared by essentially the same method as route A and containing 535 ppm 14-hydroxycodeinone was added to a hydrogenation bottle. Isopropanol (9 ml), water (9 ml) and formic acid (12 ml) were added. The mixture was hydrogenated for 23 hours using a 5 wt % palladium on carbon catalyst (0.3 g). The mixture was passed through a pad of celite and the hydrogenation bottle was rinsed with isopropanol and water. The mixture was cooled in an ice bath. 50% sodium hydroxide (14 ml) was added dropwise over 22 minutes to a pH of 9-10. The mixture was stirred at 0-5° C. for 1 hour and 20 minutes. The solid product was filtered, rinsed with cold water and dried under a vacuum pump overnight. The product was oxycodone base (2.822 g, 94.1%) and contained approximately 26 ppm 14-hydroxycodeinone (measured by HPLC). The hydrogenation step reduced the amount of 14-hydroxycodeinone in the oxycodone, but this method, wherein the pH of the mixture was not adjusted before the hydrogenation, did not afford oxycodone with an impurity level of less than 10 ppm.
Comparative Example 3b
Acidification of Oxycodone
[0035] 2 g of oxycodone base produced in Comparative Example 3a was added to a 100 ml flask. Water (4 ml) and isopropanol (9.4 ml) were added. Concentrated hydrochloric acid (0.8 ml) was added and the mixture was heated to 70-72° C. After 5 minutes at 70-72° C. the mixture was slowly cooled to room temperature. The mixture was placed in an ice bath and stirred for 1 hour and 20 minutes. The solid product was filtered, rinsed with cold isopropanol and dried under a vacuum pump overnight. The product was oxycodone hydrochloride (2.401 g) and contained approximately 38 ppm 14-hydroxycodeinone (measured by HPLC). Adjusting the pH of the oxycodone to ˜1 and heating did not further reduce the concentration of 14-hydroxycodone. Comparative Examples 3a and 3b demonstrate that oxycodone with very low level of impurities (less than 10 ppm 14-hydroxycodeinone) is not prepared by hydrogenating the oxycodone and then treating with acid.
Example 4
Preparation of Oxycodone Hydrochloride Having Low Level of Impurities
[0036] 4.35 g oxycodone prepared by essentially the same method as Route B was added to a flask containing ethanol (12.5 ml) and water (2.7 ml). Concentrated hydrochloric acid (approximately 1.5 ml) was added to the flask, providing a mixture with a pH of about 2. The pH of the mixture was increased to 5 by adding ammonia. The mixture was hydrogenated at 45 psi and 50° C. for 1.5 hours and then at 10-12 psi is and 50-55° C. for 4 hours using a 10 wt % palladium on carbon catalyst (0.06 g). The mixture was filtered to remove the catalyst and cooled. The solid product was filtered and washed with ethanol. The product was oxycodone hydrochloride (3.706 g, 76.1%) and contained approximately 12 ppm 14-hydroxycodeinone.
Example 5
Preparation of Oxycodone Hydrochloride Having Low Level of Impurities
[0037] 3 g of oxycodone product from comparative example 2 was added to a 50 ml flask. Water (1.3 ml) and ethanol (5.58 ml) were added and the mixture was stirred. Concentrated hydrochloric acid (1.58 ml) was added. Further water was added so that in total 4.5 ml of water was added. The mixture was heated to 75° C. for 10 hours, slowly cooled to room temperature and stirred overnight. The mixture was heated to 40° C. and transferred to a hydrogenation bottle. 5 wt % palladium on carbon catalyst (0.3 g) was added to the mixture and hydrogen was passed through the mixture at between 11 and 12 psi for 6.5 hours. The mixture was warmed to 56° C. and passed through two layers of filter paper. The bottle and filtrate were rinsed with a hot solution of 1 ml water and 5 ml ethanol, and with 20 ml of hot ethanol. The filtrate was slowly cooled to room temperature and then placed in an ice bath for 30 minutes. The solid product was filtered, rinsed with cold ethanol and dried overnight under a vacuum pump. The product was oxycodone hydrochloride (2.663 g, 79.6% yield). A further 0.334 g of oxycodone hydrochloride was obtained by washing the filter cake and hydrogenation bottle with water and water/ethanol (1:1), giving a combined yield of 2.997 g and 89.5%. Both samples of oxycodone hydrochloride contained 0 ppm 14-hydroxycodeinone (measured by HPLC and MS-SIM (mass spectrometry with selected ion monitoring)). | A method of purifying oxycodone or a salt thereof includes the steps of: a) preparing a solution including the oxycodone or salt thereof in a solvent, the solution having a pH less than 6, and; b) maintaining the solution at a temperature of at least 55° C. for a period of at least 1 hour; wherein the step of maintaining is performed in the absence of hydrogenation reagents. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to video game controllers and more specifically to an integrated controller and video display device for both controlling and displaying an interactive video game.
2. Description of the Related Art
Computer video games are well known in the art. Such devices range from small hand held all-in-one units, to larger stand-alone units which interact with stand alone controllers and stand alone video display devices. Small hand held devices are very portable. However, the graphics and sophistication game play are substantially inferior to stand alone units due limited processing power and associated peripherals. For more sophisticated play, stand alone computer units provide tremendous processing power and work with associated peripheral devices, such as a remote controller and television display in an attempt to bring the player a more dramatic gaming experience to that of hand held devices. One such stand-alone device is disclosed in U.S. Pat. No. 6,422,943 which is hereby incorporated by reference. These devices are widely available on the market and are well know in the art. FIGS. 8-9 depict such a conventional stand-alone computer video gaming device. A central stand-alone console contains all the essential processing components to run a computer game. A controller is connected to communicate operation control commands from a user. A separate display is connected to the gaming deice to display interactive video gaming images. As previously mentioned, this conventional arrangement is well known in the art.
With the tremendous commercial success of stand alone computer gaming systems, and entire peripheral market has emerged ranging from advanced video controllers, joysticks, steering wheel devices for racing games, multi-tap controllers, vibrating controllers, video stands, audio systems and the like. Programmable controllers are also available which allow a user to customize the operation of control buttons and to even store and retrieved such customized arrangements. One such device is disclosed in U.S. Pat. No. 5,759,100 which provides an LCDP display interface to facilitate programming the controller and is hereby incorporated herein by reference. The display device 18 of the '100 device is limited to an alphanumeric display in response to manual manipulation of program keys.
Stand alone computer gaming devices all require the use of a display device such as a television as shown in FIGS. 8-9. These devices are specifically suited for home use and do not lend them selves to portable use or in a manner which is intimate to the user. Hand held gaming systems incorporate an all-in-one processor, display and controller into a single to facilitate portability and intimate interaction with the game. One such system is disclosed in U.S. Pat. No. 5,184,830 and is incorporated herein by reference. However, as previously mentioned such systems do not provide the sophistication level of game play or graphics that stand alone systems can provide. Heretofore, the prior art has failed to integrate a display device into a controller for interaction with stand-alone computer game device.
SUMMARY OF THE INVENTION
The present invention is directed to a computer game controller with integrated video display device. The controller has a video device mounted or otherwise integrated into a hand held controller. A communication cable connects the controller with a stand-alone computer game device. The cable establishes a communication link to facilitate the transmission of both command signals and audio/video signals between the controller and computer device. The integrated controller and video display device of the present invention provides two-way interaction with the stand-alone computer device within a single accessory device. The integrated controller and video display device may also incorporate a speaker or headphone jack to deliver audio stimulation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a controller with integrated vide display device according to one embodiment of the present invention.
FIG. 2 is a plan view of a controller and integrated display device having a cover according to an alternate embodiment of the present invention.
FIG. 3 is a plan view of the controller of FIG. 2 with the cover in an open position.
FIG. 4 is an exploded view of an alternate embodiment a removable display component.
FIG. 5 is a view of the controller of FIG. 4 with the display component connected to the controller.
FIG. 6 is a front view of the controller portion of the embodiment of FIG. 4 exposing a connection port.
FIG. 7 is a side view of the embodiment of FIG. 4 .
FIG. 7 a is an isolated view of the pin out connection portion of the removable display of FIG. 7 .
FIG. 8 is a schematic representation of a stand-alone video game system arrangement of the prior art.
FIG. 9 is a plan view of a stand-alone video game arrangement according to the prior art.
FIG. 10 is a schematic representation of a stand-alone video game system with an integrated controller/video display according to the present invention.
FIG. 11 is a plan view of a stand-alone video game system with an integrated controller/video display according to the present invention.
FIG. 12 is a plan view of a stand-alone video game system with an integrated controller/video display with adapter cable according to the present invention.
FIG. 13 is a side view of an alternate embodiment of the present invention with a pivotal display -screen.
FIG. 14 is a top plan view of an alternate embodiment of the present invention having a retractable display screen.
FIG. 15 is a top plan view of an alternate embodiment of the present invention having a flip up display screen in the closed position.
FIG. 16 is a top plan view of the embodiment of FIG. 15 in a raised position.
FIG. 17 is a plan view of a stand-alone video game system with a wireless integrated controller/video display according to an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts a video game controller with integrated video display 1 according to one embodiment of the present invention. A hand held unit 3 ergonomically formed to be held by a hand(s) of a user. The hand held unit 3 includes a plurality of operating members for manipulation of the users hand to facilitate interaction with game play. The controller may be the programmable type, include a vibratory member for heightened game play as well as lighted buttons etc. A communication cable 7 , details of which will be explained later, is also provided to facilitate communication with a stand-alone computer gaming device. Such controllers and operating members are well known and within the knowledge of one of ordinary skill in the art.
The video game controller further incorporates an integrated display device 9 . Preferably the display device is a color LCD (Liquid Crystal Display) type with associated driver circuitry to facilitate display of a video signal. Preferably the driver and other associated circuitry are contained within the body of the hand held unit 3 . It is understood that small high resolution color LCD displays with associated circuitry are readily available and are known to one of ordinary skill in the art. Small high-resolution LCD displays have been incorporated into small hand held color televisions, video recorders, digital cameras, and other devices. Such readily available off the shelf LCD displays and associated circuitry can easily fit within the confines of the hand held unit 3 as contemplated by the present invention. In the embodiment of FIG. 1, a 3.2 inch LCD video display having a conventional 4:3 aspect ratio is be integrally molded into the front portion of the hand held unit 3 to form an integral one piece device. Off course both smaller and larger LCD display systems may be employed. The LCD display is positioned to be readily visible to the user when holding the hand held unit. The communication cable 7 contains both a conventional bundle for communicating operating control commands in response to manipulation of the operating members by the user and a separate bundle carrying video signals to the video circuitry of the LCD display.
State of the art stand alone computer gaming platforms also transmit low DC voltage across the communication bundle to power circuitry within the controller, power vibration devices, etc. Currently available LCDs do not consume much power and it is preferred to use the incoming low voltage DC source from the computer gaming system to rung the LCD display. According to the present invention, the console of the gaming platform is modified to provide a single connection point to connect the communication cable 7 including conventional control command communication bundle, a voltage source line and a video cable integrated into a single cable. The details of such a connection will be explained later. However, if such additional voltage is necessary, the hand held unit may incorporate a battery or other connection directly to an external voltage source.
FIGS. 2-3 represents an alternate embodiment of the present invention. A cover 11 is pivotally mounted above the LCD display screen 9 . Raised hinged members 13 may be simply formed into the molding of the hand held unit 3 for engagement with a pintle member 14 integrally formed in the cover. The cover 11 then may be installed simply by snap fitting the pintle 14 members into the hinge member 13 . Preferably the cover member 11 is made of plastic or other material similar to the construction of the hand held body 3 . FIG. 2 represents the cover in a closed position covering the LCD display 9 . FIG. 3 depicts the cover 11 in an open position visually exposing the LCD display 9 .
FIGS. 4-7 represents another alternate embodiment of the present invention having a removable display device 109 . By allowing the removal of the display screen, the controller portion 103 can be utilized with a conventional stand-alone display device. The removable display device is preferably equipped with a pass through device 120 to facilitate a single connection point to the communication cable 107 . The use of a pass through device 120 for the selective removal of the display device 109 facilitates the use of a common communication cable 7 , 107 for both embodiments where the display device 9 is unitarily formed with the hand held body 3 and the controller 103 having a removable display device 109 . To achieve this, both the integral display device 9 of FIG. 1 and the removable disloyal device 109 of FIGS. 4-5 include a connection opening 130 . The connection opening has a first port 131 with a female mounting arrangement and pinout to receive a male plug having corresponding pins to operatively form a connection of a control command communication bundle (such as those found within conventional controller cables of conventional gaming platforms such as the Playstation II by Sony). The connection opening 130 further has a video 133 and audio 135 female RCA jacks (or other known connections) to form a connection with an audio and video signal bundle for the controller embodiment of FIG. 1 . (It is noted that for the controller of FIGS. 4-5, not such audio/video connections are necessary, as those communication signals will be directly ported to the LCD display and audio device within the removable device 109 .) Alternately, a voltage source pinout jack 137 may exist to establish a connection to a voltage source flowing from the game console in additional to any voltage available through the first port 131 .
The pass through portion 120 has an oval shaped stem 121 projecting from a central portion 125 to matingly fit within the opening 130 . As can be seen in FIG. 7 a, the oval shaped stem includes corresponding male connections (not labeled) to establish a connection with corresponding portions of the controller. On the opposite side of the central portion 125 , a female connection opening is formed identical to opening 130 of the controller with associated connections portions identical to portions 131 , 133 , 135 and 137 of the controller. An electrical connection between the male and female pinout connections of the pass through device 120 is simply contained within the central body 125 . The pass through device further simply routes the audio/video signals directly to the associated devices within removable display 109 . Thus as can be readily seen in FIG. 7, the communication cable 107 may be either connected to the pass through device 120 of removable display 109 or directly to the opening 130 of the hand held unit 3 . It is to be understood that the shape of stem 121 need not be oval. However, it is preferred to employ a non-circular shape to prevent any rotational movement between the controller and associated pass through device or cable bundle.
The pass-through device 120 is preferably pivotally mounted to the LCD display screen 109 to selectively customized viewing for the user. The pivotal connection further provides the ability to fold down the LCD display screen 109 on top of the controller 103 .
FIGS. 10-11 respectively depict schematic and plan views of the integrated video controller and display device 3 with a stand-alone computer gaming system 90 . As can bee seen a single communication cable 7 incorporates both a video signal cable and a conventional control command bundle. In order to provide a single point connection to the stand-alone game system 90 the console of the game platform incorporates a connection portion a pinout substantially identical to the opening 130 and connection pinout portions 133 , 135 and 137 of the controller 3 . Such an arrangement facilitates the use of a single communication cable 7 / 107 having identical male pinouts and mounting portions on either end. However, it is to be understood that male/female portions may be interchanges so long corresponding portions of associated pieces match to complete the communication between the stand alone gaming platform 90 and either the controller of FIG. 1 or the pass through device 120 of FIG. 7 .
In order to enable the use of the video game controller 1 and integrated display device of the present invention with conventional stand-alone gaming platforms 190 , an adapter cable 50 may be utilized. As can be seen in FIG. 12, the adapter 50 has a first end which mates with the communication cable 7 , 107 . The adapter 50 serves to split the conventional command bundles and other bundles to facilitate separate connection to a controller interface of the conventional 190 device and the video/audio outputs.
While the present invention has been preferably described for connection of the communication cable 7 / 107 directly to the stand alone game console 90 through a single connection port, the controller 1 , and integrated video display can be used with conventional gaming systems 190 having separate controller ports and video outputs. AS previously discussed, FIG. 12 depicts and alternate embodiment of the present invention. In order to facilitate connection to a conventional game platform 190 , the adaptor 50 is employed. The adaptor 50 is simply a pass through device for operation command to connect to the conventional controller port of the game console. The pass through device bifurcates the command data bundle from audio, video or other lines such as a voltage source line into separate cables. As can be seen in FIG. 12. a video cable runs to the rear of the console to connect with an video output jack 71 . The video output jack can be a conventional single line RCA jack, S-video or three-line connection as is well known in the art. A second audio line 53 extends to stereo audio output jacks 63 , 64 . The audio may be a mono or stereo line and is connect to a conventional RCA audio jack. The pass through portion of the adaptor 50 simply mirrors that of command port 131 with a female mounting arrangement and pinout to receive the male plug of the communication cable having corresponding pins to operatively form a connection of a control command communication bundle and audio/video jacks. Within 50 the control command bundle splits off from the audio/video bundle and the 50 has a male end simulating the male connection portion of a conventional controller port connection similar to the upper portion of the pas through device 121 of FIG. 7 . The audio/video cables simply extend from 50 to the rear portion of the console and connect to respective ports as is conventional in the art. The controller/integrated display 1 further may contain speakers 81 within the controller as shown in FIG. 12 to provide audio as generated by the gaming circuitry.
FIG. 13 depicts a controller 201 with a display device 209 pivotally secured to the hand held unit 203 . A display device 201 is simply secured to the hand held unit 203 with a simple hinge device 265 with corresponding portions integrally formed with the body of each of the hand held unit 203 and the display device 209 . The display device 209 may then be pivoted towards and away from a user handling the controller 201 to optimize viewing comfort. Alternately, the display device 209 may connected via a ball and socket connection to facilitate an additional degree of freedom to allow both pivotal and rotational movement of the display device 209 relative to the hand held unit 201 . A stop member is preferably integrated into the pivotal connection 265 to limit the extent of rotation. The particular structure of the pivotal connection 265 is not critical to the present invention so long as the display device 209 can move relative to the hand held unit 203 without disturbing communication between the LCD display the circuitry within the hand held unit 203 . In this embodiment, the communication cable may extend directly from the hand held unit 203 to the stand alone gaming device and a smaller communication cable simply extends through the pivotal connection 265 to interconnect the display device 209 and the circuitry contained within the hand held unit 203 .
FIG. 14 represents an alternate embodiment. The integrated controller 301 includes a retractable display device 309 . In the present embodiment, the display device 309 preferable slides in and out of the hand held unit 303 . The sides of the LCD display 109 may be disposed within a channel track integrally formed into the body of the hand held unit 303 . A stop member may simply be formed on the inside edge of the display device 109 to prevent the display device from dislodging from the hand held unit 203 . Here again, the specific structure of the retractable connection between the display device 309 and the hand held unit 303 is not crucial so long as the display device is permitted to be displaced without effecting the ability to display video images. The display device 309 may further be pivotally connected to a portion that slides within the channels formed in the hand held unit 303 to provide additional positional control of the display device 309 relative to the hand held unit 303 . Such an arrangement not only provides customized positional viewing control but facilitates protection of the display device 309 when not in use.
FIGS. 15-16 represents yet another embodiment of the present invention. According to the present embodiment, the display device 409 is pivotally connected to a top portion of the hand held unit 403 . Such an arrangement facilitates a flip up display device. When the display device is on the closed position, the back of the display device 409 serves as a cover to protect the LCD display. The display device 409 may simply flip up to an optimized viewing position during use. The display device 409 may simply be pivotally connected to the top potion of the hand held unit 403 . Raised hinged members 413 may be simply formed into the molding of the hand held unit 403 for engagement with a pintle member 414 integrally formed display device. A communication cable may simply extend from the display device 409 to within the circuitry within the hand held unit 403 . Preferably the body of the display device is made of plastic or other material similar to the construction of the hand held body 403 and suitable for integrally forming the respective pintle and hinge members unitarily with their associated component.
While the foregoing invention has been shown and described with reference to a preferred embodiment, it will be understood by those possessing skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. For example, FIG. 17 contemplates a wireless embodiment where the integrated controller 501 communicates with the stand-alone console 590 via radio waves. A transmitter 550 may simply be inserted into a controller port and further connected to audio/video outputs of the console. Wireless controllers are known in the art. However, such controllers are limited to communicating operational data between the stand-alone console and controller device. The transmitter of the present invention transmits not only operational commands between the controller and stand-alone game console, but video and audio signals as well. Thus the integrated controller is equipped with a receiver to receive such signals. In this embodiment, the hand held unit is equipped with batteries to provide sufficient power to run the display device 509 and associated circuitry within the hand held unit. The associated components are then neatly arranged within the confines of the hand held unit to provide a complete package to interact with the gaming processor of the stand-alone unit 590 . Such an arrangement will allow multiple players to compete without having to view a common screen. In fact, two players do not even have to be within the same room to engage in a common game adventure. It has been demonstrated that communication within the range of 1.2-2.4 Gigahertz is sufficient to transmit the necessary command controls and audio/video data to facilitate a wireless remote interaction between the stand-alone computer game console 590 and the integrated controller and video display 501 of the present invention. | A computer game controller with integrated video display device. The controller has a video device mounted or otherwise integrated into a hand held controller. A communication cable connects the controller with a stand alone computer game device. The cable establishes a communication link to facilitate the transmission of both command signals and audio/video signals between the controller and computer device. The integrated controller and video display device of the present invention provides two-way interaction with the stand-alone computer device within a single accessory device. The integrated controller and video display device may also incorporate a speaker or headphone jack to deliver additional audio stimulation. | 0 |
RELATED APPLICATION DATA
This application is a continuation-in-part of International Application No. PCT/US08/65263, filed May 30, 2008, and titled “Systems and Methods for Compensating for Large Moving Objects in Magnetic-Tracking Environments,” that claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 60/942,009, filed Jun. 5, 2007, and titled “Method Of Compensating For Large Moving Objects In Electromagnetic Tracking Environments.” Each of these applications is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to the field of magnetic-tracking. In particular, the present invention is directed to systems and methods for compensating for large moving objects in magnetic-tracking environments.
BACKGROUND
Image-guided surgical procedures typically require placing surgical instruments, for example, catheters, scopes, probes, needles, ultrasound, ablators, drills, therapy delivery, therapy measure, physiological measure, etc., at a particular place, often at a particular orientation as well. Guiding these instruments in real-time is typically with respect to pre-acquired images from an imaging device, such as a computed tomography (CT) device, magnetic resonance imaging (MRI) device, etc., that are aligned with the guidance device. Images can also be acquired during the surgical procedure to update and correct pre-planned procedures, thus ensuring the best results practicable.
One of the best ways of guiding surgical instruments, both internal and external to a body being operated upon, is to use magnetic tracking technology. Numerous U.S. patents disclose magnetic tracking technology. These technologies all rely on a means of generating magnetic fields, sensing magnetic fields, and computing the position and orientation (P&O) of a device using the sensed fields. A drawback of magnetic tracking technology is when a live imaging device, such as an X-ray image intensifier (a/k/a a “C-arm”), is used during the surgical procedure: the device causes significant inaccuracies in the determination of the P&O. This inaccuracy is caused by the distortion of the magnetic field due to the metallic components of the imaging device, which are not accounted for (adequately, or at all) by the magnetic tracking algorithm being used. Many attempts have been made to account for these inaccuracies and are disclosed in numerous U.S. patents.
SUMMARY OF THE DISCLOSURE
In one implementation, the present disclosure is directed to a method of magnetic tracking in a tracking volume in the presence of movable magnetic-field distorter. The method includes: generating a magnetic field capable of being sensed by a magnetic-field sensor when the magnetic-field sensor is located in the tracking volume; obtaining first magnetic-field data regarding the magnetic field via the magnetic-field sensor while the magnetic-field sensor is in the tracking volume; calculating, within a machine, position and orientation of the magnetic-field sensor as a function of the first magnetic-field data and a difference between a first set of data items and a second set of data items, wherein the first set of data items results from second magnetic-field data collected from the tracking volume when the movable magnetic-field distorter is present in the tracking volume, and the second set of data items results from third magnetic-field data collected from the tracking volume when the movable magnetic-field distorter is not present in the tracking volume; and outputting from the machine information that is a function of the position and orientation of the magnetic-field sensor.
In another implementation, the present disclosure is directed to a system for magnetic tracking in a tracking volume in the presence of movable magnetic-field distorter. The system includes: a magnetic-field sensor; a magnetic field generator for generating a magnetic field capable of being sensed by the magnetic-field sensor when the magnetic-field sensor is located in the tracking volume; and means for: collecting first magnetic-field data regarding the magnetic field via the magnetic-field sensor while the magnetic-field sensor is in the tracking volume; and calculating position and orientation of the magnetic-field sensor as a function of the first magnetic-field data and a difference between a first set of data items and a second set of data items, wherein the first set of data items results from second magnetic-field data collected from the tracking volume when the movable magnetic-field distorter is present in the tracking volume, and the second set of data items results from third magnetic-field data collected from the tracking volume when the movable magnetic-field distorter is not present in the tracking volume.
In still another implementation, the present disclosure is directed to a computer-readable medium containing computer-executable instructions for use in performing a method of magnetic tracking in a tracking volume in the presence of movable magnetic-field distorter. The computer-executable instructions include: a first set of computer-executable instructions for obtaining first magnetic-field data regarding the magnetic field via the magnetic-field sensor while the magnetic-field sensor is in the tracking volume; a second set of computer-executable instructions for calculating position and orientation of the magnetic-field sensor as a function of the first magnetic-field data and a difference between a first set of data items and a second set of data items, wherein the first set of data items results from second magnetic-field data collected from the tracking volume when the movable magnetic-field distorter is present in the tracking volume, and the second set of data items results from third magnetic-field data collected from the tracking volume when the movable magnetic-field distorter is not present in the tracking volume; and a third set of computer-executable instructions for outputting from a machine information that is a function of the position and orientation of the magnetic-field sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:
FIG. 1 is a schematic plan view of a surgical setting that includes a magnetic tracking system (MTS) that implements a method of improving the accuracy of the MTS;
FIGS. 2A-B contain a flow diagram illustrating a method of improving accuracy of an MTS that can be used, for example, in the surgical setting of FIG. 1 ;
FIG. 3 is a flow diagram illustrating another method of improving accuracy of an MTS that can be used, for example, in the surgical setting of FIG. 1 ;
FIG. 4 is a flow diagram illustrating a further method of improving accuracy of an MTS that can be used, for example, in the surgical setting of FIG. 1 ;
FIGS. 5A-B contain a flow diagram illustrating yet another method of improving accuracy of an MTS that can be used, for example, in the surgical setting of FIG. 1 ;
FIG. 6A is a flow diagram illustrating a characterization phase of a multipole-model-based method that can be used to improve the accuracy of an MTS; FIG. 6B is a flow diagram illustrating a distortion compensation determination stage that may be used following the characterization phase of FIG. 6A ;
FIG. 7 is a flow diagram illustrating a real-time distortion compensation phase that may be used following the distortion compensation determination phase; and
FIG. 8 is a block diagram of a computer system that may be used to implement a method of improving accuracy of an MTS.
DETAILED DESCRIPTION
This application discloses novel methods of improving the accuracy of magnetic tracking systems (MTSs) when in the presence of one or more large, movable objects. Referring now to the drawings, FIG. 1 illustrates an exemplary setting, here a surgical setting 100 , in which any one of the novel methods of the present disclosure may be implemented. As those skilled in the art will readily appreciate, surgical setting 100 is but one example of settings in which a method of the present disclosure may be implemented and other settings will be recognizable to a skilled artisan. Other settings include helmet mounted sights used in both actual and simulated cockpits, VR applications (e.g., the CAVE), and labor and delivery assistive technology, to name a few. In this example, surgical setting 100 includes a C-arm 104 , which constitutes the large, movable object mentioned above. Surgical setting 100 also includes a procedure table 108 , an MTS 112 and a medical computer 116 , among other things that are not particularly shown and are not necessary to describe the broad concepts and implementations of the present invention.
In this example, MTS 112 includes a base electronics unit 120 , a six-degree-of-freedom (6DOF) sensor 124 and one or more magnetic field generators. In the present setup, a single magnetic field generator 128 is placed on the underside of procedure table 108 . A patient is not shown for clarity. That said, those skilled in the art will understand that 6DOF sensor 124 may be located inside or outside the patient depending on the procedure being performed and/or the stage of the procedure and whether or not the patient is present. In one example, 6DOF sensor 124 and magnetic field generator 128 may be obtained from Ascension Technology Corporation, Milton, Vt. Base electronics unit 120 contains the circuitry and other components for providing the base functionality of MTS 112 . MTS 112 is in communication with medical computer 116 , which provides, among other things, the remaining functionality of the MTS, such as a graphical user interface and display. As those skilled in the art will readily appreciate, medical computer 116 may be a general purpose computer specially adapted for an operating room environment and may include one or more displays 132 for providing images, graphics and other visual information and/or graphical input functionality to medical personnel during use. In some cases, a reference sensor 136 may be used for correcting the accuracy of MTS 112 , as described below. In other cases, one or more additional reference sensors 140 may be use for correcting the accuracy of MTS 112 . Each of reference sensors 136 , 140 may be any magnetic sensor suitable for this application and may be located inside or outside the patient depending on the procedure being performed and/or the stage of the procedure and whether or not the patient is present. Reference sensors do not need to be placed at “fixed” locations. While some applications benefit from having the reference sensor fixed, other applications may require the reference to move. Allowing the reference to move provides a means for negating the effects of respiratory, heart, or other patient movements on the tracked sensor (dynamic compensation). Measured movement of the reference sensor(s) can be subtracted from the tracked sensor(s) to achieve “quasi-stationary” tracked sensor measurements, free from motion artifact.
Referring now to FIGS. 2A-B , and also to FIG. 1 , FIGS. 2A-B illustrate a method 200 of calculating corrected position and orientation (P&O) of a sensor in a setting that contains a large, movable object that may be moved during the time that P&O information is needed. For convenience, method 200 is described in the context of surgical setting 100 of FIG. 1 . Consequently, the sensor under consideration is 6DOF sensor 124 and the large, movable object under consideration is C-arm 104 . Those skilled in the art will understand that although method 200 is explained in the context of surgical setting 100 of FIG. 1 , this method may indeed be used in other settings. At step 201 , which is performed prior to performing the surgical procedure utilizing MTS 112 , 6DOF sensor 124 is placed at or near a desired location, such as the location depicted in FIG. 1 . This can be accomplished by the use of imaging available via C-arm 104 , or not, and using tracking by MTS 112 . After 6DOF sensor 124 is placed, C-arm 104 is withdrawn from surgical setting 100 , and at steps 203 and 205 , respectively, MTS 112 measures the fields at the sensor and calculates the P&O of the sensor. The sensed field data S 0 and the calculated P&O L 0 are saved at respective steps 207 and 209 for further processing. C-arm 104 is then brought back into surgical setting 100 . 6DOF sensor 124 may be located inside or outside the patient depending on the procedure being performed and/or the stage of the procedure and whether or not the patient is present. Multiple measurements of the 6DOF sensor 124 may be obtained with and without the C-arm 104 in place but during patient movements to accomplish dynamic compensation.
After C-arm 104 has been brought back into surgical setting 100 , at steps 211 and 213 , respectively, new field measurements are collected using 6DOF sensor 124 and the P&O of the sensor is calculated. The sensed field data Sc and the calculated P&O Lc are saved at respective steps 215 and 217 . It is noted that in the present example, the calculations may be performed by base electronics unit 120 , medical computer 116 or a combination of both, depending on the setups of these components. Similarly, sensed field data S 0 , Sc and calculated P&O L 0 , Lc may be stored in base electronics unit 120 , medical computer 116 or a combination of both.
At respective steps 219 , 221 each set of field data S 0 , Sc is rotated to achieve zero orientation using corresponding matrices A 0 , Ac to rotate the fields. Each matrix A 0 , Ac is calculated from the corresponding respective orientation portion of P&O L 0 , Lc calculated at steps 205 , 213 , respectively, in a manner known in the art. These corrections are transformed into a zero sensor orientation reference frame so that they may be retransformed into any other orientation. Other methods may also be used to rotate the fields, and it may be advantageous to transform them into something other than a zero sensor orientation reference frame. At corresponding respective steps 223 and 225 , ranges R 0 , Rc (as determined from steps 205 , 213 ) are backed out of zero orientation matrices A 0 , Ac. Ranges R 0 , Rc can also be determined by other methods known in the art that are found in magnetic tracking algorithms and, in certain cases, may not need to be accounted for.
The resulting matrices contain information that can be extracted and used to provide corrections. This is represented in steps 227 , 229 of method 200 . In this example, the important properties calculated/obtained in steps 227 , 229 are identified as components V_ 0 , V_c of matrices V 0 , Vc, respectively and the difference between these matrices is used for correction of the distorting field. At step 231 the difference (dig) between matrices V 0 , Vc is calculated. Once this data is collected and saved, the run time collection of distorted field data can be started at step 233 . In step 235 , this data is also decomposed by singular value decomposition into three matrices. At this point, the V matrix is no longer ideal, so to correct it, the dV matrix is added to it at step 237 . At step 239 orientation is then corrected by multiplying the result of step 237 by the A 0 t ·Ac t (which also happens to equal the inverse of A 0 ·Ac). At step 241 a corrected P&O for 6DOF sensor 124 is calculated using the matrix resulting from step 239 by methods known in the art. The corrected P&O is output at step 243 . It is noted that small displacements of 6DOF sensor 124 off from the original measurement will still benefit from this correction, but will degrade as the sensor is moved further away from its original measurement position. Small displacements may occur, for example, during respiration, mechanical heart motion, or other patient movements.
For a 5DOF sensor (not shown), only one vector need be measured. Therefore, corrections are only applicable if the sensor does not change position or orientation much from the original measurement. Measurements from 6DOF sensors, such as 6DOF sensor 124 of FIG. 1 , can be used to correct both 6DOF and 5DOF sensors. Multiple 5DOF sensors, or measurements taken at various positions and orientations using 5DOF sensors, can also correct both 6DOF and 5DOF sensors.
Multiple sensor data sets (fields and P&O) can also be collected for use with method 200 of FIGS. 2A-B . While it is often preferable to collect the data sets with 6DOF sensors for maximum collection efficiency, 5DOF sensors can also be used. In certain applications, robotic instrumentation may place the sensors at known positions and orientations. In other applications, one or more surgical instruments, for example, catheters, probes, needles, etc., may place multiple sensors at multiple locations. The placement may be determined by an MTS, for example, MTS 112 of FIG. 1 , when the large, movable object is removed from the sensor region, for example, when C-arm 104 is retracted, or may be determined by other means such as 2D fluoroscopy. While it is often preferred that all the data be collected from the multiple sensors in parallel, a single sensor may be translated and rotated throughout the area requiring compensation in order to build up a complete data set if needed. Single and multiple sensors may also be repositioned in space by repositioning the patient or taking advantage of patient movement artifact due to respiration, mechanical heart motion, etc.
At step 231 dV is typically calculated from an interpolated set of data. The same typically occurs at step 239 , wherein the rotation matrices arise from an interpolated set of data. A minimum set of data for interpolation comes from at least four non-coplanar locations, with more data generally providing better results. Any number of methods may be used for the interpolation, depending on the data collected. This can be a polynomial fit, a spline, a table lookup, a Fourier or wavelet transform, the results from a partial differential equation solver, etc. Extrapolation can also be performed, but with worse results typical beyond the enclosed volume.
FIG. 3 illustrates a method 300 that can also be used to calculate corrected P&O of a sensor in a setting that contains a large, movable object that acts to distort magnetic fields in its vicinity. For convenience, method 300 , like method 200 , is described in the context of surgical setting of FIG. 1 , with the understanding that this context is merely exemplary of different settings in which method 300 can be implemented. Those skilled in the art will readily understand how to adapt method 300 to the setting under consideration.
At a high level, instead of using field differences dV as in method 200 of FIGS. 2A-B , method 300 uses the P&O solutions before and after introducing C-arm 104 ( FIG. 1 ) into surgical setting 100 . As seen below, suitable rotation and translation are calculated to bring the P&O solution back to the original value (before introduction of C-arm 104 ). This transformation is used on all subsequent P&O calculations. This provides a purely relative measurement for localization. In many procedures, P&O of one sensor with respect to another sensor is all that is required for accurate localization of the second sensor. Sensors may be located inside or outside the patient depending on the procedure being performed and/or the stage of the procedure and whether or not the patient is present. Reference sensors do not need to be placed at “fixed” locations. While some applications benefit from having the reference sensor fixed, other applications may require the reference to move. Allowing the reference to move provides a means for negating the effects of respiratory, heart, or other patient movements on the tracked sensor (dynamic compensation). Measured movement of the reference sensor(s) can be subtracted from the tracked sensor(s) to achieve “quasi-stationary” tracked sensor measurements, free from motion artifact.
Referring now to FIG. 3 , and also occasionally to FIG. 1 , at step 301 reference sensor 136 is placed at a known location, for example, at an anatomical landmark (not shown). Such a known location can be determined using C-arm 104 or other means, such as ultrasound, if needed. At step 303 , if C-arm 104 is present, the actual P&O data R 1 for reference sensor 136 is determined by any suitable means other than MTS 112 . However, if C-arm 104 is not present, MTS 112 can be used to determine actual P&O data R 1 for reference sensor 136 . At step 305 , with the C-arm in the tracking volume, actual data is collected by MTS 112 and reference sensor 136 , and the distorted P&O data S 1 of the reference sensor is calculated. The two sets of P&O data R 1 , S 1 for reference sensor 136 from steps 303 and 305 are stored, respectively, at steps 307 and 309 .
Any distortion error will distort reference sensor 136 and the real-time tracked sensor(s), here 6DOF sensor 124 , in a similar manner, allowing computing of the P&O of the tracked sensor(s) with respect to the reference sensor and suffer only a small error. To accomplish this, at step 311 a best-fit transformation matrix T is calculated as between the actual P&O R 1 of reference sensor 136 and the P&O solution S 1 with or without C-arm 104 . The transformation consists of a translation and a rotation. Calculating transformation matrix T can be accomplished in many ways, as is known in the art. After transformation matrix T has been calculated, real-time calculation of actual P&O data S 2 for 6DOF sensor 124 can begin at step 313 , for example, during an actual surgical procedure. At step 315 transformation matrix T from step 311 is then applied to the P&O data calculated from 6DOF sensor 124 , with the corrected P&O solution being output at step 317 . A simple version of method 300 is to use a fixed reference sensor (on or near the patient in this example) and calculate the P&O of the second sensor with respect to the fixed reference sensor. In this case, both the reference and real-time tracked sensors are subjected to almost the same distortion effects, so a simple subtraction removes the distortion effects. If the reference moves due to respiratory, heart, or other patient movements the measured movement of the reference sensor(s) can be subtracted from the tracked sensor(s) to achieve “quasi-stationary” tracked sensor measurements, free from motion artifact.
FIG. 4 illustrates a method 400 that is based on method 300 of FIG. 3 and involves placing multiple reference sensors in the volume of interest at known locations. With these sensors all at known locations, interpolation methods are used to further increase the accuracy of the position determination of the tracked sensor, again with or without moving the large, movable object out of the tracking volume. A suitable rotation and translation are calculated to bring the P&O solutions of the reference sensors back to the original value (before introduction of the large, movable object). This transformation is used on all subsequent P&O calculations. This provides a purely relative measurement for localization. As mentioned above, in many procedures P&O of one sensor with respect to another sensor is all that is required for accurate localization of the second sensor. Sensors may be located inside or outside the patient depending on the procedure being performed and/or the stage of the procedure and whether or not the patient is present. If the reference sensors move due to respiratory, heart, or other patient movements the measured movement of the reference sensor(s) can be subtracted from the tracked sensor(s) to achieve “quasi-stationary” tracked sensor measurements, free from motion artifact.
Referring now to FIG. 4 , and also occasionally to FIG. 1 , at step 401 of method 400 reference sensors 136 , 140 are placed at corresponding respective anatomical landmarks (not shown) or at other known locations. Such known locations can be determined using C-arm 104 or other means, such as ultrasound, if needed. At step 403 , if C-arm 104 is present, the actual P&O data R 1 -Rn for reference sensors 136 , 140 is determined by any suitable means other than MTS 112 . However, if C-arm 104 is not present, MTS 112 can be used to determine actual P&O data R 1 -Rn for reference sensors 136 , 140 . At step 405 , with the C-arm in the tracking volume, actual data is collected by MTS 112 and reference sensors 136 , 140 , and the distorted P&O data S 1 -Sn for the reference sensors is calculated. The two sets of P&O data R 1 -Rn, S 1 -Sn for reference sensors 136 , 140 from steps 403 and 405 are stored, respectively, at steps 407 and 409 .
Any distortion error will distort reference sensors 136 , 140 and 6DOF sensor 124 in a similar manner, allowing computing of the P&O of the 6DOF sensor with respect to the reference sensors and suffer only a small error. To accomplish this, at step 411 best-fit transformation matrices T 1 -Tn are calculated that convert the actual P&Os R 1 -Rn of reference sensors 136 , 140 into the P&O solution S 1 -Sn. Each transformation consists of a translation and a rotation. Calculating transformation matrices T 1 -Tn can be accomplished in many ways, as is known in the art. At step 413 an interpolation function ƒ is formed from transformation matrices T 1 -Tn. Function ƒ is interpolated and/or extrapolated to yield corrections within the volume defined by the space where the correction data was collected. A minimum set of data comes from at least four non-coplanar locations, with more data being better. Any number of methods may be used for the interpolation/extrapolation at step 413 , depending on the data collected. This may be a polynomial fit, a spline, a table lookup, etc. The interpolation will be a function of position and orientation of the P&O calculated by each real-time tracked sensor. After function ƒ has been formed, real-time calculation of actual P&O data S 3 for 6DOF sensor 124 can begin at step 415 , for example, during an actual surgical procedure. At step 417 function ƒ from step 413 is then applied to the P&O data calculated from 6DOF sensor 124 , with the corrected P&O solution being output at step 419 .
FIGS. 5A-B illustrate a method 500 that can be used to calculate corrected P&O of a sensor in a setting that contains a large, movable object that acts to distort magnetic fields in its vicinity. For convenience, method 500 is described in two parts: Part 1 ( FIG. 5A ) details an initialization stage, while Part 2 ( FIG. 5B ) describes use of data obtained in the initialization phase. At a high level, and as described below in more detail, field data collected from multiple sensors (or one sensor translated/rotated to multiple locations), is used to determine the position, orientation and strength of imaginary dipoles that can account for the distortion effects. A sufficient number of measurements are required to calculate this. For dipole fitting, the minimum number of data points is five, but more data provides a better fit. The fit can be determined using non-linear least squares techniques, Kalman filtering, or other known methods that allow the solution. Multiple dipoles can be fit if a sufficient quantity of field data is collected. Once the imaginary dipoles are calculated, their effects on the fields can be calculated for any position and orientation of a sensor within the tracking volume. Sensors may be located inside or outside the patient depending on the procedure being performed and/or the stage of the procedure and whether or not the patient is present. If the reference sensors move due to respiratory, heart, or other patient movements the measured movement of the reference sensor(s) can be subtracted from the tracked sensor(s) to achieve “quasi-stationary” tracked sensor measurements, free from motion artifact.
With that general overview in mind, attention is now directed to FIG. 5A , and also to FIG. 1 . Again, surgical setting 100 of FIG. 1 is simply used for convenience to describe the broad concepts of method 500 . In other words, the broad concepts of method 500 may be used in other settings. At step 501 in FIG. 5A multiple sensors, such as sensors 136 , 140 (note that in this method sensors 136 , 140 are not used as “reference” sensors in the same manner as discussed above relative to methods 200 and 300 ) are placed at known locations. At step 503 field data from sensors 124 , 136 , 140 is collected with C-arm 104 placed at a known location and orientation. (This can also be accomplished by placing a single sensor in multiple locations and collecting data in a serial manner.) Because sensors 124 , 136 , 140 are at known locations and orientations, at step 505 the field data expected at these places can be calculated. At step 507 , the difference between the calculated field data and the measured field data is calculated and stored as a difference matrix dF. Using this difference matrix dF and the sensor placement and the C-arm placement from step 503 , the parameters of a dipole model may be calculated at step 509 using an initial guess of dipole parameters and tolerance provided at step 511 . The parameters calculated at step 509 can include a scale term (one parameter) and location and orientation terms (five parameters). More detailed models may contain additional parameters, as is known in the art. The method of determining the parameters includes non-linear least squares techniques, Kalman filtering, or other methods that allow the solution.
Once the dipole model parameters are calculated, at step 513 these parameters are plugged into the model to calculate the field contribution M based on the data collected in step 503 . At step 515 field contributions M are compared against difference matrix dF. If the absolute difference between field contributions M and difference matrix dF is smaller than the user-supplied tolerance supplied at step 511 , the parameters are saved off at step 517 . At step 519 , it is determined whether additional models are desired for other locations of C-arm 104 . If so, C-arm 104 is moved to a new location and steps 503 through 519 are repeated to construct an additional model for different placements of C-arm 104 . This process may be repeated to create models for all desired placements of C-arm 104 . If no further models are desired at step 519 , method 500 may continue to step 521 of Part 2 ( FIG. 5B ).
Referring to FIG. 5A , if at step 515 it is determined that the absolute difference between field contributions M and difference matrix dF is not smaller than the user-supplied tolerance supplied at step 511 , at step 523 difference matrix dF is updated with the difference between field contributions M and difference matrix dF and method 500 re-enters step 509 . An additional model is determined as before, and this process repeats until a sufficient number of models are determined to adequately fit the distortion from C-arm 104 , as determined by the tolerance check at step 515 . Again, tolerance is a user input that a user inputs at step 511 and is determined by how much error can be tolerated in the tracking algorithm.
After all the models and their parameters are determined in Part 1, the runtime dipole use of Part 2 ( FIG. 5B ) comes into play. At step 521 a real-time tracked sensor, here 6DOF sensor 124 , is introduced and the P&O data for this sensor is calculated from its field data S 3 , and this field data is saved. At step 525 , the location and orientation of C-arm 104 is identified by some mechanism, such as a controller (not shown) for the C-arm, as was used when the dipoles were modeled in Part 1. It is noted that if enough configurations of C-arm 104 are modeled, intermediate C-arm configurations can be interpolated to yield interpolated parameters to non-parameterized locations. At step 527 , the contribution of the dipoles (D) is calculated based on the present P&O calculated at step 521 . It is understood at the startup of this algorithm that the P&O is incorrect due to the fact that no modeled sources have yet been applied. The contributions to the fields are added (S 3 +D) at step 529 . At step 531 , this modified field data S 3 is used to calculate a new P&O solution.
At optional step 533 , it is determined whether the P&O solution of step 531 has settled and/or whether the modified field data S 3 calculated at step 529 has settled. If a P&O solution that is settled to its final value is desired, step 533 compares the immediately previous P&O solution with the present one. If they are similar enough (last cycle's P&O solution approximately equal to the present cycles P&O and/or last cycle's field data S 3 approximately equal to this cycle's field data S 3 ), then the result is output at step 535 . If they are not close enough, another iteration of correction is made by returning method 500 to step 527 . In those situations where the corrections may never be good enough or timing is of a concern, a limitation on the number of branch backs can be provided, for example, by integrating a counter into step 533 . In many applications, however, step 533 need not be used such that the P&O solution from step 531 is directly output at step 535 , as indicated by dashed line 537 . This will provide continuous output for every P&O solution. Once the P&O calculation settles after startup, real-time operation and correction tends to keep up because changes are based on incremental changes to the dipole D matrix.
Since motorized C-arms are common, data collected from known C-arm placements can be stored in a database (that, in the context of surgical setting 100 of FIG. 1 , may reside in medical computer 116 ) to facilitate the distortion compensation. If the C-arm is placed at an already compensated location, the database is queried for the compensation data and applied forthwith. As noted, a C-arm can be modeled as one or more dipoles (also by differing dipoles at differing P&Os of the C-arm). This data can be collected once the C-arm is installed at a hospital, for example, and the dipole models can be stored as a function of C-arm position/orientation. Intermediate C-arm P&Os could be modeled by interpolating the predetermined dipole models. As a further enhancement, if C-arm P&O is not readily available, a fixed sensor in the tracking environment could monitor the distortion in the environment when the C-arm is positioned/oriented. This data, either distorted field data or distorted sensor P&O data, would then be mapped to the dipole models so that the correct model would be used.
One or more sensors can also be mounted to the field generator 128 or in the head of the C-arm, at known locations, to facilitate data collection. Sensors mounted in the transmitter are already at known, fixed positions and orientations. Sensors mounted on the C-arm need to be mounted in a known geometry. This sensor configuration would be characterized before installation on the C-arm. Once mounted, the distortion effect of the C-arm is measured and used to further refine the imaginary dipole calculations.
Other dipole determination methods are also disclosed in the literature and in patents. Some of these methods work in a similar manner, by first collecting field data from multiple sensors 503 , fitting dipoles to data 509 , calculating dipole contributions 513 and saving the dipole parameters for future use 517 . For example, submarine warfare utilizes techniques for modeling submarines as dipoles. Magneto-encephalograms and certain cardiac electro-physiology applications also model various conditions using dipoles.
FIGS. 6A-B are directed to portions of a method in which multipole fields are used to characterize the distorter, i.e., the large movable object (e.g., a C-arm). Discussions and methods directed to multipole modeling are disclosed in “Magnetic-Multipole Techniques for Moveable-Scatterer Compensation,” Raab, F., and Brewster, C., Technical Report AAMRL-TR-88-054, November 1988, which is incorporated herein by reference in its entirety. Multipole moments are linearly related to the transmitted magnetic field and its gradients by a set of scattering coefficients. Scattering coefficients are determined from field measurements by applying, for example, linear coefficient fitting techniques.
Scalar magnetic potential theory is used to define a set of gradients that excite the multipole moments. Transformations for computing the distorting field from an arbitrarily positioned and oriented distorter (e.g., a C-arm) can be obtained by transforming the scalar magnetic potential gradients from one coordinate system to another. While it is preferred to have closed form solutions for the scatterer, mapping can be used to handle difficult, hard to characterize, gradients.
Referring to FIG. 6A , this figure details a characterization phase 600 wherein the distorter, for example, a movable imaging device such as C-arm 104 of FIG. 1 , is characterized. At step 601 a field measurement sensor, for example 6DOF sensor 124 of FIG. 1 , is moved about a tracking volume and magnetic field measurements are taken without the distorter present. Typically, this sensor would measure the three vector components from each of the positions in the volume of interest (i.e., the tracking volume). It is also possible to use multiple, single component measurements to build up this information.
The measurement data from step 601 is then curve fit at step 603 to extract the scalar magnetic potentials (g j ). These gradients are multidimensional partial derivatives of the measured magnetic fields. If the fields are not known, or not known well enough, then the gradients can be determined numerically. This can be accomplished when using polynomials or splines, which can be manipulated to determine derivatives, for example. This can be done by many methods known in the art, including polynomials, splines, rational functions, trigonometric functions, wavelets, to name a few. If a known function is available describing the fields and scatterer, then these are used directly instead of performing step 603 .
The distorter is now introduced and, at step 605 the tracking volume is again mapped as was done at step 601 . With this data available, at step 607 the induced moments (p k ) are extracted from the distorted data. Given p k and g j , at step 609 the scattering matrices (s k,j ) are calculated from the following equation:
p k = ∑ j = 1 J s k , j g j ( x , y , z )
This can be performed by methods known in the art, which include least squares methods for best fitting the scattering matrices to the data. The resulting matrices and gradients are saved at step 611 . These results will be used in a distortion compensation determination phase 620 as detailed in FIG. 6B .
Referring to FIG. 6B , at step 621 the P&O of the scatterer (i.e., distorter, e.g., a C-arm) are determined. For this, the scatterer may be instrumented so that its P&O are noted and/or controlled with respect to the tracking volume. This can also be achieved with a dedicated sensor mounted on the scatterer that is in the tracking volume. After the P&O of the scatterer are known, at step 623 the gradients and scattering matrices saved at step 611 of FIG. 6A are evaluated at the position of the scatterer and rotated. At step 625 the rotated gradient and scattering matrices are then used to calculate the moments. At step 627 the scattered field components are then calculated, and at step 629 the field components are transformed into the desired tracking reference frame.
The scattered components calculated at step 627 are then used to correct for distortion as shown in FIG. 7 , which details a method 700 of applying the distortion correction to an MTS. At step 701 field measurements are obtained from a sensor within the tracking volume discussed above relative to FIGS. 6A-B . The sensor may be located inside or outside the patient depending on the procedure being performed and/or the stage of the procedure and whether or not the patient is present. At the startup of method 700 , no adjustments are available for the summation at step 703 , and so the field measurements pass unchanged (i.e., initially, the corrected fields output at step 705 is equals to the field measurements input at step 701 ) through summation step 703 . At step 707 the P&O of the sensor is calculated from the corrected fields at step 705 and is output to a user at step 709 . The P&O algorithm used at step 707 may be any suitable algorithm known in the art. At step 711 , the calculated P&O of step 709 is used to determine the scattered field components that effect it. At step 713 corrections are output from step 711 . These corrections are then low pass filtered at step 715 to inhibit excessive changes between iterations, but this is not a necessity. At step 703 the filtered corrections are then added into the next field readings from step 701 and the process repeats.
In some embodiments, where distortion is at a minimum, or in the limiting case, non-existent, reference sensors may still be used to gain some advantage. As described above, reference sensors can compensate for patient or patient organ movement. This is true independent of the method of distortion compensation applied.
As will be readily understood by those skilled in the art, many steps of any one of methods 200 , 300 , 400 , 500 , 700 and phases 600 , 620 may be performed by one or more computers, such as medical computer 116 of FIG. 1 , and/or other machine(s), such as based electronics unit 120 of FIG. 1 . Such computers and machines are typically microprocessor-based and can be programmed according to the teachings of the present specification, as will be apparent to those of ordinary skill in the computer arts. Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those of ordinary skill in the software art.
Such software may be a computer program product that employs one or more machine-readable media and/or one or more machine-readable signals. A machine-readable medium may be any medium that is capable of storing and/or encoding a sequence of instructions for execution by a machine (e.g., a general purpose computing device) and that causes the machine to perform any one of the methodologies and/or embodiments described herein. Examples of a machine-readable medium include, but are not limited to, a magnetic disk (e.g., a conventional floppy disk, a hard drive disk), an optical disk (e.g., a compact disk “CD”, such as a readable, writeable, and/or re-writable CD; a digital video disk “DVD”, such as a readable, writeable, and/or rewritable DVD), a magneto-optical disk, a read-only memory “ROM” device, a random access memory “RAM” device, a magnetic card, an optical card, a solid-state memory device (e.g., a flash memory), an EPROM, an EEPROM, and any combination thereof. A machine-readable medium, as used herein, is intended to include a single medium as well as a collection of physically separate media, such as, for example, a collection of compact disks or one or more hard disk drives in combination with a computer memory.
Examples of a computing device include, but are not limited to, a computer workstation, a terminal computer, a server computer, a handheld device (e.g., tablet computer, a personal digital assistant “PDA”, a mobile telephone, etc.), a web appliance, a network router, a network switch, a network bridge, a computerized device, such as a wireless sensor or dedicated proxy device, any machine capable of executing a sequence of instructions that specify an action to be taken by that machine, and any combination thereof. Medical devices, e.g., a C-arm, that are now digitally enhanced, could also include the computing device necessary to perform methods 200 , 300 , 400 , 500 , 700 and phases 600 , 620 .
FIG. 8 shows a diagrammatic representation of one embodiment of a computing device in the exemplary form of a computer system 800 within which a set of instructions for causing the device to perform any one or more of the aspects and/or methodologies of the present disclosure may be executed. Computer system 800 includes a processor 804 (e.g., a microprocessor or DSP) (more than one may be provided) and a memory 808 that communicate with each other, and with other components, via a bus 812 . Bus 812 may include any of several types of bus structures including, but not limited to, a memory bus, a memory controller, a peripheral bus, a local bus, and any combination thereof, using any of a variety of bus architectures well known in the art.
Memory 808 may include various components including, but not limited to, a random access read/write memory component (e.g, a static RAM (SRAM), a dynamic RAM (DRAM), etc.), a read only component, and any combination thereof. In one example, a basic input/output system 816 (BIOS), including basic routines that help to transfer information between elements within computer system 800 , such as during start-up, may be stored in memory 808 . Memory 808 may also include (e.g., stored on one or more machine-readable media) instructions (e.g., software) 820 embodying any one or more of the aspects and/or methodologies of the present disclosure. In another example, memory 808 may further include any number of instruction sets including, but not limited to, an operating system, one or more application programs, other program modules, program data, and any combination thereof.
Computer system 800 may also include one or more storage devices 824 . Examples of storage devices suitable for use as any one of the storage devices 824 include, but are not limited to, a hard disk drive device that reads from and/or writes to a hard disk, a magnetic disk drive device that reads from and/or writes to a removable magnetic disk, an optical disk drive device that reads from and/or writes to an optical media (e.g., a CD, a DVD, etc.), a solid-state memory device, and any combination thereof. Each storage device 824 may be connected to bus 812 by an appropriate interface (not shown). Example interfaces include, but are not limited to, Small Computer Systems Interface (SCSI), advanced technology attachment (ATA), serial ATA, universal serial bus (USB), IEEE 13144 (FIREWIRE), and any combination thereof. In one example, storage device 824 may be removably interfaced with computer system 800 (e.g., via an external port connector (not shown)). Particularly, storage device 824 and an associated machine-readable medium 828 may provide nonvolatile and/or volatile storage of machine-readable instructions, data structures, program modules, and/or other data and/or data storage for computer system 800 . In one example, software 820 may reside, completely or partially, within machine-readable medium 828 . In another example, software 820 may reside, completely or partially, within processor 804 .
In some embodiments, such as a general purpose computer, computer system 800 may also include one or more input devices 832 . In one example, a user of computer system 800 may enter commands and/or other information into the computer system via one or more of the input devices 832 . Examples of input devices that can be used as any one of input devices 832 include, but are not limited to, an alpha-numeric input device (e.g., a keyboard), a pointing device, a joystick, an audio input device (e.g., a microphone, a voice response system, etc.), a cursor control device (e.g., a mouse), a touchpad, an optical scanner, a video capture device (e.g., a still camera, a video camera), touchscreen, a digitizer pad, and any combination thereof. Each input device 832 may be interfaced to bus 812 via any of a variety of interfaces (not shown) including, but not limited to, a serial interface, a parallel interface, a game port, a Universal Serial Bus (USB) interface, a FIREWIRE interface, a direct interface to the bus, a wireless interface (e.g., a Bluetooth® connection) and any combination thereof.
Commands and/or other information may be input to computer system 800 via storage device 824 (e.g., a removable disk drive, a flash drive, etc.) and/or one or more network interface devices 836 . A network interface device, such as network interface device 836 , may be utilized for connecting computer system 800 to one or more of a variety of networks, such as network 840 , and one or more remote devices 844 connected thereto. Examples of a network interface device include, but are not limited to, a network interface card, a modem, a wireless transceiver (e.g., a Bluetooth® transceiver) and any combination thereof. Examples of a network include, but are not limited to, a wide area network (e.g., the Internet, an enterprise network), a local area network (e.g., a network associated with an office, a building, a campus, a group of wireless sensors or other group of data streaming devices, or other relatively small geographic space), a telephone network, a direct connection between two computing devices, and any combination thereof. A network, such as network 840 , may employ a wired and/or a wireless mode of communication. In general, any network topology may be used. Information (e.g., data, software 820 , etc.) may be communicated to and/or from computer system 800 via the one or more network interface devices 836 .
In some embodiments, such as a general purpose or medical computer, computer system 800 may further include a video display adapter 848 for communicating a displayable image to a display device, such as display device 852 . Examples of a display device include, but are not limited to, a liquid crystal display (LCD), a cathode ray tube (CRT), a plasma display, and any combination thereof. In addition to a display device, a computer system 800 may include one or more other peripheral output devices including, but not limited to, an audio speaker, a printer, and any combination thereof. Such peripheral output devices may be connected to bus 812 via a peripheral interface 856 . Examples of a peripheral interface include, but are not limited to, a serial port, a USB connection, a FIREWIRE connection, a parallel connection, and any combination thereof.
In some embodiments, computations and data storage may be distributed over multiple devices. Data relating to C-arm calibration, for example, might reside with the C-arm, while P&O calculations might occur in base electronics unit 120 and the corrections might occur in medical computer 116 . The Digital Imaging and Communications in Medicine (DICOM) standard for distributing and viewing any kind of medical image regardless of the origin could also be used for enabling methods 200 , 300 , 400 , 500 , 700 and phases 600 , 620 , while integrating C-arm imaging.
A digitizer (not shown) and an accompanying pen/stylus, if needed, may be included in order to digitally capture freehand input. A pen digitizer may be separately configured or coextensive with a display area of display device 852 . Accordingly, a digitizer may be integrated with display device 852 , or may exist as a separate device overlaying or otherwise appended to the display device.
Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention. | Methods for accurately tracking position and orientation of a magnetic-field sensor in a tracking volume when a large magnetic-field distorter is present in the tracking volume. In some of the methods, magnetic field data is collected from within the tracking volume both with and without the large magnetic-field distorter present in the tracking volume. This data is used to obtain correction information that is subsequently used during real-time operation of the magnetic-field sensor to correct the position and orientation solutions for the sensor for magnetic-field distortions caused by the presence of the large magnetic-field distorter in the tracking volume. Others of the methods involve modeling the large magnetic-field distorter using dipole and multipole modeling. Magnetic tracking systems for implementing the methods include hardware and software for carrying out the methods. | 0 |
BACKGROUND OF THE INVENTION
The Invention concerns a method of operating an electrochromic element which consists of at least the following layers:
a first electrode layer;
first layer, in which ions can be reversibly inserted;
a transparent ion-conducting layer;
a second layer, in which ions can be reversibly inserted; and
a second electrode layer,
where the first and/or the second layer, in which ions can be reversibly inserted, is an electrochromic layer and the other of these layers acts as counter-electrode to the electrochromic layer, and where a voltage is applied to the electrode layers which induces a colour-change process, which voltage possesses values in a redox-stability range of the electrochromic layer system and the current flows through electrochromic element is measured continuously.
1. Field of the Invention
The term colour-change process denotes either forced colouring, that is to say a reduction in transmittance or reflectance of the electrochromic element, in particular in the visible region of the spectrum, or decolouring or bleaching, that is to say increasing the transmittance or reflectance. It can also however consist primarily of a change in the colour location of the transmitted or reflected radiation. Voltage values in a redox-stability range of the electrochromic layer system denotes voltages where the electrochromic layer system consisting of the electrochromic layer, the ion-conductive layer and the layer acting as counter-electrode experiences no or at all events very slight irreversible changes.
The electrochromic element incorporates at least one electrochromic layer, whose colour can be reversibly changed. This is combined as counter-electrode either with another electrochromic layer or with a transparent ion storage layer, which does not change its transparency significantly as a result of the insertion of ions. For the sake of simplicity, the two layers in which ions can be inserted are both designated below as electrochromic layers.
The layers of the electrochromic element mentioned above can also if necessary follow one another with further layers being interposed, such as for example protective layers, insulating layers, optically effective auxiliary layers, reference electrode layers, or the like. At least one of the electrode layers is a transparent layer. If the electrochromic element is to be used as a transparent window element with variable transmittance, the second electrode layer will also be transparent. If, on the other hand, the electrochromic element is to be used as a mirror with variable reflectance, one of the two electrode layers will preferably take the form of an opaque reflection layer of a suitable metal, such as aluminium or silver. It is also possible however to operate with two transparent electrode layers and to provide an additional metal reflection layer. For the sake of simplicity, only electrochromic elements with variable transmittance will be discussed, without however the Invention being restricted to this.
It is possible, by means of the voltage applied via the electrode layers to the electrochromic element, to alter its transmittance. This change generally takes place more quickly, the higher is the voltage applied. Of course, if the electrochromic element is not operated in optimum fashion, if therefore, in particular, the voltage applied is too high, it can be permanently damaged. It is then possible for the transmittance of the electrochromic element to cease being variable, or that the difference between minimum and maximum transmittance will no longer be as great as in undamaged state, under otherwise identical ambient conditions. It is also to be feared that the electrochromic element will no longer colour homogeneously, possibly irreversibly coloured or no longer colourable areas will be formed.
Above all, if a polymer electrolyte is used as ion-conductive layer, there is also a risk of the electrochromic layer delaminating, that is to say that the ion-conductive layer will become detached from the electrochromic layers in some areas.
According to the application of the electrochromic element, it will be exposed to a greater or lesser degree to wide temperature fluctuations. Thus, for example, in the case of an electrochromic element which is used in motor vehicles as window glass, roof glazing panel, or the like, it can be expected that it will operate satisfactorily at temperatures in the range of −20° C. to +80° C. Similar temperatures are to be expected in the case of applications in the outer skin of buildings, for example in the field of building curtain walls. It is known that a temperature increase will lead to reduction of the specific resistance of the system components. In particular, the resistance of the ion-conductive layer can decrease drastically with a temperature increase. If suitable measures are not taken, this can easily lead to the fact that, at high temperatures, the redox stability range of the electrochromic layer system will be exceeded and irreversible changes will occur.
2. Description of the Prior Art
From EP 0 475 847 B1, according to which the Preamble of the Patent Claim is formulated, a process for operating an electrochromic element is known, where the voltage applied to the electrochromic element is temperature-dependent. The temperature is measured directly with a thermometer, or indirectly, by a voltage pulse being generated prior to each colour-change process, by means of which with simultaneous current measurement, the resistance of the ion-conductive layer is determined, and from this the temperature of the electrochromic element is determined. According to the temperature determined, a voltage is applied to the electrochromic element for a predetermined time. When the desired transmittance is reached, the voltage is disconnected.
EP 0 718 667 A1 has as its subject a process for operating an electrochromic element which can be influenced by the user, which process can be adapted via an interface to electrochromic elements of different designs, to the ambient temperature and to the dimensions of the electrochromic element. Here, the voltage with which the electrochromic element is operated is also to be a function of the temperature. A disadvantage of the known process is that, for each individual electrochromic element, matching of the control parameters to the window dimensions must take place.
EP 0 683 419 A1 discloses a method to trigger an electrochromic element in which a current is impressed on this.
SUMMARY OF THE INVENTION
The purpose of the present Invention is to provide a process for operating an electrochromic element which will operate over a wide temperature range, which is largely independent of the area of the electrochromic element, which permits a change in transmittance over a wide range, which permits sufficiently rapid colour change, and with which a long service life of the electrochromic element can be achieved.
This problem is solved by a process in accordance with Patent claim 1 . Advantageous configurations are the subject of the Subclaims.
According to the Invention, provision is made for the current I flowing through the electrochromic element to be measured continuously, for the voltage U applied to the electrochromic element during a starting stage of the colour-change process to be increased or reduced continuously up to maximum to a final value U max predetermined as a function of temperature, where the temperature dependence of the final value U max is determined by the design of the electrochromic element, but is independent of the area to be subjected to colour change, and that the voltage U is controlled during the course of the colour-change process as a function of the current I, where the voltage U does not exceed in magnitude the magnitude of the final value U max . The final value U max can possess a different magnitude for a colouring process than for a bleaching process.
Current measurements will normally take place regularly at always the same, sufficiently short intervals of time, typically several times a second. It is also possible to proceed in such a way that, for example in the starting stage of the colour-change process, measurements are carried out at shorter intervals than in later stages, because in the starting stage, the current and the voltage will normally change at the fastest rate.
For most applications, it will suffice for the temperature dependence of the final value U max of the voltage U is determined by a linear relationship, for example:
U max =A−B·T, (1)
where T is the temperature of the electrochromic element, and A and B are constants determined by the design of the electrochromic element, which are to be established empirically. If the temperature T is in ° C., A will correspond in value to the voltage U which may be applied as maximum to the electrochromic element at 0° C. With the constant B is determined to what extent the final value U max of voltage U is to be modified in the event of temperature changes. A and B may be different for a colouring process and a bleaching process respectively. They are characteristic of a certain design of electrochromic element, but independent of its dimensions. They can be established on the basis of cyclic voltammetric preliminary investigations on the electrochromic layers, for example by means of systematic test series, where electrochromic elements of the same design and dimensions are operated with different values of U max at different temperatures, and the maximum voltages in magnitude determined at which the electrochromic elements do not, over a large number of (minimum approximately 1,000−10,000) colour-change cycles, experience any significant deterioration in their colour-change properties.
An essential feature of the Invention is the regulation of the voltage U applied to the electrochromic element as a function of the current I. The Invention utilizes the surprising principle that evaluation of the continuous measurements of the current I renders superfluous any knowledge of the exact dimensions of the electrochromic element for safe operation of this element. The measured values of the current I can basically be utilized in a different fashion for regulation of the voltage U. Thus, for example, provision can be made for the voltage U to be increased in magnitude initially in the starting stage up to the final value U max and subsequently to maintain it at the value reached until the current I falls below a temperature-dependent first threshold referred to the maximum current I max —as explained in detail below—following which the voltage U is reduced in value continuously or in several steps, until the current I reaches a lower switch-off threshold also referred to the maximum current I max , dependent on temperature. Advantageously, this current-controlled regulation of the voltage U takes place however with the aid of an arithmetic value for the total resistance R ges of the electrochromic element determined from current and voltage measurements.
The total resistance R ges of the electrochromic element can be determined preferably in the starting stage of the colour-change process from the voltage U and the current I. To compensate for any voltage offset (open-circuit voltages), the total resistance R ges is preferably calculated as the first derivative of the voltage U to the current I. This is obtained in first approximation by the formation of the quotient ΔU/ΔI of the magnitudes of voltage difference and current difference at consecutive moments of time t i , t i+1 , ΔU=|U (t i+1 )−U (t i )|, ΔI=|I (t i+1 )−I (t i )|. The accuracy of the calculation can be increased by averaging being carried out from several quotients ΔU/ΔI determined at different points in time. By carrying out the measurements and calculation in the starting stage of the colour-change process, it is possible to a large extent to avoid falsifying the measurement results due to internal voltages occurring during the course of the colour change.
As the total resistance R ges is temperature-dependent, it is basically possible to conclude the temperature T of the electrochromic element from this, if it should be necessary to dispense with separate temperature sensors. Particularly in the case of large-area electrochromic elements, preference should of course be given to direct temperature measurement with the aid of a temperature sensor, on account of the greater degree of accuracy obtained.
Especially long service life of the electrochromic element can be achieved by calculating from the voltage U, the current I and the total resistance R ges , a voltage U eff which is effective electrochemically at the electrochromic layers, and by regulating the voltage U such that U eff does not in magnitude exceed a predetermined value U eff,max , above which irreversible changes can occur at the electrochromic element. Here, the following Approximation Equation is preferably used to determine the voltage U eff effective electrochemically at the electrochromic layers; how it is arrived at is described below:
U eff =U−I·D·R ges (2)
where D is a correcting variable, to be used where necessary to compensate for approximation errors. It will suffice in most cases to use the value of 1 for D. To optimize the voltage regulation with a view to maximum possible service life of the electrochromic element, it may however be advantageous to work with a correcting variable D differing from 1, this being determined in orientation trials. Cases are conceivable, for example, where measurement of the total resistance R ges is only carried out at a relatively late stage of a colour-change process, in which the individual resistances of the electrochromic layer system depend to an especially large extent on the colouration state or in which the electrochromic layers possess an unusually high ohmic resistance.
Rapid, but nevertheless careful colour change is achieved by an especially simple method of control if, after completion of the starting stage, and as long as the voltage U eff electrochemically effective at the electrochromic layers does not yet reach the maximum permissible value U eff,max in magnitude, the voltage U is kept essentially constant at the final value U max , reached at the end of starting stage. Of course, it could even be possible to operate with voltages U which are lower in magnitude than the final value U max . Such a process would however result in longer colour-change times, which is normally undesirable.
A switch-off criterion of the voltage U can, in particular where complete colouring or bleaching is desired, be defined particularly simply according to the Invention with the aid of the maximum current I max which has flowed during the colour-change process. It can thus be determined that the voltage U is switched off when the ratio of instantaneously flowing current I to maximum current I max falls below a specified value which is determined by the design, the type of colour-change process and generally by the temperature T.
If only partial colour change is desired, it is possible for example to monitor the transmittance or the reflectance of the electrochromic element and to switch off the voltage U when the transmittance or reflectance reaches a predetermined value.
Another alternative consists of determining the quantity of electricity which has flowed in the electrochromic element since commencement of the colour-change process and to switch off the voltage U when the quantity of electricity which has flowed reaches a specified value. The quantity of electricity which has flowed can be determined by time integration of the current I.
With the process according to the Invention it is possible, as soon as the design-related parameters A, B, D, U eff,max and the switch-off ratio I/I max have been determined, to carry out self-calibration of the control process, essentially independently of the area of the electrochromic element to be subjected to colour change, which will permit safe operation of the electrochromic element. It lies within the scope of the Invention however, for the purpose of refining and further optimizing the control process to define various size classes for electrochromic elements, within which in each case the same design-dependent parameters are applied, for example in increments of approximately 0.5 to 1 meter, referred to the shortest element dimension.
The process according to the Invention permits, with a simple method of control, rapid, reproducible and uniform colour change of electrochromic elements, where additional switch-off criteria can be applied for partial colour change. In practical form, it is determined decisively by its starting stage, in which self-calibration is carried out, that is to say in which essential control parameters of the process are determined.
BRIEF DESCRIPTION OF THE DRAWINGS
The Invention will be explained in detail with the aid of the enclosed Drawings. These show:
FIG. 1 the diagrammatic construction of an electrochromic element;
FIG. 2 a simplified equivalent circuit diagram of the electrochromic element of FIG. 1;
FIG. 3 a diagrammatic block diagram to illustrate the measurement and control variables for operating an electrochromic element according to the Invention;
FIG. 4 the diagrammatic characteristic curve of current and voltage when the electrochromic element of FIG. 1 is operated in accordance with a preferred embodiment of the process according to the Invention;
FIG. 5 a measurement curve of the current and voltage characteristic during a colouring process which utilizes a preferred process according to the present Invention, carried out on an electrochromic element with the dimensions 70 cm·100 cm; and
FIG. 6 a bleaching process according to the Invention with an electrochromic element in accordance with FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates in diagrammatic form the construction of a specimen electrochromic element. On a glass substrate 10 is located a first transparent electrode layer 12 , on which as first layer, in which ions can be reversibly inserted, is provided an electrochromic layer 14 . A transparent ion-conductive layer 16 , which may take the form of polymer electrolyte, separates the electrochromic layer 14 from the second layer, in which ions can be reversibly inserted, here an ion storage layer 18 which acts as counter-electrode to the electrochromic layer 14 . The ion storage layer 18 can take the form of a layer with transmittance essentially independent of the insertion state. It can however possess more or less pronounced electrochromic properties. Layers 14 , 18 are designated for the sake of simplicity as electrochromic layers 14 , 18 , without the field of use of the process according to the Invention being restricted to electrochromic elements with layers capable of changing their colour.
The layer construction is symmetrically supplemented by a second transparent electrode layer 20 and a glass plate 22 . The electrode layers 12 and 20 are provided with electrical connections 24 , 26 , to which a control voltage U can be applied via supply leads which are not illustrated. The electrochromic layer 14 and the ion storage layer 18 consist of materials which are known and suitable for this purpose, as are described for example in EP 0 475 847 B1, in which cations can be reversibly inserted, in particular protons or Li + ions, where the electrochromic layer 14 assumes differing degrees of colouring according to the insertion state.
The voltage U applied to the electrochromic element must fulfil two conditions during the entire process of colour change:
(I) The magnitude of the voltage U may not exceed the magnitude of a specified final value U max dependent on the temperature T. The temperature dependence of this final value U max is dependent of the design of the electrochromic element and is determined primarily by the material used for the electrochromic layers 14 , 18 and for the ion-conductive layer 16 .
(II) The voltage U eff , which is effective electrochemically at the electrochromic layers 14 , 18 may not exceed a certain value U eff,max . As the potentials prevailing on the electrochromic layers 14 , 18 can only be influenced indirectly and only recorded at considerable expense, the voltage U applied to the electrochromic element is preferably regulated on the basis of the total resistance R ges determined in the starting stage of the colour-change process and by evaluation of the continuous measurements of the current I in such a way that condition (II) is complied with at all times. The maximum permissible magnitude U eff,max of the voltage U eff effective electrochemically at the electrochromic layers 14 , 18 generally depends on different parameters, that is to say for example on the temperature T of the electrochromic element, on its design and on the nature of the colour-change process (colouring or bleaching).
The voltage U eff effective electrochemically at the electrochromic layers 14 , 18 is reduced in magnitude in relation to the voltage U applied externally to the electrochromic element, that is to say by the ohmic losses at the various other components of the electrochromic element including its supply leads. The voltage U eff is in fact not accessible for direct measurement with an electrochromic element producible at an industrially viable cost. It can however be calculated approximately with sufficient degree of accuracy, as described below.
FIG. 2 shows a simplified equivalent circuit diagram of the electrochromic element according to FIG. 1 . Here, R 1 is the ohmic resistance of the electrode layer 12 including connection 24 , as well as any supply leads not illustrated, R 2 the ohmic resistance of electrochromic layer 14 , R 3 the ohmic resistance of the ion-conductive layer 16 , R 4 the ohmic resistance of the ion storage layer 18 and R 5 the ohmic resistance of the electrode layer 20 , including connection 26 as well as any supply leads not illustrated.
The total resistance R ges of the electrochromic element is thus obtained as the total of resistances R 1 to R 5 ,
R ges =R 1 +R 2 +R 3 +R 4 +R 5 .
With the current I flowing through the electrochromic element , one obtains therefrom the applied voltage U=I·R ges , where the voltage components I·R 2 +I·R 4 dropping across the electrochromic layers 14 , 18 correspond to the previously mentioned electrochemically effective voltage U eff . It is therefore true to say that:
U=U eff +I·(R 1 +R 3 +R 5 )
or—resolved according to U eff —:
U eff =U−I·(R 1 +R 3 +R 5 ). (3)
From this Equation (3) it is possible, assuming that in any case in the starting stage of the colour-change process, the resistances R 2 and R 4 are small in relation to R 1 +R 3 +R 5 , with R ges ≈R 1 +R 3 +R 5 to derive the Approximation Equation (2) stated above.
From Equation (3) or Approximation Equation (2) it can be deduced directly that the voltage U eff effective electrochemically at the electrochromic layers 14 , 18 can be regulated by means of voltage U and with the aid of measurement of the current I. The value of U eff calculated in this way can of course only be an approximate value, as the voltage drop I·R, in particular in the case of large-area electrochromic elements is not constant over the entire area of the element, but is greatest at the edges, whilst it assumes a minimum value at its centre. The resistance characteristic of an electrochromic element is described correctly in physical terms by means of complex variables (impedances). The determination of complex impedances however requires comparatively complex instrumentation, which is not justified in terms of cost-effectiveness. It has been found that in practice, for determination of the required operating parameters of the control process, merely taking account of the ohmic part of the impedances of the system components will provide a quite adequate approximate value.
From the two above-mentioned conditions (I) and (II), which are to be maintained during operation of the electrochromic element in a redox-stability range of the electrochromic layer system, in combination with Approximation Equation (2) for each moment in time of the colour-change process, two upper limits are determined for the magnitude of the voltage U to be applied to the electrochromic element, neither of which may be exceeded:
|U|≦|U eff| (4)
|U|≦|U eff,max +I·D·R ges| (5)
The voltage U is regulated by evaluation of the continuous measurements of the current I so that the lower of the upper limits obtained from the Relations (4) and (5) is not exceeded in magnitude.
In order to initiate a colour-change process, a voltage U is applied to the electrical connections 24 and 26 (FIG. 1) of the electrochromic element, this voltage proceeding from a measurable open-circuit voltage U EC with the electrochromic element in zero-current state. The voltage U is now—according to the type of process desired —increased or decreased, increase or decrease taking place continuously, but need not necessarily proceed linearly. Of course, according to the sign of the open-circuit voltage U EC , initially zero crossing of the voltage U can take place, where therefore the magnitude of the voltage U will initially drop, before finally an increase in the voltage magnitude will take place. The increase in the voltage magnitude and thus the starting stage of the colour-change process will be completed at the latest when the lower of the upper limits according to Relations (4) and (5) is reached.
In the case of the process described here, Relation (4) will normally provide the lower upper limit, whilst the upper limit according to Relation (5) will only come into consideration during the further course of the colour-change process. It can however happen that the increase in the magnitude of the voltage U is completed in the starting stage of the colour-change process as a result of reaching the upper limit according to Relation (5), and thus before reaching the final value U max .
During the starting stage of the colour-change process, according to the Invention the total resistance R ges of the electrochromic element is determined as previously defined from the quotient ΔU/ΔI. Here, a mean value is preferably formed from several individual values of the total resistance R ges determined at different moments in time, in order to increase accuracy of measurement.
During the further course of the process according to the Invention, it is preferable as long as the upper limit according to Relation (5) is higher than that from Relation (4), for the voltage U to be maintained at or close to the final value U max . The current I through the electrochromic element generally decreases with time. Thus, the upper limit from Relation (5) decreases as well. This then generally results after a certain period of time in the situation that Relation (5) provides the lower upper limit for the magnitude of the voltage U, so that from then onwards the voltage U is regulated in accordance with Relation (5), that is to say, is generally reduced in magnitude according to the progressive reduction of current I at the end of the colour-change process.
According to the Invention, the current I is also measured continuously after the starting stage in order to ensure observance of Relations (4) and (5) by continuous correction of the voltage U. It is of course permissible to undershoot the upper limits provided, where in respect of magnitude, time duration, frequency of undershoot and the like, there is basically no form of restriction from safety aspects. It should be taken into account at all times that undershoot of the permissible upper limits for the magnitude of the voltage U will extend the times until complete colour change is reached, which is generally undesirable.
FIG. 3 shows a highly simplified block diagram to explain the measured and controlled variables in the process according to the Invention for operating an electrochromic element (ec element). The temperature of the electrochromic element is generally established by means of a suitable temperature sensor (designated T), whose measured values are sampled by the controller monitoring and controlling the colour-change process. The temperature sensor can be arranged in a suitable position outside or inside the electrochromic element. Furthermore, the current flowing through the electrochromic element is measured with a measuring instrument designated I and the measured values are passed to the controller. The controller then carries out the calculations as described above and passes the resultant controlled variable to a voltage source (designated U), which in turn applies the adjusted value to the electrochromic element. According to the type of voltage source, either the controlled variable passed to the voltage source can be used directly as a measure of the voltage applied to the electrochromic element, or the latter can be determined with the aid of a separate measuring instrument, which is not illustrated. The controller, the measuring instruments and the voltage source combine to form a control unit for implementing the process according to the Invention. The controller comprises inter alia means for carrying out the necessary calculations (for example a microprocessor) for input and output of measured and controlled variables, and for storage of the control parameters, as well as of other variables, such as for example of the maximum current which has flowed I max .
The end of the complete colour-change process is reached when the current I flowing through the electrochromic element falls below a predetermined fraction of the maximum current I max which has flowed since the beginning of the colour-change process. The value of this ratio I/I max serving as a termination criterion is determined by the temperature T and the design of the electrochromic element, as well as the nature of the process taking place, that is to say colouring or bleaching. As the current I is measured continuously during the entire colour-change process, it presents no difficulty in determining a maximum value I max and for storing the termination criterion.
The process according to the Invention in its preferred embodiment can normally be divided into three stages, as illustrated in FIG. 4 . The colour-change process commences with the starting stage designated Stage I, in which voltage U and current I are increased or reduced steadily, avoiding voltage or current peaks, until the voltage reached a specified final value U max . This is followed by Stage II, in which the voltage remains at the final value U max . Generally, Stage II takes the longest time of the colour-change process. Stage III, with current I reducing until it reaches a value corresponding to the termination criterion according to the Invention and voltage U reducing in magnitude, follows as soon as the upper limit of Relation (5) drops below U max . In the starting stage, the total resistance R ges , which is important for the moment of inception of Stage III and for the time characteristic of the voltage U to be obtained in this stage, is determined. The smooth, steady increase in the current I and of the magnitude of the voltage U in the starting stage also surprisingly ensures an evening out of the degree of colouration over the surface of the electrochromic element.
EXAMPLE
The Invention will be explained in its use for a completely bleached electrochromic element, where, on application of a positive voltage U, a current with positive polarity flows through the element, which leads to colouring of the element. Proceeding from a coloured state of the electrochromic element, a voltage U of negative polarity induces a current I of negative polarity, which leads to bleaching of the electrochromic element.
A suitable control unit, consisting of controller, voltage generator and measuring instruments in accordance with the schematic in FIG. 3 provides the necessary voltages and currents and continuously measures, preferably at regular intervals, the voltage U, the current I and the temperature T. In practice it has proved useful with colour-change times in the minutes range to measure the current I several times per second.
In the example chosen, the electrochromic element is in its bleached state. Between the connections of the electrochromic element, an open-circuit voltage U EC is measurable with the electrochromic element in zero-current state. Proceeding from this open-circuit voltage, a voltage U is applied to the electrochromic element, so that a current I, which leads to colouring of the element, flows. The voltage U is increased steadily and —apart from an initial stage with increasing slope of the current/voltage curve—preferably essentially in a linear relation to time. The current/voltage characteristic is in any case regulated in each case such that no current or voltage peaks occur. During this stage of increase of the voltage U, the values of the voltage applied to the electrochromic element U (t i ), U (t i+1 ) are determined at various moments in time t i , t i+1 . At the same moments in time, the current flowing through the electrochromic element I (t i ), I (t i+1 ) is measured in each case. From the pairs of variates:
ΔU=|U(t i )−U(t i+1 )|
and
ΔI=|I(t i )−I(t i+1 )|
a resistance value R ges (t i , t i+1 ) is determined. As soon as there is a sufficient number of resistance values to permit averaging, but at the latest on reaching the final value U max , the arithmetic mean is formed from the individual values R ges (t i , t i+1 ), and thus the total resistance R ges is calculated. The current I flowing through the electrochromic element is measured continuously from the beginning of the colouring process; the maximum value I max measured in this time is stored.
As soon as the voltage U reaches the final value U max , the starting stage (Stage I in FIG. 4) is completed. The final value U max is temperature-dependent. A simple relationship of the temperature dependence of the final value U max is obtained from the equation already stated above:
U max =A−B·T (1)
where T is the temperature. The parameters A and B must be determined in advance for each design of an electrochromic element. They are essentially independent of the area of the electrochromic element.
On reaching the final value U max for the voltage, Stage II commences (FIG. 4 ), in which the voltage U remains at or below the final value U max , if quickest possible colouring is desired. The current I is measured continuously by the control unit during Stage II as well. If at any point in time, a higher value for I is measured than was previously stored for I max , the higher value at this point is stored as I max . In addition, checking is carried out continuously based on the measured values for the current I, as to whether the upper limit according to Relation (5) is higher than the final value U max currently set for the voltage U. The value used in this Relation (5) for the maximum permissible voltage U eff effective electrochemically at the electrochromic layers 14 , 18 is not generally a constant, but varies in a similar fashion to U max as a function of temperature T. When it is found from Relation (5) that the upper limit established has dropped in magnitude below the final value U max , Stage II ends.
In the immediately following Stage III, Relation (5) now leads to limitation in magnitude of the voltage U to be applied to the electrochromic element. As the voltage U eff , which is effective electrochemically at the electrochromic layers 14 , 18 , can be influenced by means of the voltage U, the voltage U is regulated in Stage III such that U eff does not exceed the specified value U eff,max . The upper limit for the magnitude of the voltage U which is calculatable from Relation (5) is at all times during Stage III lower than the final value U max valid in Stage II as upper limit. As the current I influencing U eff according to Approximation Equation (2) varies as a function of time, that is to say normally decreases steadily towards the end of the colour-change process, U must constantly be corrected by the control unit. In the process, the voltage U is preferably adjusted to the upper limit steadily decreasing in magnitude according to Relation (5), in order to minimize the colour-change time. During Stage III, current I is also measured continuously for this purpose. In addition, the measured values for current I are used in this stage to establish when complete colouring is reached. This moment is reached according to the Invention when the current I drops below a specified threshold value in relation to the maximum current I max which has flowed. As soon as the control unit establishes that the end of Stage III has been reached, the voltage is switched off and thus the current flow through the electrochromic element terminated. The threshold value for I/I max generally dependent on temperature is determined by the design of the electrochromic element and by the process in progress (colouring, bleaching) and can be established beforehand by means of orientation trials.
The reverse process of bleaching essentially takes place as described previously. Starting from an open-circuit voltage U EC , which normally differs from that at the beginning of the colouring process, the voltage U is steadily reduced in the starting stage, that is to say at its maximum in this case up to a negative final value U max , whose magnitude may differ from that for the colouring process. This is followed by Stage II, in which the voltage remains at the final value U max until the upper limit from Relation (5) becomes lower in magnitude than U max . In the final stage III, the voltage U increases successively, that is to say decreases in magnitude, until on account of reaching the switch-off criterion, which may differ from that for the colouring criterion, switch-off takes place. The bleaching process is completed, the electrochromic element is again in the same state as at the beginning of the example.
FIGS. 5 and 6 show for an electrochromic element with the dimensions 70 cm·100 cm the characteristic curve respectively of a complete colouring and bleaching process at room temperature, where the voltage U and the current I have been plotted in each case as a function of the time t. The electrochromic element (see FIG. 1) incorporated two glass substrates 10 , 22 provided with transparent electrode layers 12 , 20 of ITO (indium tin oxide) with a surface resistance of approximately 10 ohms. On the electrode layer 12 was applied an electrochromic layer 14 of WO 3 , with a thickness of approximately 300 nm, whilst on the electrode layer 20 was also arranged an approximately 300 nm thick ion storage layer 18 of cerium titanium oxide. As ion-conductive layer 16 , a polymer electrolyte according to WO 95/31746 was used, with a thickness of 1 mm. The electrical connections 24 , 26 in the form of metal strips were applied along the longer element sides diagonally opposite one another and joined conductively to the corresponding electrode layers 12 , 20 . The parameters necessary for control according to the Invention of the colouring process and the bleaching process were determined using a series of preliminary tests (cyclic voltammetry, cyclic colour-change at various temperatures over up to 1000 cycles on electrochromic elements of the same design). For U eff,max , cyclic voltammetric trials for both types of colour-change processes provided magnitudes of 2 V (20° C.) or 1 V (80° C.), from which magnitudes for other temperatures can be determined by linear extrapolation. Proceeding therefrom, the magnitudes of U max at 20° C. as being 3.5 V and at 80° C. as being 2 V were determined with the aid of further systematic tests as described above. This provided the magnitudes of the parameters A and B for Equation (1) as A=4 V and B=0.025 V/° C. (temperature T in ° C. ), that is to say U max =4 V−0.025 V/° C. ·T for the colouring process and U max =−4 V+0.025 V/° C. ·T for the bleaching process. From FIGS. 5 and 6 , it can be seen that the voltage U starting in each case from an open-circuit voltage of approximately−0.7 V (colouring) and+0.7 V (bleaching) was steadily increased or respectively reduced, where the starting stage was completed in the case of the colouring process after approximately 16 seconds, and in the case of the bleaching process after approximately 12 seconds by reaching the final value U max of 3.5 V and−3.5 V respectively. The voltage U was subsequently maintained for approximately 75 seconds at this value until the current had reduced to the extent that the upper limit from Relation (5) dropped in magnitude below U max . The correction variable D from Relation (5) had the value of 1. In Stage III, the voltage U was adjusted to the gradually decreasing upper limit according to Relation (5). The current I had reached its maximum value I max =460 mA in each case at the end of the starting stage. Stage III was completed in both cases when I/I max fell below 20%, which in the case of the colouring process was after approximately 95 seconds and in the case of the bleaching process was after about 100 seconds. At a temperature of 80° C., the switch-off ratio I/I max was 50%.
The features of the Invention disclosed in the Specification, in the Drawing and in the Claims can be essential both individually and in any combination for the implementation of the Invention. | A process is disclosed for driving an electrochromic element which consists of at least the following layers: a first electrode layer; a first layer in which ions can be reversibly intercalated; a transparent ion-conducting layer; a second layer in which ions can be reversibly intercalated; and a second electrode layer. One of the layers in which ions can be reversibly intercalated is an electrochromic layer and the other layer acts as a counter-electrode to the electrochromic layer. A voltage with values in a redox stability range of the electrochromic layer system is applied to the electrode layers and causes a change in color. The process is characterised in that the current (I) which flows through the electrochromic element is continuously measured. During a starting phase of the change in color, the voltage (U) rises or diminishes continuously to a maximum, predetermined, temperature-dependent end value (U max ). The extent to which the end value depends on the temperature varies with the model of the electrochromic element, but not with the surface area of the electrochromic element which changes color. During the change in color, the voltage (U) is controlled depending on the current (I) and does not exceed the end value (U max ). | 4 |
BACKGROUND
[0001] Technical Field
[0002] The present disclosure relates to the field of heating but not combustion technologies, and in particular, a filter-type distillation suction apparatus, and more particularly, a tobacco baking device.
[0003] Related Art
[0004] Compared with smoking cigarettes directly, the tobacco baking device is more healthy as smoking of baked tobacco with precise temperature controlled during baking which can also cut down the probability of producing harmful staff by tobacco, so people are more and more fond of tobacco baking devices.
[0005] However, as for current tobacco baking devices which bake the tobacco to produce vapor for smoking directly or filtered via a simply filter screen before smoking, the unhealthy substances such as dust of tobacco are also easily smoked; Moreover, it's easy to occur air leakage due to the air tightness of current tobacco baking devices is not good, and the devices have the feature of disposable, once the baking chamber damaged, it has to discard the whole device, can't just replace the chamber.
SUMMARY
[0006] In view of the above, the present disclosure provides a tobacco baking device, which aims at solving the problem that during smoking period much impurity absorbed in with vapor produced by current tobacco baking devices, and at the same time, reducing use costs of consumers, so as to be more environmentally friendly.
[0007] Technical solutions according to the present disclosure to solve the foregoing technical problem are as follows.
[0008] A tobacco baking device, comprising a mouthpiece component, a baking component, and a filter component, where the filter component is located below the baking component; the mouthpiece component is located above the baking component; the baking component is detachably connected to the filter component; where there is sealed connection on the butted terminal portions of the mouthpiece component, the filtration component and the baking component; and an air flow channel is provided among the mouthpiece component, the filter component, and the baking component; the baking component bake tobacco therein to generate vapor, and the vapor goes down along the air flow channel to the filter component, and goes up after being filtered by the filter component and is released via the mouthpiece component.
[0009] Further, the baking component is in a detachable connection to the filter component, and a silicon seal is provided at a joint between the baking component and the filter component; a positive electrode, a negative electrode, and a sensor electrode are provided on an end portion of the baking component, where the baking component is butted with the filter component; a power supply positive electrode, a power supply negative electrode, and a sensor electrode are provided on an end portion of the filter component, where the filter component is butted with baking component; when the baking component is fixedly connected to the filter component, the positive electrode on the end portion of the baking component is butted with the power supply positive electrode of the filter component; the negative electrode of the baking component is butted with the power supply negative electrode of the filter component; and the sensor electrode of the baking component is butted with the sensor electrode of the filter component.
[0010] Further, the filter component comprises an air inlet pipe, an air outlet pipe, a filter pipe, and an external pipe; where the air inlet pipe is inserted into the air outlet pipe, and a first space is formed between an outer wall of the air inlet pipe and an inner wall of the air outlet pipe; the air outlet pipe is inserted into the filter pipe, and a second space is formed between an outer wall of the air outlet pipe and an inner wall of the filter pipe; the filter pipe is inserted into the external pipe, and a third space is formed between an outer wall of the filter pipe and an inner wall of the external pipe; an airflow hole is provided on a pipe wall of the air inlet pipe and a pipe wall of the air outlet pipe; an airflow hole is provided on a bottom part of the filter pipe; a filtrate is provided in the second space and third space; and a height of the filtrate does not exceed the airflow hole's height on the pipe wall of the air outlet pipe.
[0011] Further, the air inlet pipe, the air outlet pipe, the filter pipe, and the external pipe are all hollow pipes.
[0012] Further, the filtrate is water or other liquid.
[0013] Further, the mouthpiece component is in a detachable connection to the baking component, and a silicon seal is provided at a joint between the baking component and the mouthpiece component.
[0014] Further, the baking component comprises a heater, an inner cavity, and an airflow pipe and a seal pipe that are provided outside of the heater; the airflow pipe is vertically connected to the seal pipe, and the seal pipe is provided below the airflow pipe; the inner cavity is provided in the heater; tobacco are provided in the inner cavity; and an airflow channel is formed between an inner wall of the airflow pipe and the seal pipe and an outer wall of the heater.
[0015] Further, the heater comprises a heat insulation pipe, heat insulation cotton, and a heating pipe; the heat insulation cotton is provided in the heat insulation pipe; the heating pipe is provided in the heat insulation cotton; a heat sensitive sensor is provided on an outer wall of the heating pipe; the heating pipe is connected to a positive electrode and a negative electrode on the baking component; and the heat sensitive sensor is connected to a sensor electrode on the baking component.
[0016] Further, the inner cavity is a tobacco pouch that is detachably mounted on the heater; multiple vent holes are provided on a wall of the tobacco pouch.
[0017] Further, an air inlet and an air outlet channel are provided on the mouthpiece component; an intake air via the air inlet is mixed with vapor and then goes down to the filter component; the air outlet channel is connected to the filter component and a mouthpiece of the mouthpiece component, so that vapor filtered by the filter component is released from the mouthpiece via the air outlet channel of the mouthpiece component.
[0018] The tobacco baking device implemented by the present disclosure is provided with a filter component, so that vapor generated by baked tobacco is smoked after being filtered, which not only decreases the temperature of vapor, but also filters impurities contained in vapor, so as to reduce harmful substances in vapor; secondly the baking apparatus is a detachable structure, so that replacing the components is convenient; the seal configuration of the entire tobacco baking device is more perfect, thereby reducing leakage risks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is an overall schematic sectional view in an air inlet state of the present disclosure;
[0020] FIG. 2 is an overall schematic sectional view in an air shut-off state of the present disclosure;
[0021] FIG. 3 is a schematic exploded view of the mouthpiece component of the present disclosure;
[0022] FIG. 4 is a schematic exploded view of a baking component of the present disclosure;
[0023] FIG. 5 is a schematic exploded view of a filter component of the present disclosure;
[0024] FIG. 6 is an overall schematic sectional view of a filter component of the present disclosure;
[0025] FIG. 7 is a schematic diagram of components in a separated state of the present disclosure; and
[0026] FIG. 8 is a schematic diagram of components in a combined state of the present disclosure.
[0000]
100
mouthpiece component
1
mouthpiece
2
movable ring
3
vent core
31
air inlet hole
32
air outlet hole
4
rubber ring
5
airflow pipe
6
seal pipe
7
vapor channel
200
baking component
8
heat insulation pipe
9
heat insulation cotton
10
ceramic heating pipe
11
tobacco pouch
12
air inlet pipe
13
air inlet hole on the wall of
14
air outlet pipe
the air inlet pipe
15
filter pipe
300
filter component
16
external pipe
17
first space
18
second space
19
third space
20
air outlet hole on the wall of the
21
air outlet hole on the wall
air inlet pipe
of the air outlet pipe
22
air outlet hole on the wall of the
23
injection hole
filter pipe
24
filtrate
25
negative electrode
26
positive electrode
27
power supply negative
electrode
28
power supply positive electrode
29
NTC electrode I
30
NTC electrode II
DETAILED DESCRIPTION
[0027] The following describes a specific implementation process and implementation effects of the present disclosure in detail with reference to the accompanying drawings.
[0028] A tobacco baking device includes a mouthpiece component 100 , a baking component 200 , and a filter component 300 ; as shown in FIG. 1 , the filter component 300 is located below the baking component 200 ; the mouthpiece component 100 is located above the baking component 200 ; the baking component 200 is in a detachable connection to the filter component 300 ; a communicated air flow channel is provided among the mouthpiece component 100 , the filter component 200 , and the baking component 300 ; after being heated, the baking component 200 bakes tobacco provided therein to generate vapor, and the vapor goes down along the air flow channel to the filter component, and goes up after being filtered by the filter component and is released via the mouthpiece component 100 .
[0029] Specifically, as shown in FIG. 3 and FIG. 1 , the mouthpiece component 100 includes a mouthpiece 1 , which is used to contact human mouth for smoking; a through hole is provided in the mouthpiece for discharging filtered vapor. The mouthpiece 1 further includes a movable ring 2 and a vent core 3 , where the movable ring 2 is provided outside the vent core 3 ; an air inlet hole 31 and an air outlet hole 32 are provided on the vent core 3 ; the air inlet hole 31 and the air outlet hole 32 are opposite perforations provided on a wall of the vent core, and they are set in a vertically-crossed manner; a peripheral plane where the air inlet hole 31 is located is not the same as a peripheral plane where the air outlet hole 32 is located; as shown in FIG. 1 , preferably, the peripheral plane where the air inlet hole 31 is located is below the peripheral plane where the air outlet hole 32 is located. Two seal rings 4 are provided between the movable ring 2 and the vent core 4 ; the seal rings 4 are used to close the air inlet hole and the air outlet hole or separate the air inlet hole from the air outlet hole. Specifically, when the movable ring 2 moves upwards to a location where a limiting ring is located, it indicates that the air inlet hole and the air outlet hole on the vent core are in an open state, that is, the two seal rings move upwards with the movable ring 2 and disengage from locations of the air inlet hole 31 and the air outlet hole 32 , so that the air inlet hole 31 and the air outlet hole 32 are in a communication state, that is, the state shown in FIG. 1 ; when the movable ring moves downwards to be far away from the limiting ring, the two seal rings move downwards with the movable ring 2 to the peripheral plane where the air inlet hole 31 is located and the peripheral plane where the air outlet hole 32 is located, so that the air inlet hole 31 and the air outlet hole 32 are blocked by the seal rings, it indicates that the air inlet hole 31 and the air outlet hole 32 are in a closed state, that is, the state shown in FIG. 2 .
[0030] As shown in FIG. 4 and FIG. 1 , the baking component 200 includes a heater and an inner cavity, where tobacco are provided, and the heater is used to bake the tobacco in the inner cavity. In this embodiment, the inner cavity is a tobacco pouch 11 , which is a metal cylinder, and several through holes are provided on the wall of the tobacco pouch; tobacco are provided in the tobacco pouch.
[0031] Specifically, the heater includes a heat insulation pipe 8 , heat insulation cotton 9 , and a ceramic heating pipe 10 ; the heat insulation cotton 9 is provided in the heat insulation pipe 8 ; the ceramic heating pipe 10 is provided in the heat insulation cotton 9 ; and the ceramic heating pipe is connected to a heating circuit. An airflow pipe 5 and a seal pipe 6 are provided outside of the heat insulation pipe 8 ; the airflow pipe 5 is vertically connected to the seal pipe 6 , and the seal pipe is provided below the airflow pipe; and an airflow channel is formed between the inner wall of the airflow pipe 5 and the seal pipe 6 and the outer wall of the heat insulation pipe 8 . The ceramic heating pipe 10 is connected to the heating circuit, which accurately controls the heating temperature of the ceramic heating pipe 10 by using a heat sensitive sensor; the ceramic heating pipe 10 bakes tobacco in the tobacco pouch 11 , so that vapor generated by baking the tobacco moves downwards with an air flow entered via the air inlet hole 31 into the filter component 300 .
[0032] As shown in FIG. 5 and FIG. 1 , the filter component 300 includes an air inlet pipe 12 , an air outlet pipe 14 , a filter pipe 15 , and an external pipe 16 ; preferably, the air inlet pipe 12 , the air outlet pipe 14 , the filter pipe 15 , and the external pipe 16 are all cylindrical hollow pipes; the air inlet pipe 12 is inserted into the air outlet pipe 14 , and a first space 17 is formed between the outer wall of the air inlet pipe 12 and the inner wall of the air outlet pipe 14 ; the air outlet pipe 14 is inserted into the filter pipe 15 , and a second space 18 is formed between the outer wall of the air outlet pipe 14 and the inner wall of the filter pipe 15 ; the filter pipe 15 is inserted into the external pipe 16 , and a third space 19 is formed between the outer wall of the filter pipe 15 and the inner wall of the external pipe 16 ; an airflow hole is provided on the pipe wall of the air inlet pipe and the pipe wall of the air outlet pipe; an airflow hole is provided on the bottom part of the filter pipe 15 ; a filtrate is provided in the second space and third space; and the height of the filtrate does not exceed the height of the airflow hole on the pipe wall of the air outlet pipe, and the filtrate is water or other liquid.
[0033] Specifically, as shown in FIG. 1 , the air inlet pipe 12 is connected to the airflow channel of the baking component; airflow holes provided on the wall of the air inlet pipe 12 are an air inlet hole 13 on the wall of the air inlet pipe and an air outlet hole 20 on the wall of the air inlet pipe; an airflow hole provided on the air outlet pipe 14 is an air outlet hole 21 on the wall of the air outlet pipe; and an airflow hole provided on the filter pipe 15 is an air outlet hole 22 on the wall of the filter pipe.
[0034] When the tobacco baking device is in an air inlet state, that is, the state shown in FIG. 1 , air is sucked by a person at the mouthpiece 1 , and air enters the air inlet hole 31 of the mouthpiece component, and the baking component 200 bakes tobacco in the tobacco pouch 11 to generate vapor; the vapor moves downwards with air that enters the air inlet hole 31 , as the direction indicated by a downgoing arrow head in FIG. 1 , and then the vapor enters the air inlet pipe 12 via the air inlet hole 13 on the wall of the air inlet pipe of the filter component 300 , and then enters the first space 17 via the air outlet hole 20 on the wall of the air inlet pipe, and then enters the second space 18 via the air outlet hole 21 on the wall of the air outlet pipe; a filtrate is provided in the second space 18 and the third space 19 ; the filtrate is water in this embodiment; the smoke enters the third space 19 via the air outlet hole 22 on the wall of the filter pipe on the filter pipe 15 after being filtered by water; after coming out from the third space 19 , the vapor enters an upgoing air flow channel, that is, goes up via a space between the outer wall of the heater insulation pipe 8 and the inner wall of the airflow pipe 5 and the seal pipe 6 , and finally flows out of the mouthpiece via the air outlet hole 32 on the vent core of the mouthpiece component 100 , and enters into the mouth of a smoker.
[0035] To make it convenient for the filter component to add a filtrate, and to make it convenient for replacing the baking component, the baking component is in a detachable connection, for example, threaded connection, to the filter component; a tail end of the filter component is connected to a power supply component (not shown), and the power supply component supplies power to the baking component by using a conductor in the filter component. As shown in FIG. 7 , a positive electrode 26 , a negative electrode 25 , and a sensor electrode are provided on an end portion of the baking component, where the baking component with the filter component is butted, herein the sensor electrode is an NTC electrode I 29 and an NTC electrode II 30 in FIG. 7 ; a power supply positive electrode 28 , a power supply negative electrode 27 , and a sensor electrode are provided on an end portion of the filter component, where the filter component is butted with the baking component; a heat sensitive sensor is provided on the outer wall of the ceramic heating pipe 10 in the baking component; the ceramic heating pipe 10 is connected to the positive electrode 26 and the negative electrode 25 on the baking component, and the heat sensitive sensor is connected to the sensor electrode on the baking component, that is, the NTC electrode I 29 and the NTC electrode II 30 in FIG. 7 . When the baking component is fixedly connected to the filter component, as shown in FIG. 8 , moreover, a center of the filter component is clipped to a center of the baking component, the positive electrode 26 of the end portion of the baking component is butted with the power supply positive electrode 28 of the filter component; the negative electrode 25 of the baking component is butted with the power supply negative electrode 27 of the filter component; the NTC electrode I 29 of the baking component is butted with the sensor electrode of the filter component; the NTC electrode II 30 is butted with the power supply positive electrode 28 of the filter component, and the power supply positive electrode 28 is shared by the NTC electrode II 30 and the positive electrode 26 .
[0036] A silicon seal is provided at a joint between the baking component and the filter component; the mouthpiece component is in a threaded connection to the baking component, and a silicon seal is provided at a joint between the baking component and the mouthpiece component, so as to ensure seal of channels except the normal air flow channel, so that the filtrate is not leaked and the vapor is not leaked in the channels except the air flow channel. As shown in FIG. 6 , after the filter component 300 disengages with the baking component, an open state is formed above the external pipe 16 and the filter pipe 15 so as to form a injection hole 23 ; in this way, a filtrate 24 can be added into the third space 19 via the injection hole, and the filtrate flows to the second space 18 via the through hole on the bottom part of the filter pipe. To prevent the filtrate from entering the first space via the through hole on the air outlet pipe 14 as much as possible, the amount of the filtrate should be controlled not to exceed the height of the through hole on the air outlet pipe 14 .
[0037] By means of the foregoing implemented tobacco baking device, vapor generated by baking tobacco is filtered by liquid, so as to greatly reduce particle substances in the vapor, thereby reducing harms of smoking; the baking component is in a detachable connection to other components, so as to facilitate replacing components of the baking component and adding the filtrate for the filter component; multiple seal rings are provided at a joint between components in the entire tobacco baking device, so as to ensure that vapor is not leaked via connection seams between the components.
[0038] Preferable embodiments of the present disclosure are described above with reference to the accompanying drawings, and the embodiments are not intended to limit the scope of claims of the present disclosure. Any modification, equivalent replacement, or improvement that does not depart from the scope and essence of the present disclosure and is made by a person skilled in the art should fall within the scope of claims of the present disclosure. | A tobacco baking device, comprising a mouthpiece component, a baking component, and a filter component, where the filter component is located below a baking component; the mouthpiece component is located above the baking component; the baking component is detachably connected to the filter component; where there is sealed connection on the butted terminal portions of the mouthpiece component, the filtration component and the baking component; an air flow channel is provided between the mouthpiece component, the filter component, and the baking component. Vapor goes down along the air flow channel to the filtration component, and goes up after being filtered by the filter component and is released via the mouthpiece component. As the vapor is filtered by the filter component, harmful substances in the vapor are greatly reduced, and also cool the vapor and the whole device, so as to enable the device to be more suitable for using. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a turbo compressor, and more particularly, to a turbo compressor that is capable of effectively cooling a bearing which supports a rotational shaft.
2. Description of the Background Art
FIG. 1 is a sectional view of a turbo compressor in accordance with a conventional art.
As shown in FIG. 1, the conventional turbo compressor includes a casing 106 having a suction hole 102 for sucking a fluid from an outside and a discharge hole 104 for discharging the sucked fluid, and having a certain space; a driving unit 108 installed inside the casing 106 and generating a rotational force; a first compressing part 112 connected to the driving unit 108 by a rotational shaft 110 and first compressing fluid; and a second compressing part 114 for secondly compressing the fluid compressed by the first compressing part 112 .
In the casing 106 , a fluid chamber 120 for sucking a fluid through the suction hole is formed, a first support member 116 for rotatably supporting one end portion of the rotational shaft 110 is fixed at one side of the casing 106 , and a second support member 118 for rotatably supporting the other end portion of the rotational shaft 110 is fixed at the other side of the casing 106 .
The driving unit 108 includes a stator 122 fixed at an outer circumferential face of the casing 106 and receiving a power from an external source, and a rotor 124 fixed at a circumferential face of the rotational shaft 110 and being rotated by an interaction with the stator 122 .
The first compressing part 112 includes a first impeller 126 connected to one end portion of the rotational shaft 110 and compressing the fluid by being rotated along with the rotational shaft 110 ; and a first cover member 132 in which the first impleller 126 is rotatably inserted, a first compression chamber 128 is connected to the discharge hole 104 of the main body, into which the fluid of the fluid chamber 120 is introduced and first compressed, and a transfer passage 130 is formed to discharge the compressed fluid.
The second compressing part 114 includes a second impeller 134 connected to the other end portion of the rotational shaft 110 and compressing the fluid by being rotated along with the rotational shaft 110 ; and a second cover member 140 in which the second impeller 134 is rotatably inserted, a second compression chamber 136 is formed connected to the transfer passage 130 into which the first compressed fluid is introduced and secondly compressed, and a discharge hole 138 is formed to externally discharge the compressed coolant.
A radial bearing 142 is inserted between the first support member 116 and the outer circumferential face of the rotational shaft 110 and between the second support member 118 and the outer circumferential face of the rotational shaft 110 , to support a load working in a radial direction of the rotational shaft 110 .
A bearing bush 144 is connected in a vertical direction to the rotational shaft at one side thereof. The bearing bush 144 is supplied by a thrust bearing 146 which supports a load working in an axial direction of the rotational shaft 110 .
The thrust bearing 146 is installed between the first cover member 132 and the first support member 116 , and a bearing chamber 148 is formed where the bearing bush 144 is rotatably positioned.
A sealing member 150 is inserted between the outer circumferential face of both end portions of the rotational shaft 110 and the first cover member 132 , to prevent leakage of the fluid compressed in the first and the second compression chambers 128 and 136 .
The operation of the turbo compressor in accordance with the conventional art constructed as described above will now be explained.
When the driving unit 108 is driven, the rotational shaft 110 is rotated. Then the first impeller 126 and the second impeller 134 connected to the rotational shaft 110 are rotated to perform a compressing operation of the fluid.
That is, the fluid is introduced into the fluid chamber 120 through the suction hole 102 , and the fluid introduced into the fluid chamber 120 is introduced into the first compression chamber 128 through the discharge hole 104 , first compressed according to the rotation of the first impeller 126 and then supplied to the transfer passage 130 .
The fluid supplied to the transfer passage 130 is introduced into the second compression chamber 136 , secondly compressed by the rotation of the second impeller 134 and then externally discharged through the discharge hole 138 .
At this time, when the rotational shaft 110 is being rotation, a load working in a radial direction of the rotational shaft 110 is supported by the radial bearing 142 .
Since the pressure in the first compression chamber 128 which compresses the fluid first is smaller than that of the second compression chamber 136 , an axial-directional load works on the rotational shaft 110 due to the pressure difference between the first compression chamber 128 and the second compression chamber 136 . Such axial-directional load is supported by the thrust bearing 146 .
In this respect, since the rotational shaft 110 is rotated at a high speed, a temperature of the bearing chamber 148 with the thrust bearing 146 is inserted is increased and the thrust bearing 146 is degraded. Thus, in view of the performance of the whole system and in order to lengthen the life of the bearing, it is requisite to cool the thrust bearing 146 and maintain its temperature to below a certain level.
The conventional bearing cooling method is that, in designing a structure of the sealing member 150 inserted between the first cover member 132 and the rotational shaft 110 , a certain leakage of fluid is allowed to occur, so that when the fluid which is first compressed after being introduced into the first compression chamber 128 is introduced into the bearing chamber 148 through the sealing member 150 , thereby performing a cooling operation of the thrust bearing 146 .
However, the conventional turbo compressor has a problem that the leakage amount of fluid supplied from the first compression chamber to the bearing chamber differs depending on a structure designing of the sealing member.
That is, if a small amount of fluid is leaked to the bearing chamber, the cooling operation of the thrust bearing is not smoothly performed, and thus, the temperature is increased according to the friction of the bearing. Then, a coating layer of the bearing is damaged, resulting in that the performance of the whole system is degraded, the durability of the bearing is shortened, and a reliability is degraded.
On the other hand, if a large amount of fluid is leaked to the bearing chamber, when the fluid is compressed, a large amount of fluid is leaked, resulting in that a compression efficiency of the compressor is degraded.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a turbo compressor that is capable of smoothly performing a cooling operation of a bearing without degrading a compression performance of a compressor in such a manner that when a temperature of a bearing chamber with a thrust bearing inserted therein increases, a fluid is supplied to perform a cooing operation, and when the temperature of the bearing chamber reaches a suitable level, the fluid supply to the bearing chamber is cut off.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a turbo compressor including: a casing having a fluid chamber for receiving a fluid from an external source; a driving unit disposed in the casing and generating a rotational force; a first compressing part installed at one side of a rotational shaft rotated according to the driving of the driving unit and first compressing the fluid; a second compressing part installed at the other side of the rotational shaft and secondly compressing the fluid compressed in the first compressing part; and a bearing cooling unit for supplying a fluid of the fluid chamber to a bearing chamber to perform a cooling operation when a temperature of the bearing chamber where the thrust bearing for supporting a load working in an axial direction of the rotational shaft is mounted is increased, and cutting off the fluid from being introduced into the bearing chamber when the temperature of the bearing chamber is maintained at a proper level.
In the turbo compressor of the present invention, the bearing cooling unit includes a supply passage formed inside the casing to allow the bearing chamber and the fluid chamber to communicate with each other; and an open-and-shut valve installed at the supply passage and opening and closing the supply passage according to an internal temperature of the bearing chamber.
In the turbo compressor of the present invention, the supply passage is penetratingly formed at a first support member which is fixed at the inner side of the casing and rotatably supports one side of the rotational shaft.
In the turbo compressor of the present invention, the open-and-shut valve includes a valve body part formed having a certain space at the supply passage, a fixed plate fixed at one side of the valve body part and having a through hole communicating with the supply passage at a center thereof; and a bi-metal positioned adhesive to one face of the fixed plate, having a plurality of through holes at its marginal portion, and being deformed according to a temperature inside the bearing chamber.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a sectional view of a turbo compressor in accordance with a conventional art;
FIG. 2 is a sectional view of a turbo compressor in accordance with a preferred embodiment of the present invention;
FIG. 3 is an enlarged sectional view showing a structure of a first compressing part of the turbo compressor in accordance with the preferred embodiment of the present invention;
FIG. 4 is an enlarged view of portion ‘A’ of FIG. 3 showing a bearing cooling unit of the turbo compressor in accordance with the preferred embodiment of the present invention; and
FIG. 5 is a view showing an operation state of the bearing cooling unit of the turbo compressor in accordance with the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
There may exist a plurality of embodiment of a turbo compressor in accordance with the present invention, of which the most preferred one will now be described.
FIG. 1 is a sectional view of a turbo compressor in accordance with a conventional art, and FIG. 2 is a sectional view of a turbo compressor in accordance with a preferred embodiment of the present invention.
A turbo compressor of the present invention includes: a a casing 6 having a suction hole 2 for sucking a fluid from an outside and a discharge hole 4 for discharging the sucked fluid, and having a certain space; a driving unit 8 installed inside the casing 6 and generating a rotational force; a first compressing part 12 connected to the driving unit 8 by a rotational shaft 10 and first compressing fluid which is discharged from the discharge hole 4 of the casing 6 ; and a second compressing part 14 for secondly compressing the fluid compressed by the first compressing part 12 .
The casing 6 has a cylindrical form, and a first support member 16 rotatably supporting one side of the rotational shaft 10 is hermetically fixed at one side of the casing 6 , and a second support member 18 rotatably supporting the other side of the rotational shaft 10 is hermetically fixed at the other side of the casing 6 .
A fluid chamber 20 is formed inside the casing 6 . The fluid chamber 20 is hermetically sealed by the first and the second support members 16 and 18 and a fluid is sucked into the fluid chamber 20 through a suction hole 2 .
The driving unit 8 includes a stator 22 fixed at an outer circumferential face of the casing and receiving a power supply from an external source, and a rotor 24 fixed at a circumferrential face of the rotational shaft 10 and is rotated according to an interaction with the stator 22 .
The first compressing part 12 includes a first cover member 30 provided with a first compression chamber 26 fixed at a side face of the first support member 16 and connected to the discharge hole 4 of the main body and a transfer passage 28 for moving the fluid compressed in the first compression chamber 26 to a second compression chamber; and a first impeller 32 rotatably disposed at the first compression chamber 26 of the first cover member, connected to the rotational shaft 10 , and compressing first the fluid introduced into the first compression chamber 26 .
The second compressing part 14 includes a second cover member 36 having a second compression chamber 39 fixed at side face of the second support member 18 and connected to the transfer passage 28 and a discharge hole 34 for externally discharging the fluid which has been secondly compressed in the second compression chamber 39 ; and a second impeller 38 rotatably disposed at the second compression chamber 39 and secondly compressing the fluid introduced into the second compression chamber 39 .
Sealing members 40 and 42 are respectively inserted between the rotational shaft 10 and the first cover member 30 and between the rotational shaft 10 and the second cover member 36 , in order to prevent leakage of the fluid compressed in the first compression chamber 26 and the second compression chamber 39 .
A radial bearing 44 is inserted between the rotational shaft 10 and the first support member 16 and between the rotational shaft 10 and the second support member 18 , in order to support a load working in a radial direction of the rotational shaft 10 .
A bearing bush 46 is fixed at one side of the rotational shaft 10 in a vertical direction to the rotational shaft 10 . The bearing bush 46 is rotatably supported by a thrust bearing 48 which supports a load working in an axial direction of the rotational shaft 10 .
The thrust bearing 48 is mounted between the first cover member 30 and the first support member 16 , and a bearing chamber 50 is formed where the bearing bush 46 is rotatably positioned.
A bearing cooling unit is formed at one side of the first support member, to supply the fluid introduced into the fluid chamber 20 to the bearing chamber 50 to perform a cooling operation when a temperature of the bearing chamber 50 increases, and cut off the fluid from being introduced into the bearing chamber 50 when the temperature of the bearing chamber 50 is maintained at a suitable level.
The bearing cooling unit includes a supply passage formed at one side of the first support member 16 and allows the bearing chamber 50 and the fluid chamber 20 to communicate with each other and supplying the fluid inside the fluid chamber to the bearing chamber 50 , and an open-and-shut valve 54 installed at the supply passage 52 and opening and closing the supply passage 52 according to an internal temperature of the bearing chamber 50 .
The supply passage 52 is penetratingly formed at the first support member 16 and serves to supply the fluid introduced into the fluid chamber 20 to the bearing chamber 50 .
The open-and-shut valve 54 includes a valve body part 60 formed having a space in a certain shape at one side of the supply passage 52 , a fixed plate 62 hermetically fixed at the supply passage 52 of the valve body part 60 and having a through hole 66 communicating with the supply passage 52 at its central portion; and a bi-metal 64 positioned contacting one side of the fixed plate 62 , having a plurality of through holes 68 at its marginal portion, and being deformed according to a temperature inside the bearing chamber 50 .
That is, in the open-and-shut valve 54 , when a temperature of the bearing chamber 50 is increased to a certain degree, the bi-metal 64 is deformed and separated from the fixed plate 62 . Then, the supply passage 52 is opened so that the fluid inside the fluid chamber 20 is introduced into the bearing chamber 50 through the supply passage 52 to the bearing chamber 50 , to perform a cooling operation.
When the temperature of the bearing chamber 50 is cooled to a proper level, the bi-metal 64 is restored to its original state and adhered to the fixed plate 62 , thereby shutting the supply passage 52 .
The operation of the turbo compressor constructed as described above will now be described.
When the driving unit 8 is driven, the rotor 24 is rotated. Then, the rotational shaft 10 is rotated and the first and the second impellers 32 and 38 connected to the rotational shaft are rotated, thereby performing a compression operation of the fluid.
That is, the fluid is sucked into the fluid chamber 20 through the suction hole 2 of the main body, supplied to the first compression chamber 26 through the discharge hole 4 , first compressed according to rotation of the first impeller 32 and then moved to the transfer passage 28 .
After being discharged into the transfer passage 28 , the fluid is supplied to the second compression chamber 39 , secondly compressed according to rotation of the second impeller 38 , and then externally discharged through the discharge hole 34 .
At this time, the radial directional load of the rotational shaft 10 is supplied by the radial bearing 44 mounted between the rotational shaft 10 and the first and the second support member 16 and 18 .
A load is generated in an axial direction at the rotational shaft 10 due to the pressure difference between the first compression chamber 26 which compresses the fluid first and the second compression chamber 39 which compresses the fluid secondly, the load working in the axial direction of the rotational shaft 10 is supported by the thrust bearing 48 mounted in the bearing chamber 50 .
During the compression operation, when a temperature of the bearing chamber 50 is increased due to the friction of the thrust bearing 48 , the open-and-shut valve 54 is operated to open the supply passage 52 allowing the fluid chamber 20 and the bearing chamber 50 to communication with each other.
Then, the fluid introduced into the fluid chamber 20 is supplied to the bearing chamber 50 through the supply passage 52 , to thereby perform a cooling operation of the thrust bearing 48 .
As for the open-and-shut valve 54 , when a temperature of the bearing chamber 50 is increased, the bi-metal 64 is deformed and separated from the fixed plate 62 , and accordingly, the through hole 66 formed at the fixed plate 62 and the through hole 68 formed at the bi-metal 64 are communicated with each other, to open the supply passage 52 .
And then, as the fluid is introduced into the bearing chamber 50 and cools the thrust bearing 48 , when the temperature of the bearing chamber drops to a proper level, the bi-metal 64 is returned to its original state and adhered to the fixed plate 62 , to thereby shut the supply passage 52 .
The turbo compressor constructed and operated as described above is preferably used as a compressor of a freezing cycle.
As so far described, the turbo compressor of the present invention has many advantages.
That is, for example, the supply passage for allowing the bearing chamber and the fluid chamber receiving the fluid to communicate each other is formed at the first support member where the radial bearing supporting a load working in an axial direction of the rotational direction is formed and the open-and-shut valve is formed to open and shut the supply passage according to a temperature of the bearing chamber, in order to supply fluid to the bearing chamber according to the temperature of the bearing chamber and perform a cooling operation of the radial bearing.
Thus, the temperature of the radial bearing can be constantly maintained at a proper level, so that a degradation due to a friction of the bearing can be prevented, and the lifespan and a reliability of the bearing can be improved.
In addition, since the fluid is supplied to the bearing chamber only when the temperature of the bearing chamber is increased, a performance degradation of the compressor according to a leakage of the fluid can be prevented.
As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the meets and bounds of the claims, or equivalence of such meets and bounds are therefore intended to be embraced by the appended claims. | A system for cooling a turbo compressor includes two compressing parts on opposite ends of a rotational shaft driven by a motor. Fluid from a fluid chamber within the casing of the device is supplied to a bearing chamber when the temperature of the bearing chamber increases. A supply passage is formed in a first support where the radial bearing for supporting a load in the axial direction is formed. The open-and-shut valve supplies fluid when the temperature of the bearing chamber increases. | 5 |
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