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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to giant magnetoresistive (GMR) magnetic field sensors having a spin valve structure and a “current-perpendicular-to-the-plane” (CPP) configuration. More particularly, it relates to such a sensor that has both an enhanced GMR ratio and low coefficient of magnetostriction.
[0003] 2. Description of the Related Art
[0004] Magnetic read sensors that utilize the giant magnetoresistive (GMR) effect for their operation are generally of the “current-in-the-plane” (CIP) configuration, wherein current is fed into the structure by leads that are laterally disposed to either side of an active sensor region and the current moves through the structure essentially within the planes of its magnetic and other conducting layers. Since the operation of GMR sensors depends on the detection of resistance variations in their active magnetic layers caused by changes in the relative directions of their magnetic moments, it is important that a substantial portion of the current passes through those layers so that their resistance variations can have a maximally detectable effect. Unfortunately, CIP GMR sensor configurations typically involve layer stacks comprising layers that are electrically conductive but not magnetically active and that play no role in providing resistance variations. As a result, portions of the current are shunted through regions that produce no detectable responses and, thereby, the overall sensitivity of the sensor is adversely affected. The CPP sensor configuration avoids this current shunting problem by disposing its conducting leads vertically above and below the active sensor stack, so that all of the current passes perpendicularly through all of the layers as it goes from the lower to the upper lead. The CPP configuration thereby holds the promise of being effective in reading magnetically recorded media having recording densities exceeding 100 Gbit/in 2 .
[0005] The pertinent prior art cited below has offered no similar method for improving the sensitivity of the CPP design having a synthetic spin valve stack configuration. Lederman et al. (U.S. Pat. No. 5,627,704) discloses a CPP GMR stack structure formed within a gap located in one of two pole layers of a magnetic yoke structure which also has a transducing gap formed in an ABS plane. The two pole pieces of the yoke serve to guide magnetic flux to the GMR stack which has current leads above and below it and permanent magnet biasing layers horizontally disposed on either side of it.
[0006] Dykes et al. (U.S. Pat. No. 5,668,688) discloses a spin valve CPP configuration in which the active layers form a stack of uniform width disposed between upper and lower shield and conductor layers.
[0007] Smith et al. (U.S. Pat. No. 6,473,279) teaches a CPP-GMR sensor whose ferromagnetic free layer is maintained in a single domain state by a layer configuration in which the free layer is separated from a pinning layer (below the free layer) by a non-magnetic spacer layer and an additional ferromagnetic layer is formed above the free layer and separated from it by an additional non-magnetic spacer layer formed of Ru. The Ru layer induces an anti-ferromagnetic exchange coupling between the additional ferromagnetic layer and the free layer and there is also a direct magnetostatic coupling between the additional ferromagnetic layer and the free layer. This combined interaction stabilizes the domain state of the free layer.
[0008] Redon et al. (U.S. Pat. No. 6,344,954) teaches a magneto-resistive tunnel junction whose ferromagnetic free layer and pinned layers are made of various layers of spin polarizing materials.
[0009] Nishimura (U.S. Pat. No. 6,226,197) teaches a magnetic thin film memory using a variety of ferromagnetic layered materials While the prior art cited above does make use of ferromagnetic materials like those to be used in the novel formation of the present invention, they do not address the issue of improving the sensitivity of a CPP device by a the formation of a free layer having improved magnetic characteristics. In particular, a good free layer for read head operation should be magnetically soft (have low coercivity) so that it can easily respond to external magnetic field fluctuations, yet it must also exhibit a small positive magnetostriction between 10 −6 and 10 −7 to reduce stress-induced magnetic anisotropy common in a free layer that is typically under compressive stress. The method of the present invention will produce such an improved free layer. In addition, the method of the present invention can also be advantageously applied to the formation of a synthetic antiferromagnetic pinned layer with improved characteristics. The cited prior art does not make reference to the improvement of CPP device performance by either such free layer or pinned layer improvement.
SUMMARY OF THE INVENTION
[0010] Accordingly, it is a first object of this invention is to provide a novel current-perpendicular-to-plane (CPP) giant magnetoresistive (GMR) read-sensor stack structure of a synthetic spin valve configuration, having improved sensitivity and small positive magnetostriction.
[0011] It is a second object of this invention to provide a method to controllably optimize the magnetostriction of a free layer to fulfill requirements of specific applications.
[0012] It is a third object of this invention to provide a method of improving CPP GMR sensor performance by the formation of a synthetic antiferromagnetic pinned layer having improved characteristics.
[0013] The objects stated above will be achieved by a novel laminated free layer configuration within a CPP synthetic spin valve design and/or a novel laminated pinned layer configuration. The free layer comprises layers of CoFe or CoFe laminated on Cu (CoFe when used hereinafter will refer specifically to Co 90 Fe 10 of approximately 5 angstroms thickness, interspersed with very thin layers (called lamina herein, because of their thinness) of FeCo (specifically Fe 50 Co 50 ) of less than 3 angstroms but preferably approximately 0.5 angstroms thickness. While the examples discussed below will all use Fe 50 Co 50 , the same advantages of the present invention can be obtained by using layers of any of the Fe-rich ferromagnetic alloys Co 75 Fe 25 , Co 70 Fe 30 , Co 60 Fe 40 , Co 65 Fe 35 or more generally Co x Fe 1-x with x between 0.25 and 0.75. Therefore, when the symbol FeCo is used hereinafter, it will refer to layers of the Fe-rich ferromagnetic alloys such as Co 75 Fe 25 , Co 70 Fe 30 , Co 60 Fe 40 , Co 65 Fe 35 or, more generally Co x Fe 1-x with x between 0.25 and 0.75.
[0014] While FeCo, used alone or grown on a Cu layer (FeCo/Cu), has certain properties that are advantageous in a free layer, it has other properties that make it undesirable for that use. For example, FeCo has larger bulk and interface spin asymmetry parameters than a CoFe layer, which is advantageous. On the other hand, FeCo has a high coercivity and a large positive magnetostriction, both of which are distinctly disadvantageous. CoFe by itself or when grown on a Cu layer (CoFe/Cu), on the other hand, has a low coercivity, which is distinctly advantageous in a free layer, yet it also has a large negative magnetostriction, in the range between −10 −6 to −10 −7 , which is disadvantageous.
[0015] The objects of the present invention will be realized by interspersing thin lamina of FeCo with thicker layers of CoFe and Cu spacer layers in repeated structures. These combinations will retain the low coercivity of the CoFe, introduce the advantageous spin asymmetry of the FeCo while bringing magnetostriction values within the acceptable positive limits between 10 −7 and 10 −6 by combining the large positive magnetostriction values of the FeCo with the large negative magnetostriction values of the CoFe. In addition, the bulk and interface properties of the FeCo enhance the overall bulk scattering coefficient of the laminated free layer, thereby enhancing the CPP GMR ratio. Moreover, the arrangement and multiplicity of the lamina make it possible to fine-tune the coercivity and magnetostriction of the free layer, which is distinctly advantageous for the fabrication of a variety of devices.
[0016] The novel laminated free layer will be formed within a typical CPP bottom synthetic type spin valve structure common in the prior art, such as that illustrated schematically in FIG. 1 . The CPP structure may or may not also include the novel pinned layer to be described below. The layers of such a CPP structure include a seed layer ( 44 ), an antiferromagnetic pinning layer ( 46 ), a synthetic antiferromagnetic pinned layer ( 48 ) further comprising a second ferromagnetic layer (denoted AP 2 ) ( 50 ), a coupling layer ( 52 ) and a first ferromagnetic layer (AP 1 ) ( 54 ), a Cu spacer layer ( 25 ), a ferromagnetic free layer ( 20 ) and a capping layer ( 12 ). In such a prior art formation the AP 1 and AP 2 layers would typically be layers of CoFe in a thickness range of between approximately 20-40 angstroms and the free layer ( 20 ) would also be a layer of CoFe within the same thickness range or a layer of CoFe grown on a layer of Cu (not shown). Biasing layers and conductor layers are not shown. In the present invention, the novel laminated free layer will replace the single free layer of CoFe shown in the figure.
[0017] The novel laminated pinned layer configuration, which can be used alone or in conjunction with the novel free layer, refers specifically to a new formation of the structure of the first ferromagnetic layer (AP 1 ), which is ( 54 ) in FIG. 1 . Two different laminated AP 1 layers were formed and tested in a CPP sensor stack that was otherwise identical. AP 1 layer “A,” which may be considered a reference layer, was formed in a multiply laminated configuration: (CoFe 10/Cu 2)×7/CoFe 10, which means seven repeated layers of 10 angstrom thick CoFe on 2 angstrom thick Cu, formed on a 10 angstrom thick layer of CoFe. This configuration was compared to AP 1 layer “B,” which was formed as (CoFe 10/Cu 2)×3/(FeCo 10/Cu 2)×3/FeCo10. Thus, in configuration B, part of AP 1 is replaced by FeCo 10/Cu 2 laminations, keeping the total magnetic moment of AP 1 constant.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic cross-sectional view through the air-bearing surface (ABS) of a prior art CPP GMR sensor configuration of the synthetic spin valve type.
[0019] FIGS. 2 a - e are schematic cross-sectional views of five sample CPP GMR sensor configurations, four of which ( b - e ) incorporate the laminated free layer structures of the present invention and one of which ( a ) is a reference configuration. These are used to make coercivity and magnetostriction comparisons.
[0020] FIGS. 3 a - c are graphs of sensor resistance vs. applied magnetic field for three different free layer configurations in otherwise identical sensor stack configurations, illustrating the improvement in coercivity for the laminated free layer of the present invention.
[0021] FIGS. 4 a and b are schematic cross-sectional views of two synthetic antiferromagnetic pinned layers, with 4 a formed in accord with the present invention.
[0022] FIGS. 5 a - b are graphs of sensor resistance vs. applied magnetic field for two different AP 1 configurations within the pinned layer of otherwise identical sensor stack configurations, illustrating the improvement in GMR ratio for the laminated AP 1 layer of the present invention. FIG. 5 b refers to the configuration shown schematically in FIG. 4 b.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention is a GMR spin valve sensor in a CPP (current-perpendicular-to-plane) synthetic pinned layer spin-valve configuration, having a novel laminated free layer of low coercivity and low positive magnetostriction. This sensor may also include a novel laminated synthetic pinned layer. The novel free layer includes multiple thin lamina of FeCo interspersed with thicker layers of CoFe, which can be varied to provide an optimal combination of coercivity and magnetostriction. The novel pinned layer includes a ferromagnetic layer in which layers of FeCo replace layers of CoFe for an improvement in the GMR ratio of the sensor.
[0024] Referring to FIGS. 2 a - e , there is shown in each figure a schematic cross-sectional view of a stack configuration (a configuration of layers) used to experimentally determine optimum free layer configurations for achieving desired coercivity and magnetostriction values. Within these stack formations, the various layers are formed advantageously by sputtering. FIG. 2 a is a reference stack having a prior art free layer, while FIGS 2 b - e are exemplary stacks comprising laminated free layers of the present invention in various configurations. Each stack is formed so that its particular free layer configuration is formed between a substrate layer, which is a [seed layer/pinning layer/spacer layer] and a capping layer, which are the same for each stack. More specifically, each of the five configurations has the form:
Ta50/Ru20/MnPt150/Cu30[Free Layer]Cu10/Ta50
where Ta50 is a layer of tantalum 50 angstroms thick, Ru20 is a layer of ruthenium 20 angstroms thick, MnPt is a layer of antiferromagnetic manganese-platinum 150 angstroms thick and Cu30 is a layer of copper 30 angstroms thick. This combination of five layers, the substrate layer, is referred to simply as ( 10 ) in each of the figures, FIGS. 2 a - e . The capping layer is a layer of copper 10 angstroms thick over which is a layer of tantalum 50 angstroms thick. This capping layer is referred to as ( 100 ) in each of the figures FIGS. 2 a - d . The free layer, denoted generically as ( 20 ) in each of the figures, FIGS. 2 a - d , is configured differently in each figure, and will now be described in detail.
[0025] Referring first to FIG. 2 a , there is shown the prior art reference configuration. There is seen the free layer ( 20 ) which is a single layer of CoFe (Co 90 Fe 10 ) formed to a thickness of approximately 30 angstroms, which is typical of a prior art sensor such as illustrated in FIG. 1 . Testing of this configuration indicates a coefficient of magnetostriction, λ=−6.90×10 −6 and a coercivity, H c =6 Oe.
[0026] Referring next to FIG. 2 b , there is shown a first exemplary free layer ( 20 ) which is a laminated configuration formed in accord with the present invention and which will be formed between the substrate ( 10 ) and capping layer ( 100 ). As we will see in this and the succeeding figures of FIG. 2 , the variation of laminas, layers and spacer layers will permit the formation of a free layer with magnetostriction coefficients ranging between positive and negative values.
[0027] The first layer of this free layer is a first layer of CoFe ( 22 ) formed to a thickness between approximately 5 and 15 angstroms, with approximately 10 angstroms being preferred. On this layer is formed an ultra-thin layer (referred to hereinafter as a lamina) of FeCo ( 24 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. In all the following examples, FeCo refers specifically to Fe 50 Co 50 , of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred; but as has been noted above, more generally Co x Fe 1-x with x between 0.25 and 0.75 can be used to fulfill the objects of the invention. On this lamina is formed a second layer of CoFe ( 26 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this layer is formed a Cu layer ( 28 ) of thickness between approximately 1 and 4 angstroms, with approximately 2 angstroms being preferred. The non-magnetic Cu layer acts as a spacer layer and has been experimentally shown to have beneficial effects on the magnetic performance parameters of ferromagnetic layers grown upon it and to allow the advantageous adjustment of magnetostriction values and GMR enhancement. On this Cu layer is formed a third layer of CoFe ( 30 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this CoFe layer there is formed a second lamina of FeCo ( 32 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a second layer of Cu ( 33 ) of thickness between approximately 1 and 4 angstroms, with approximately 2 angstroms being preferred. On this Cu layer is formed a fourth layer of CoFe( 34 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. Testing of this configuration indicates a coefficient of magnetostriction, λ=+9.00×10 −7 and a coercivity, H c =13.
[0028] Referring next to FIG. 2 c , there is shown a second exemplary free layer ( 20 ) which is a laminated configuration formed in accord with the present invention. The first layer of this free layer is a first layer of CoFe ( 42 ) formed to a thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this layer is formed a layer of Cu ( 44 ) of thickness between approximately 1 and 4 angstroms, with approximately 2 angstroms being preferred. On this Cu layer is formed a second layer of CoFe ( 46 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this CoFe layer is formed a lamina of FeCo ( 48 ) (in all these examples, specifically Fe 50 Co 50 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a third layer of CoFe ( 50 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this layer is formed a second Cu layer ( 52 ) of thickness between approximately 1 and 4 angstroms, with approximately 2 angstroms being preferred. On this Cu layer is formed a fourth layer of CoFe ( 54 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this CoFe layer there is formed a second lamina of FeCo ( 56 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a fifth layer of CoFe ( 58 ) of thickness between approximately 2.5 and 7.5 angstroms with approximately 5 angstroms being preferred. On this CoFe layer is then formed a third layer of Cu ( 60 ) of thickness between approximately 1 and 4 angstroms, with approximately 2 angstroms being preferred. On this Cu layer is formed a sixth layer of CoFe( 62 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. Testing of this configuration indicates a coefficient of magnetostriction, λ=−8.90×10 −7 and a coercivity, H c =13.9.
[0029] Referring next to FIG. 2 d , there is shown a third exemplary free layer ( 20 ) which is a laminated configuration formed in accord with the present invention. The first layer of this free layer is a first layer of CoFe ( 72 ) formed to a thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this layer is formed a layer of Cu ( 74 ) of thickness between approximately 1 and 4 angstroms, with approximately 1 angstrom being preferred. On this Cu layer is formed a second layer of CoFe ( 76 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this CoFe layer is formed a lamina of FeCo ( 78 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a third layer of CoFe ( 80 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this layer is formed a second Cu layer ( 82 ) of thickness between approximately 1 and 4 angstroms, with approximately 1 angstrom being preferred. On this Cu layer is formed a fourth layer of CoFe ( 84 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this CoFe layer there is formed a second lamina of FeCo ( 86 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a fifth layer of CoFe ( 88 ) of thickness between approximately 2.5 and 7.5 angstroms with approximately 5 angstroms being preferred. On this CoFe layer is then formed a third layer of Cu ( 90 ) of thickness between approximately 1 and 4 angstroms, with approximately 1 angstrom being preferred. On this Cu layer is formed a sixth layer of CoFe( 91 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. Testing of this configuration indicates a coefficient of magnetostriction, λ=−8.00×10 −7 and a coercivity, H c =12.0.
[0030] Referring next to FIG. 2 e , there is shown a fourth exemplary free layer ( 20 ) which is a laminated configuration formed in accord with the present invention. The first layer of this free layer is a first layer of CoFe ( 102 ) formed to a thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this layer is formed a lamina of FeCo ( 104 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a second layer of CoFe ( 106 ) of thickness between approximately 2.5 and 7.5 angstroms with approximately 5 angstroms being preferred. On this layer is formed a first layer of Cu ( 108 ) of thickness between approximately 1 and 4 angstroms, with approximately 2 angstrom being preferred. On this Cu layer is formed a third layer of CoFe ( 110 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this CoFe layer is formed a second lamina of FeCo ( 112 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a fourth layer of CoFe ( 114 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this layer is formed a second Cu layer ( 116 ) of thickness between approximately 1 and 4 angstroms, with approximately 2 angstrom being preferred. On this Cu layer is formed a fifth layer of CoFe ( 118 ) of thickness between approximately 2.5 and 7.5 angstroms, with approximately 5 angstroms being preferred. On this CoFe layer there is formed a third lamina of FeCo ( 120 ) of thickness less than 3 angstroms, with approximately 0.5 angstroms being preferred. On this lamina is formed a sixth layer of CoFe ( 122 ) of thickness between approximately 2.5 and 7.5 angstroms with approximately 5 angstroms being preferred. Testing of this configuration indicates a coefficient of magnetostriction, λ=− 1 . 90 × 10 −7 and a coercivity, H c =8.0.
[0031] It is to be noted that one purpose of presenting these examples is to indicate the degree of control over magnetostriction and coercivity that is provided by the interspersal of the FeCo lamina and the Cu layers with the CoFe layers. Although the first example ( FIG. 2 a ) provided a desirable positive magnetostriction, it should not be considered as the only configuration that would yield such a magnetostriction.
[0032] Referring next to FIGS 3 a - c , there are shown three graphs, schematically indicating the relationship between CPP resistance (vertical axis) and applied magnetic field, Hy (Oe) (horizontal axis) for three different free layer configurations. The maximum height differential of the graphs (shown as ΔR) is indicative of the GMR ratio (ΔR/R) and the horizontal distance (arrows) between the two portions of the graph (forward and reverse swing of the magnetic field) is an indication of the coercivity of the free layer. Referring first to FIG. 3 a , there is shown the performance of a prior art type free layer of the form (the numbers in parentheses being thicknesses in angstroms):
CoFe(10)/Cu(2)/CoFe(10)/Cu(2)/CoFe(10)
[0033] The graph is indicative of a low coercivity, which is measured to be approximately 6.2 Oe and a good GMR ratio of approximately 2.05%.
[0034] Referring next to FIG. 3 b , there is shown the performance of a free layer containing only FeCo, specifically:
FeCo(10)/Cu(2)/FeCo(10)/Cu(2)/FeCo(10).
[0035] As has been previously noted, one of the disadvantages of FeCo is its high coercivity and this can be clearly seen in the graph. The measured coercivity of this configuration is 151 Oe and the GMR ratio is a good 2.25%. The good GMR ratio produced by FeCo has also been noted above.
[0036] Referring next to FIG. 3 c , there is shown the performance of a free layer formed in accord with the present invention:
CoFe(10)/FeCo(0.5)/Cu(2)/FeCo(0.5)/CoFe(10)/FeCo(0.5)/Cu(2)/FeCo(0.5)/CoFe(10).
[0037] As can be seen in the graph, the GMR ratio is quite similar to that displayed by the pure FeCo free layer ( FIG. 3 b ), while the coercivity is comparable to that of the CoFe/Cu free layer of FIG. 3 a . Specifically, the GMR ratio is 2.22% and the coercivity is 5.9 Oe. Referring next to FIG. 4 a , there is shown a schematic cross-sectional view of a synthetic antiferromagnetic pinned layer such as is illustrated in prior art FIG. 1 as layer ( 48 ), but having one layer (the AP 1 layer) formed in accord with the present invention. Referring again to FIG. 1 , it is seen that the two ferromagnetic layers forming the pinning layer are designated AP 1 ( 54 ) and AP 2 ( 50 ), with AP 1 being closest to the free layer. The present invention provides a laminated structure for the AP 1 layer, utilizing FeCo layers in a thickness range between approximately 5 and 15 angstroms, with 10 angstroms being preferred, in place of the prior art CoFe layers. Note that the FeCo layers could also be layers of the Fe-rich ferromagnetic alloys Co 75 Fe 25 , Co 70 Fe 30 , Co 60 Fe 40 , Co 65 Fe 35 or more generally Co x Fe 1-x with x between 0.25 and 0.75. To this structure there is added thin layers of Cu, in a thickness range between 1 and 4 angstroms with approximately 2 angstroms being preferred. This new structure produces greatly improved sensor performance. Note, we are using the more generic term “layer” to describe the thicker FeCo layers in the pinned layer as opposed to our use of “lamina” as a distinguishing term to describe the ultra-thin layers of FeCo used in forming the free layer of the sensor.
[0038] Referring back to FIG. 4 a , there is seen an enlarged cross-sectional schematic view of an AP 1 layer ( 54 ), which is formed as a 7-layer structure, of which the first 3 layers ( 540 ), ( 541 ) and ( 542 ) are identical bilayers of (CoFe10/Cu2), the second 3 layers ( 643 ), ( 644 ) and ( 645 ) are identical bilayers of (FeCo10/Cu2) and the 7 th layer ( 746 ) is a single layer of FeCo 10. All the numbers refer to thicknesses in angstroms.
[0039] Referring next to FIG. 4 b , there is shown a reference AP 1 layer ( 54 ) of similar total magnetic moment, but formed of six identical (CoFe10/Cu2) bilayers ( 540 ), ( 541 ), ( 542 ), ( 543 ), ( 544 ) and ( 545 ) on a single layer of CoFe 10 ( 546 ) and therefore lacking any FeCo lamina. When the AP 1 layers of FIG. 4 a and 4 b were incorporated within an identical CPP sensor configuration, the layer of FIG. 4 a , with FeCo lamina as indicated, demonstrated a marked improvement in sensor performance compared with the reference layer.
[0040] Referring next to FIGS 5 a and b , there is shown graphical evidence of the improved performance of the FIG. 4 a layered sensor element of the present invention as compared with the FIG. 4 b layered sensor element. The two graphs plot variations in sensor resistance (ΔR) as an external magnetic field sweeps in two directions (the GMR ratio being ΔR/R), which is an indication of the sensor's sensitivity to the magnetic field variations in magnetically encoded media. The sensor element of FIG. 4 a , as indicated in the graph of FIG. 5 a , shows a GMR ratio of 2.25% that is enhanced by approximately 20% to the GMR ratio of 2.64% of the element of FIG. 4 b as shown graphically in FIG. 5 b.
[0041] As is understood by a person skilled in the art, the preferred embodiments of the present invention are illustrative of the present invention rather than limiting of the present invention. Revisions and modifications may be made to methods, materials, structures and dimensions employed in forming a CPP GMR sensor of the synthetic spin valve type whose laminated free layer has good coercivity, a high GMR ratio and low coefficient of magnetostriction, while still providing the CPP GMR sensor of the synthetic spin valve type whose laminated free layer has good coercivity, a high GMR ratio and low coefficient of magnetostriction so formed, in accord with the spirit and scope of the present invention as defined by the appended claims. | A current-perpendicular-to-plane (CPP) giant magnetoresistive (GMR) sensor of the synthetic spin valve type and its method of formation are disclosed, the sensor including a novel laminated free layer having ultra-thin (less than 3 angstroms thickness) laminas of Fe 50 Co 50 (or any iron rich alloy of the form Co x Fe 1-x with x between 0.25 and 0.75) interspersed with thicker layers of Co 90 Fe 10 and Cu spacer layers to produce a free layer with good coercivity, a coefficient of magnetostriction that can be varied between positive and negative values and a high GMR ratio, due to enhancement of the bulk scattering coefficient by the laminas. The configuration of the lamina and layers in periodic groupings allow the coefficient of magnetostriction to be finely adjusted and the coercivity and GMR ratio to be optimized. The sensor performance can be further improved by including layers of Cu and Fe 50 Co 50 in the synthetic antiferromagnetic pinned layer. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to a drug delivery needle and more specifically to a needle for percutaneous injection of a drug into an implanted drug delivery device having a catheter for drug delivery to a patient.
BACKGROUND OF THE INVENTION
[0002] Drug delivery devices are commonly implanted in a patient for long-term administration of drugs. These devices generally include a chamber with a self-sealing silicone septum and a catheter attached to the chamber and positioned for delivery of the drug to a suitable location, for example, into a vein. The chamber contains the drug for delivery to the patient through the catheter and is implanted such that the septum is located just under the skin of the patient. In order to access the chamber, the patient's skin and the septum of the drug delivery device are pierced using a needle and the drug is introduced into the chamber by injection using a syringe or other delivery device.
[0003] Conventional hypodermic needles are not used for the introduction of a drug to a drug delivery device for various reasons including, for example, the possibility that these needles can damage the septum. Instead, specially designed needles are used to pierce the skin and the septum. These needles include a right angle bend (approximately a ninety degree bend) for convenient access to the chamber and are designed to inhibit coring of the septum and ensure penetration of the skin and septum at approximately ninety degrees. The needles are appropriately sized to access the chamber of the device. A portion of the needle lies approximately parallel with the surface of the skin of the patient, to allow the needle to be taped down.
[0004] While they are an improvement over conventional needles, right-angle needles can still be somewhat difficult to hold and to push through the skin and the septum since the physician must firmly grasp the needle in order to drive the needle through the septum. Also, when taped down on the patient, prior art needles do not allow flow of air around the wound site. This can contribute to infection of the wound.
[0005] One particular prior art drug delivery needle is disclosed in U.S. Pat. No. 4,743,231, issued May 10, 1988 to Kay et al. This patent teaches a right angle drug administration needle with a rigid base for taping down to the skin of a patient and a releasably connectable handle for ease of handling. A foam pad extends around the periphery of the underside of the base and includes an adhesive surface for adhering to the skin of the patient. A low profile allows for the right angled needle device to be taped down to the user while the foam pad provides flow of air around the wound site.
[0006] Although this structure provides a handle for firmly grasping the needle and a foam pad for flow of air around the wound site, the drug delivery needle device still suffers from some disadvantages. The handle is molded separately from the remainder of the needle device and is releasable to provide a low profile when the device is taped down. Thus, when the tape is removed from the patient, the physician is required to find the handle and attach the handle to the base in order to remove the needle. Since the handle is removable, it can easily be misplaced or lost. Also, the base is rigid and does not conform to the skin surface of the patient.
[0007] Accordingly, it is an object of an aspect of the present invention to provide a drug delivery needle for percutaneous delivery of a drug into an implanted drug delivery device that obviates or mitigates at least one of the disadvantages of the prior art.
SUMMARY OF THE INVENTION
[0008] In one aspect of the present invention there is provided a needle device for percutaneous drug delivery to a patient. The device comprises a substantially L-shaped, hollow needle for drug delivery therethrough and a body. The needle includes a needle end and the body is secured to the needle and longitudinally spaced from the needle end. The body includes an integral pair of flexible handles adapted to be grasped for insertion of the needle device into and removal of the device from the patient.
[0009] Advantageously, the handles of the drug delivery device are attached to the remainder of the device. Also, the drug delivery device includes a spacer that spaces the handles away from the wound site when the drug delivery device is taped down on the patient. In an aspect of the invention, a portion of the L-shaped needle extends approximately from the center of a body between the pair of flexible handles. Thus, downward force on the body of the device is transmitted to the needle when the needle is inserted into the patient. This provides support and accuracy during insertion of the needle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be better understood with reference to the drawings, and following description, in which:
[0011] [0011]FIG. 1 is a perspective view of a needle device according to a preferred embodiment of the present invention;
[0012] [0012]FIG. 2 is an alternative perspective view of the needle device of FIG. 1;
[0013] [0013]FIG. 3 is a cross-sectional front view of the needle device of FIG. 1 showing the device in use with a needle inserted into a chamber (shown in ghost outline) under the skin of a patient and showing a pair of handles, flexed in opposing directions in ghost outline;
[0014] [0014]FIG. 4 is a bottom view of the needle device of FIG. 1, showing the needle in cross-section;
[0015] [0015]FIG. 5 is a perspective view of the needle device of FIG. 1, showing the handles being grasped; and
[0016] [0016]FIG. 6 is a front view of the needle device of FIG. 5, showing the handles being grasped.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] Reference is first made to FIGS. 1 and 2 to describe a preferred embodiment of a drug delivery needle device designated generally by the numeral 20 . The drug delivery needle device includes a substantially L-shaped needle 22 for drug delivery therethrough. The needle 22 consists of first portion 24 and a second portion 26 with an included angle between the first portion 24 and second portion 26 , forming the L-shape. In the present embodiment, the included angle is approximately ninety degrees. The needle 22 is hollow to define a continuous fluid passage through the first and second portions 24 , 26 , respectively. The first portion 24 of the needle 22 is attached to a flexible tube and will be described further below. The second portion 26 of the needle 22 includes a needle end 30 that is slightly bent with respect to the remainder of the second portion 26 and is longitudinally spaced from the first portion 24 . The end 30 is bent to provide a non-coring needle, as will be understood by those of skill in the art. As shown in the figures, the continuous fluid passage is open at the needle end 30 and the needle end 30 is sharp for piercing the skin of a patient and for piercing a septum of a chamber of a catheter, for example.
[0018] A body 32 is molded of a resiliently flexible plastic around the first and second portions 24 , 26 , respectively. The body 32 includes a substantially rectangular base 34 , a spacer 36 , a pair of flexible handles 38 , 39 and a cover 40 , as discussed further below.
[0019] The substantially rectangular base 34 is molded around the second portion 26 and is longitudinally spaced from the end 30 such that the second portion 26 of the needle 22 passes through and extends from the base 34 . A foam pad 42 extends around the periphery of one side of the base 34 . The foam pad 42 is an open-celled plastic foam to allow air flow therethrough, thereby providing a layer that allows the flow of air between the molded plastic base 34 and the skin of a patient when in use. In the present embodiment, the foam pad and base are flexible for patient comfort.
[0020] One end 44 of the spacer 36 is coupled to a second side of the base 34 and the opposing end 46 is coupled to the cover 40 . It can be seen that the first portion 24 of the needle 22 extends through the cover 40 such that the cover 40 and the first portion 24 form a rigid spine 48 that provides rigidity for the device 20 . The second portion 26 of the needle 22 extends through the spacer 36 and the base 34 . As shown in FIGS. 1, 2 and 3 , the second portion 26 of the needle 22 extends longitudinally and is approximately perpendicular to the base 34 , while the spine 48 is approximately parallel with the base 34 .
[0021] Referring to FIG. 3, each of the flexible handles 38 , 39 extends laterally from and is coupled to the spine 48 such that the spine 48 is located between the handles 38 , 39 . The spine 48 effectively couples the handles 38 , 39 to the spacer 36 which spaces the handles 38 , 39 from the base 34 . Each of the handles 38 , 39 includes a groove 50 , 52 , respectively, extending along the width of the handles 38 , 39 , adjacent the spine 48 . The handles 38 , 39 also include distal ends 54 , 56 , respectively, that are laterally spaced from the spine 48 and the grooves 50 , 52 . These grooves 50 , 52 provide a thin region in comparison with the remainder of the handles 38 , 39 . This provides increased flexibility in this region. In order to grasp the device 20 , the handles 38 , 39 are flexed away from the base 34 such that backsides 58 , 60 of each of the respective handles 38 , 39 are in contact with each other at the distal ends 54 , 56 . Thus, the handles 38 , 39 are effectively pinched together when grasped, as best shown in FIGS. 5 and 6. When no longer grasped, the handles 38 , 39 return to their laterally extending state. As shown in the Figures, the second portion 26 of the needle 22 extends approximately from the center of the body 32 , between the pair of flexible handles, 38 , 39 .
[0022] The handles 38 , 39 can also flex in the opposite direction. It will be appreciated that the handles 38 , 39 are spaced from the base 34 in order to inhibit contact of the handles 38 , 39 with a patient's skin proximal the wound site when the device 20 is in use.
[0023] Referring again to FIG. 1, a flexible tube 62 is connected to and in fluid communication with the first portion 24 of the needle 22 . The tube 62 extends outwardly from the spine 48 . The flexible tube 62 is made of a suitable plastic for delivery of a drug through the tube 62 , into the first portion 24 of the needle. 5
[0024] Although each of these elements are described separately, it will be appreciated that in the present embodiment the base 34 , the spacer 36 , the handles 38 , 39 and the cover 40 are a unitary molded plastic.
[0025] The use of the drug delivery device 20 will now be described with reference to FIGS. 3 to 6 . For the purpose of the present description, a chamber with a self-sealing septum, shown in ghost outline in FIG. 3, is implanted such that the chamber is located just under the skin of the patient. The chamber is designed to contain the drug for delivery to the patient through a catheter. The use of a chamber and self-sealing septum is understood in the art and will not be further described herein.
[0026] In order to access the chamber, the patient's skin and the septum are pierced using the device 20 . To accomplish this, the handles 38 , 39 of the device 20 are flexed by pinching the handles 38 , 39 , preferably between the thumb and the forefinger, such that they are in contact with each other at the distal ends 54 , 56 of the backsides 58 , 60 , as shown in FIGS. 5 and 6. Next, the needle end 30 is positioned at the desired location on the skin of the patient (at the location of the self-sealing septum). Pressure is then applied towards the surface of the skin causing the end 30 of the needle 22 to puncture the skin and the self-sealing septum of the chamber. It will be appreciated that the spine 48 provides rigidity to the device 20 when the needle 22 is being inserted or extracted from a patient. As stated above, the second portion 26 of the needle 22 extends approximately from the center of the body 32 , between the pair of flexible handles, 38 , 39 . The needle is inserted until the foam pad 42 is adjacent the patient's skin. With the needle end 30 located in the chamber, the fluid or drug is then delivered to the chamber through the flexible tube 62 , through the first and second portions 24 , 26 , respectively and out the needle end 30 .
[0027] It may be desirable to leave the device 22 with the end 30 of the needle 22 inserted into the chamber for a long period of time. In such case, the device is generally taped to the skin of the patient. Thus, the handles 38 , 39 are flexed in the direction of the skin of the patient. Since the spacer 36 spaces the handles 38 , 39 from the base 34 , the handles are effectively inhibited from contacting the skin of the patient immediately around the foam pad 42 on the base 34 . The foam pad 42 allows for the flow of air around the wound site (where the needle puncture is located).
[0028] To remove the device 20 , any tape that has been used to secure the device 20 is first removed. The handles 38 , 39 are then grasped, as discussed above, and pulled outwardly, away from the patient. Thus, the needle 22 is removed from the patient and the septum of the chamber seals.
[0029] While the embodiment discussed herein is directed to a particular implementation of the present invention, it will be apparent that variations and modifications to this embodiment are possible. For example, the L-shaped needle can have any suitable included angle and can vary from ninety degrees. Also, the body structure described above does not need to be a unitary molded structure and can be individual pieces coupled together. The size and shape of many of the parts can vary while still performing the same function. All of these variations and modifications are within the scope sphere of the invention as defined by the claims appended hereto. | There is provided a needle device for percutaneous drug delivery to a patient. The device comprises a substantially L-shaped, hollow needle for drug delivery therethrough and a body. The needle includes a needle end and the body is secured to the needle and longitudinally spaced from the needle end. The body includes an integral pair of flexible handles adapted to be grasped for insertion of the needle device into and removal of the device from the patient. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a national stage of PCT/EP2004/004652 filed May 3, 2004 and based upon DE 103 21 795.9 filed May 14, 2003 under the International Convention.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a brake disk comprising a friction ring and a linking element.
[0004] 2. Related Art of the Invention
[0005] A brake disk of this type is known from EP 0 987 462.
[0006] EP 0 987 462 A1 describes brake disk comprising a friction ring and a linking element, which are interconnected by threaded fastener means (nut-and-bolt arrangement). In this case the nut-and-bolt arrangement comprises a bolt, an intermediate element, a washer and a nut. Here the bolt of the threaded fastener means extends through the bore of the linking element as well as the bore of the friction ring. The intermediate element is arranged such that it prevents contact between friction ring and linking element. The disadvantage of this arrangement is the inability of the friction ring and the linking element to expand in the axial or radial direction.
[0007] In DE 94 22 141 U1 another bolted-together arrangement of a friction ring and a linking element of a brake disk is described. Here a spring washer below the screw head enables axial expansion between friction ring and linking element. A disadvantage of this invention is the direct contact between friction ring and linking element which, especially when using dissimilar materials, likely results in corrosion. Moreover, this invention does not provide for radial expansion.
SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide a connection between friction ring and linking element allowing for radial and axial expansion which additionally prevents corrosion between friction rings and linking element.
[0009] The present invention describes a brake disk with a friction ring and a linking element which are interconnected by means of a threaded fastener arrangement. The threaded fastener arrangement includes a screw, a nut and an intermediate element in which the intermediate element is arranged such that it prevents direct contact between friction ring and linking element. The invention features a sliding block which is at least partially pushed over a sleeve element. The intermediate element is arranged such that it at least partially encloses the sliding block. Thereby the design of intermediate element provides a resilient force between friction ring and linking element in the axial direction.
[0010] According to the invention the intermediate element prevents contact between friction ring and linking element, thereby preventing corrosion between these two components. This arrangement is especially advantageous in the case that the friction ring is made from a ceramic material and the linking element is made from an aluminum alloy. In this case the intermediate element also prevents local deformations of the linking element, which can occur at elevated temperatures. Concurrently, by providing a resilient force, the linking element allows for an axial expansion between friction ring and linking element.
[0011] The design of the sliding block allows for thermal expansion of the friction ring and the linking element in radial direction. Thus friction ring and linking element have a degree of freedom in axial and radial direction, whereby mechanical stress occurring during braking is significantly reduced.
[0012] In an advantageous embodiment of the invention the friction ring features a circumferential retainer ring within itself. This retainer ring features fixing holes and allows screwing the linking element to the friction ring.
[0013] In another advantageous embodiment of the invention the linking element features oblong recesses in the radial direction. These oblong recesses can be open to the outside resembling the form of pinnacles or they can have the form of a slotted hole. The oblong recesses allow for a radial expansion of the threaded fastener arrangement through the sliding block which is hung into the oblong recesses and can sufficiently move in radial direction.
[0014] In one embodiment of the invention the intermediate element is designed as a U-shape. The long sides of the U-shaped intermediate elements feature flaps which fit into the oblong recesses of the linking element. The U-shape design and the flaps of the intermediate element securely lock the intermediate element in the oblong recesses and prevent direct contact between the linking element and the friction ring.
[0015] In another advantageous embodiment of the invention the flaps of the intermediate element feature resilient moldings. These resilient moldings provide a resilient force of the intermediate element in axial direction. Here it is advantageous that the intermediate element can simply be punched out of sheet metal and folded, hence reducing production cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Advantageous embodiments of the invention will be described in detail with the illustrations below. They show:
[0017] FIG. 1 a cross-sectional view through a brake disk with a friction ring and a linking element in the region of the threaded fastener arrangement,
[0018] FIG. 2 a perspective representation of an intermediate element,
[0019] FIG. 3 an intermediate element which is inserted into the oblong recesses of the linking element,
[0020] FIG. 4 an intermediate element which is inserted into the oblong recesses of the linking element with radial suspension.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The brake disk according to the invention is of the customary type of construction with a friction ring ( 2 ) and a linking element ( 4 ). The friction ring ( 2 ) features internal ventilation (not show here) which is confined between two friction surfaces (also not shown). Brake pads (not shown) are used to create a retarding effort on theses friction surfaces.
[0022] Preferably the friction ring is made from a carbon fiber reinforced ceramic material, e.g. a carbon fiber reinforced silicon carbide ceramic (C/SiC). Such ceramic materials show a high wear resistance and durability at high temperatures. Their mechanical strength however is slightly inferior compared to gray cast iron.
[0023] In order to keep the cost down the geometry of these friction rings needs to be simple. For that reason a brake disk made from C/SiC-material is preferably made from two pieces such that the friction ring ( 2 ) is connected to a linking element ( 4 ). In technical terms this linking element ( 4 ) is called the brake disk hub. The linking element ( 4 ) preferably consists of an aluminum alloy, furthermore optimizing the weight advantage already given by the very lightweight friction ring with respect to a conventional gray cast iron brake.
[0024] The utilization of different materials, the ceramic for the friction ring ( 2 ) and the aluminum in the linking element ( 4 ), in connection with the very high temperatures developing during the brake application results in different thermal expansion of the individual components. To avoid mechanical stress, which would inevitably result from this, a special connection between the friction ring ( 2 ) and the linking element ( 4 ) is required.
[0025] Such a threaded fastener arrangement ( 6 ) is illustrated in FIG. 1 . The threaded fastener arrangement ( 6 ) comprises a screw ( 8 ), preferably a bolt, with a shaft ( 16 ), which is secured by a nut ( 10 ). The threaded fastener arrangement ( 6 ) runs through an oblong recess ( 20 ) in the linking element ( 4 ) and through a fixing hole ( 23 ), which is located within an inner retainer ring ( 21 ) of the friction ring ( 2 ). Around the shaft ( 16 ) of the screw ( 8 ) a sleeve element ( 14 ) is located, which prevents a direct contact between the fixing hole ( 23 ) and the oblong recess ( 14 ) and the screw's shaft ( 16 ). Above the sleeve element ( 14 ) a sliding block ( 18 ) is located. The sliding block ( 18 ) is essentially of cylindrical shape, but features two parallel faces or recesses ( 30 ) which are arranged such that they can slip into the oblong recesses ( 20 ) of the linking element ( 4 ). The parallel recesses ( 30 ) of the sliding block ( 18 ) in turn create shoulders in the sliding block ( 18 ) which, as shown in FIG. 1 , serve as spacers between the linking element ( 4 ) and the retainer ring ( 21 ) of the friction ring ( 2 ).
[0026] Furthermore an intermediate element ( 12 ) is provided, which is arranged around the oblong recesses ( 20 ) of the linking element ( 4 ). The intermediate element ( 12 ) itself is illustrated in more detail in FIG. 2 . The intermediate element ( 12 ) is essentially U-shaped and features flaps ( 24 ) on its long sides ( 22 ). In the example on hand according to FIG. 2 resilient moldings ( 26 ) are punched out of these flaps ( 24 ). These resilient moldings ( 26 ) push, as shown in FIG. 1 , onto a washer ( 32 ), which in turn directly contacts the screw head ( 34 ). The resilient moldings ( 26 ) provide enough play enabling the entire threaded fastener arrangement ( 6 ) including the friction ring ( 2 ) and the linking element ( 4 ) to expand in the axial direction. Axial thermal expansions in the region of the screwing assembly ( 6 ) will be compensated by the resilient moldings ( 26 ).
[0027] Another reason for an axial play of the screwing assembly is based upon the mode of functioning of the brake caliper (not shown here). The brake caliper is one-sided rigidly mounted with respect to the brake disk. During braking a force acts onto the disk in the region of the brake caliper. Hence an axial moment acts upon the disk, the friction ring ( 2 ) the linking element ( 4 ) and the threaded fastener arrangement ( 6 ). In order to compensate for the mechanical stress caused by this axial moment, an axial play within the threaded fastener arrangement ( 6 ) is useful, which in turn is compensated by the resilient moldings ( 26 ).
[0028] Another advantageous aspect of the invention is based upon the freedom of movement of the sliding block ( 18 ). In the cross sectional view of FIG. 1 the direction of this movement of the sliding block ( 18 ) is perpendicular to the plane of the drawing.
[0029] In FIG. 3 an oblong recess ( 20 ) is slipped into the intermediate element ( 12 ). The U-shaped design of the intermediate element ( 12 ) is adjusted to the form of the oblong recess ( 20 ). The flaps ( 24 ) of the intermediate element ( 12 ) are bent such that they are positioned above boundaries ( 36 ) of the oblong recesses ( 20 ), thereby retaining the intermediate element ( 12 ) in axial and radial direction within these oblong recesses ( 20 ). It should be noted that the intermediate element ( 12 ) in FIG. 3 is not identical with the one in FIG. 2 . The intermediate element ( 12 ) in FIG. 3 is merely another advantageous embodiment. Another example for an embodiment of an intermediate element ( 12 ) is shown in FIG. 4 . In this embodiment the intermediate element ( 12 ) is radially arrested by means of a locking feature ( 44 ) of the linking element ( 4 ). In the assembly process the intermediate element ( 12 ) is slipped into the oblong recesses ( 20 ) of the linking element ( 4 ). Once it reaches the correct position the flap locking features ( 42 ) engage with the locking features ( 44 ) of the linking element ( 4 ). The locking feature ( 44 ) in this case is either a cavity in or a ridge on the linking element ( 4 ). In the case of a cavity the flap locking features ( 42 ) are bent from the flap ( 24 ) into the direction of the linking element ( 4 ).
[0030] In addition a radial suspension ( 46 ) of the intermediate element ( 12 ) at the lower end of the U-shaped intermediate element ( 12 ) ensures firm fit of the intermediate element ( 12 ) in the oblong recess ( 20 ).
[0031] The radial locking ( 42 , 44 ) of the intermediate element ( 12 ) together with the radial suspension ( 46 ) ensures that the intermediate element ( 12 ) remains in place with respect to the linking element ( 4 ). Relative radial movements (caused by thermal expansion of the linking element ( 4 ) and the friction ring ( 2 )) occur between the sliding block ( 18 ) and the intermediate element ( 12 ). Thus material abrasion in the relatively soft material of the linking element ( 4 ) (usually an aluminum alloy) is prevented. A material abrasion like this may cause noise of the brake.
[0032] The parallel recesses ( 30 ) of the sliding block ( 18 ) rest against the also parallel long sides ( 22 ) of the intermediate element ( 12 ). During a radial expansion of the friction ring ( 2 ) and the linking element ( 4 ) the sliding block ( 18 ), which is not shown in FIG. 3 , is able to move in radial direction ( 38 ) in parallel to the long sides ( 22 ) of the intermediate element ( 12 ). In FIG. 1 the radial direction ( 38 ) corresponds to a normal on the drawing plane. It should be noted that oblong recesses ( 20 ) in the example on hand are only envisioned for the linking element ( 4 ). The friction ring ( 2 ) which includes an inner retainer ring ( 21 ), which in turn features fixing holes ( 23 ), shows in this embodiment circular bores, which do not allow radial movements. Hence the radial movement occurs exclusively in the oblong recesses ( 20 ) of the linking element ( 4 ). The radial expansion of the threaded fastener arrangement ( 6 ) is provided through the sliding block ( 18 ).
[0033] In principle it is possible to constitute the oblong recesses ( 20 ) for the compensation of the radial play by a slotted hole in the linking element ( 4 ). It may also be useful to utilize circular recesses in the linking element ( 4 ) while the radial compensation is constituted through oblong recesses or slatted holes in the retainer ring ( 21 ) of the friction ring ( 2 ).
[0034] The intermediate Element ( 12 ) maybe made from a resilient stainless steel. By this it can be prevented that at high temperatures and through a high pre-stressing of the threaded fastener arrangement ( 6 ) the relatively soft aluminum material of the linking element ( 4 ) is pushed into the relatively hard material of the screw head ( 34 ) or the washer ( 32 ). The resilience of the intermediate element ( 12 ) thereby prevents irreversible material deformation in the linking element ( 4 ).
[0035] As shown in FIG. 1 the sleeve element ( 14 ) is slightly shorter than the total distance between the washer ( 32 ) and the nut ( 10 ). This is necessary to avoid crushing of the sleeve element ( 14 ) while the threaded fastener arrangement is mounted. The residual play of the sleeve element ( 14 ) along the shaft ( 16 ) of the screw can range between 1 mm and 6 mm. Hence the sliding block ( 18 ) is not supported by the sleeve element ( 14 ) throughout its entire length. An air gap ( 40 ) remains between the shaft ( 16 ) of the screw and the sliding block ( 18 ). The sliding block ( 18 ) however is separated from the shaft ( 16 ) of the screw ( 8 ) fundamentally by the sleeve element ( 14 ). The air gap ( 40 ) is kept small enough to prevent canting of the sliding block ( 18 ). It is also conceivable to constitute the sleeve element ( 14 ) as part of the sliding block ( 18 ). However the embodiment with the two parts is more cost efficient. | The invention relates to a brake disk comprising a friction ring ( 2 ) and a linking element ( 4 ) which are interconnected by means of a screwing arrangement ( 6 ). The screwing arrangement ( 6 ) encompasses a screw, a nut, and an intermediate element ( 12 ). Said intermediate element ( 12 ) prevents direct contact between the friction ring ( 2 ) and the linking element ( 4 ). Also provided is a sleeve element ( 14 ) that is disposed on a shaft ( 16 ) of the screw ( 8 ). A sliding block ( 18 ) is plugged onto the sleeve element ( 14 ). The intermediate element ( 12 ) at least partly encloses the sliding block such that thermal expansions acting in a radial direction can be compensated by a relative movement between the sliding block ( 18 ) and the intermediate element ( 12 ). The intermediate element also has a springy effect in an axial direction, by means of which mechanical and thermal stresses can be compensated in said axial direction. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to novel 1-(2,3-dihydro-1,4-benzodioxin-2-yl)-methanamine derivatives, useful as modulators of dopamine neurotransmission, and more specifically as dopaminergic stabilizers.
[0002] In other aspects the invention relates to the use of these compounds in a method for therapy and to pharmaceutical compositions comprising the compounds of the invention.
BACKGROUND OF THE INVENTION
[0003] Dopamine is a neurotransmitter in the brain. Since this discovery, made in the 1950's, the function of dopamine in the brain has been intensely explored. To date, it is well established that dopamine is essential in several aspects of brain function including motor, cognitive, sensory, emotional and autonomous functions (e.g. regulation of appetite, body temperature, sleep). Thus, modulation of dopaminergic function may be beneficial in the treatment of a wide range of disorders affecting brain functions. In fact, drugs that act, directly or indirectly at central dopamine receptors are commonly used in the treatment of neurological and psychiatric disorders, e.g. Parkinson's disease and schizophrenia. However, currently available dopaminergic pharmaceuticals can have severe side effects. One class of compounds acting through the dopamine systems of the brain are dopaminergic stabilizers, which have shown to be useful in the treatment of both neurologic and psychiatric disorders.
[0004] The typical pharmacological effects which are characteristic for dopaminergic stabilizers can be summarised as: 1) Increased turnover of dopamine in the terminal areas of the ascending dopaminergic projections of the mammalian brain; 2) No or only weak behavioural effects in otherwise untreated rats; and 3) Inhibition of behavioural effects induced by psychostimulants or psychotomimetic compounds in the rat. In the present invention this is referred to as a dopaminergic stabilizer profile.
DESCRIPTION OF PRIOR ART
[0005] WO 2005/105776 discloses arylsulfonyl benzodioxanes useful as modulators of 5-HT6 and 5-HT2A receptors.
[0006] WO 2006/116158 discloses benzodioxane and benzodioxolane derivatives useful as partial agonists or agonists at 5-HT2C receptors.
[0007] Avner et al. in Journal of Medicinal Chemistry 1974 17 (2) 197-200, disclose substituted 1,4-benzodioxanes as reversible and irreversible antagonists at adrenergic receptors.
[0008] Various chlorinated 1,4-benzodioxanes have been disclosed as ligands for α1 and α2-receptors, see e.g. Timmermans et al.; Pharmacology 1983 26 (5) 258-69; Timmermans et al.; Molecular Pharmacology 1981 20 (2) 295-301; Marini-Bettolo et al.; Gazzetta Chimica Italiana 1957 87 1303-1305; Grafe et al.; Arzneimittel - Forschunq 1974 24 (2) 153-157; and Itazaki et al.; Chemical & Pharmaceutical Bulletin 1988 36 (9) 3387-403.
[0009] The compound 3-morpholin-4-ylmethyl-2,3-dihydro-benzo[1,4]dioxine-6-carbonitrile is disclosed as a synthesis intermediate by Funke et al. in Synthesis of 7-substituted-2-aminomethyl-1,4-benazodioxanes; Gazzetta Chimica Italiana 1961 91 1268-1281.
SUMMARY OF THE INVENTION
[0010] The object of the present invention is to provide novel pharmaceutically active compounds, especially useful in treatment of disorders in the central nervous system. A further object is the provision of compounds for modulation of dopaminergic systems in the mammalian brain, including human brain. A still further object is the provision of novel compounds with a dopaminergic stabilizer profile. A further object is to provide compounds with therapeutic effects after oral administration. A still further object is the provision of compounds with more optimal pharmacodynamic properties such as e.g. kinetic behaviour, bioavailability, solubility and efficacy. A further object is to provide compounds being superior to presently known dopaminergic compounds in the treatment of several disorders related to dysfunctions of the CNS, in terms of efficacy or side effects.
[0011] The present invention concerns the unexpected discovery of the pharmacological effects of compounds of Formula 1 on the dopaminergic system in the brain. By pharmacological testing in vivo in the rat it is demonstrated that compounds of the present invention have effects on biochemical indices in the brain with the characteristic features of dopamine antagonists.
[0012] In its first aspect, the invention provides a compound of Formula 1
[0000]
[0000] any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof; wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and X are as defined below.
[0013] In its second aspect, the invention provides a pharmaceutical composition, comprising a therapeutically effective amount of a compound of the invention, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, together with at least one pharmaceutically acceptable carrier, excipient or diluent.
[0014] In a further aspect, the invention provides the use of a compound of the invention, any of its stereoisomers or any mixture of its stereoisomers or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, for the manufacture of a pharmaceutical composition for the treatment, prevention or alleviation of a disease or a disorder or a condition of a mammal, including a human, which disease, disorder or condition is responsive to responsive to modulation of dopaminergic function in the central nervous system.
[0015] In a still further aspect, the invention relates to a method for treatment, prevention or alleviation of a disease or a disorder or a condition of a living animal body, including a human, which disorder, disease or condition is responsive to modulation of dopaminergic function in the central nervous system, which method comprises the step of administering to such a living animal body in need thereof a therapeutically effective amount of a compound of the invention, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof.
[0016] Other aspects of the invention will be apparent to the person skilled in the art from the following detailed description and examples.
DETAILED DESCRIPTION OF THE INVENTION
1-(2,3-Dihydro-1,4-benzodioxin-2-yl)methanamine derivatives
[0017] In its first aspect the present invention provides compounds of Formula 1:
[0000]
[0018] any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein
[0019] X is O, S, NH or CH 2 ;
[0020] R 1 is selected from the group consisting of OSO 2 CF 3 , OSO 2 CH 3 , COR 8 , CN, OCF 3 , SCF 3 , OCHF 2 , SCHF 2 , CF 3 , F, Cl, Br, I, SF 5 , SCN, OCN, OCOCF 3 , SCOCF 3 , OCOCH 3 , SCOCH 3 and CH(OH)CF 3 ;
[0021] R 2 is selected from the group consisting of H, CN, F, Cl, Br, I and CH 3 ;
[0022] R 3 is selected from the group consisting of C 1 -C 5 alkyl, allyl, CH 2 CH 2 OCH 3 , CH 2 CH 2 CH 2 F, CH 2 CH 2 CHF 2 , CH 2 CH 2 F, 3,3,3-trifluoropropyl, 4,4,4-trifluorobutyl, CH 2 CH 2 OH, CH 2 CH 2 CH 2 OH, CH 2 CH(OH)CH 3 , CH 2 CH 2 COCH 3 , C 3 -C 6 cycloalkyl,
[0000]
[0023] R 4 is selected from the group consisting of H and C 1 -C 5 alkyl; or
[0024] R 3 and R 4 together with the nitrogen atom to which they are attached form a four- to six-membered heterocyclic ring, which heterocyclic ring may optionally comprise as a ring member, one oxygen atom, and/or one additional nitrogen atom; and which heterocyclic ring may optionally be substituted with C 1 -C 5 alkyl; and
[0025] R 5 , R 6 and R 7 are selected from the group consisting of H and CH 3 ;
[0026] R 8 is selected from the group consisting of C 1 -C 3 alkyl, CF 3 , CHF 2 , CH 2 F and CN.
[0027] In a more preferred embodiment the compound of the invention is a compound of Formula 1A:
[0000]
[0028] any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein X, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are as above.
[0029] In another more preferred embodiment the compound of the invention is a compound of Formula 1B:
[0000]
[0030] any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein X, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are as defined above.
[0031] In a third more preferred embodiment the compound of the invention is a compound of Formula 1C:
[0000]
[0032] any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein X, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are as defined above.
[0033] In a preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein X is O, S, NH or CH 2 .
[0034] In a more preferred embodiment X is O.
[0035] In another more preferred embodiment X is S.
[0036] In a third more preferred embodiment X is NH.
[0037] In a fourth more preferred embodiment X is CH 2 .
[0038] In another preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein R 1 is selected from the group consisting of OSO 2 CF 3 , OSO 2 CH 3 , COR 8 , CN, OCF 3 , SCF 3 , OCHF 2 , SCHF 2 , CF 3 , F, Cl, Br, I, SF 5 , SCN, OCN, OCOCF 3 , SCOCF 3 , OCOCH 3 , SCOCH 3 and CH(OH)CF 3 ; and R 8 is selected from the group consisting of C 1 -C 3 alkyl, CF 3 , CHF 2 , CH 2 F and CN.
[0039] In a more preferred embodiment R 1 is OSO 2 CF 3 .
[0040] In another more preferred embodiment R 1 is COR 8 ; and R 8 is selected from the group consisting of C 1 -C 3 alkyl, CF 3 , CHF 2 , CH 2 F and CN.
[0041] In a third more preferred embodiment R 1 is CN
[0042] In a fourth more preferred embodiment R 1 is OCF 3 .
[0043] In a fifth more preferred embodiment R 1 is SCF 3 .
[0044] In a sixth more preferred embodiment R 1 is OCHF 2 .
[0045] In a seventh more preferred embodiment R 1 is SCHF 2 .
[0046] In an eight more preferred embodiment R 1 is CF 3 .
[0047] In a ninth more preferred embodiment R 1 is F.
[0048] In a tenth more preferred embodiment R 1 is Cl.
[0049] In an eleventh more preferred embodiment R 1 is Cl; and with the proviso that R 4 is H.
[0050] In an twelfth more preferred embodiment R 1 is Br.
[0051] In a thirteenth more preferred embodiment R 1 is I.
[0052] In a fourteenth more preferred embodiment R 1 is SF 5 .
[0053] In a fifteenth more preferred embodiment R 1 is SCN.
[0054] In a sixteenth more preferred embodiment R 1 is OCN.
[0055] In a seventeenth more preferred embodiment R 1 is OCN, OCOCF 3 .
[0056] In a eighteenth more preferred embodiment R 1 is OCOCF 3 .
[0057] In an nineteenth more preferred embodiment R 1 is SCOCF 3 .
[0058] In a twentieth more preferred embodiment R 1 is OCOCH 3 .
[0059] In a twentyfirst more preferred embodiment R 1 is SCOCH 3 .
[0060] In a twentysecond more preferred embodiment R 1 is CH(OH)CF 3 .
[0061] In a twentythird more preferred embodiment R 1 is selected from the group consisting of CF 3 , OSO 2 CH 3 and OSO 2 CF 3 .
[0062] In a twentyfourth more preferred embodiment R 1 is selected from the group consisting F and Br.
[0063] In a third preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein R 2 is selected from the group consisting of H, CN, F, Cl, Br, I and CH 3 .
[0064] In a more preferred embodiment R 2 is H.
[0065] In another more preferred embodiment R 2 is CN.
[0066] In a third more preferred embodiment R 2 is F.
[0067] In a fourth more preferred embodiment R 2 is Cl
[0068] In a fifth more preferred embodiment R 2 is Br.
[0069] In a sixth more preferred embodiment R 2 is I.
[0070] In a seventh more preferred embodiment R 2 is CH 3 .
[0071] In an eight more preferred embodiment R 2 is selected from the group consisting of H, F and Cl.
[0072] In a ninth more preferred embodiment R 2 is H or F.
[0073] In a fourth preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein R 3 is selected from the group consisting of C 1 -C 5 alkyl, allyl, CH 2 CH 2 OCH 3 , CH 2 CH 2 CH 2 F, CH 2 CH 2 CHF 2 , CH 2 CH 2 F, 3,3,3-trifluoropropyl, 4,4,4-trifluorobutyl, CH 2 CH 2 OH, CH 2 CH 2 CH 2 OH, CH 2 CH(OH)CH 3 , CH 2 CH 2 COCH 3 , C 3 -C 6 cycloalkyl,
[0000]
[0074] In a more preferred embodiment R 3 is C 1 -C 5 alkyl.
[0075] In another more preferred embodiment R 3 is allyl.
[0076] In a third more preferred embodiment R 3 is CH 2 CH 2 OCH 3 .
[0077] In a fourth more preferred embodiment R 3 is CH 2 CH 2 CH 2 F.
[0078] In a fifth more preferred embodiment R 3 is CH 2 CH 2 CHF 2 .
[0079] In a sixth more preferred embodiment R 3 is CH 2 CH 2 F.
[0080] In a seventh more preferred embodiment R 3 is 3,3,3-trifluoropropyl.
[0081] In an eight more preferred embodiment R 3 is 4,4,4-trifluorobutyl.
[0082] In a ninth more preferred embodiment R 3 is CH 2 CH 2 OH.
[0083] In a tenth more preferred embodiment R 3 is CH 2 CH 2 CH 2 OH.
[0084] In an eleventh more preferred embodiment R 3 is CH 2 CH(OH)CH 3 .
[0085] In a twelfth more preferred embodiment R 3 is CH 2 CH 2 COCH 3 .
[0086] In a thirteenth more preferred embodiment R 3 is C 3 -C 6 cycloalkyl.
[0087] In a fourteenth more preferred embodiment R 3 is
[0000]
[0088] In a fifteenth more preferred embodiment R 3 is
[0000]
[0089] In a sixteenth more preferred embodiment R 3 is selected from the group consisting of C 1 -C 5 alkyl, allyl, CH 2 CH 2 OCH 3 and CH 2 CH 2 OH.
[0090] In a seventeenth more preferred embodiment R 3 is selected from the group consisting of C 1 -C 5 alkyl, allyl and CH 2 CH 2 OH.
[0091] In a fifth preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein R 4 is selected from the group consisting of H and C 1 -C 5 alkyl.
[0092] In a more preferred embodiment R 4 is H.
[0093] In a another more preferred embodiment R 4 is H; and with the proviso that R 1 is Cl.
[0094] In a third more preferred embodiment R 4 is C 1 -C 5 alkyl.
[0095] In a fourth more preferred embodiment R 4 is selected from the group consisting of H and C 1 -C 5 alkyl.
[0096] In a sixth preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein R 3 and R 4 together with the nitrogen atom to which they are attached form a four- to six-membered heterocyclic ring, which heterocyclic ring may optionally comprise as a ring member, one oxygen atom, and/or one additional nitrogen atom; and which heterocyclic ring may optionally be substituted with C 1 -C 5 alkyl.
[0097] In a more preferred embodiment R 3 and R 4 together with the nitrogen atom to which they are attached form a four- to six-membered heterocyclic ring.
[0098] In another more preferred embodiment R 3 and R 4 together the nitrogen atom to which they are attached form acetidine, pyrrolidine, piperidine, C 1 -C 5 alkyl-piperidine or morpholine.
[0099] In a third more preferred embodiment R 3 and R 4 together the nitrogen atom to which they are attached form an acetidine, a pyrrolidine, a piperidine or a morpholine group.
[0100] In a fourth more preferred embodiment R 3 and R 4 together the nitrogen atom to which they are attached form an acetidine group.
[0101] In a fifth more preferred embodiment R 3 and R 4 together the nitrogen atom to which they are attached form a pyrrolidine group.
[0102] In a sixth more preferred embodiment R 3 and R 4 together the nitrogen atom to which they are attached form a piperidine group.
[0103] In a seventh more preferred embodiment R 3 and R 4 together the nitrogen atom to which they are attached form a C 1 -C 5 alkyl-piperidine group.
[0104] In an eight more preferred embodiment R 3 and R 4 together the nitrogen atom to which they are attached form a morpholine group.
[0105] In a seventh preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein R 5 , R 6 and R 7 are selected from the group consisting of H and CH 3 .
[0106] In a more preferred embodiment each of R 5 , R 6 and R 7 is H.
[0107] In an eight preferred embodiment the compound of the invention is a compound of Formula 1, 1A, 1B or 1C, any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof, wherein
[0108] X is O;
[0109] R 1 is OSO 2 CF 3 , OSO 2 CH 3 , CF 3 , F, Cl, Br; and with the proviso that R 4 is H if R 1 is Cl;
[0110] R 2 is H, F;
[0111] R 3 is C 1 -C 5 alkyl, allyl or CH 2 CH 2 OH; and
[0112] R 4 is H and C 1 -C 5 alkyl; and with the proviso that R 1 is Cl if R 4 is H; or
[0113] R 3 and R 4 together the nitrogen atom to which they are attached form an acetidine, a pyrrolidine, a piperidine or a morpholine group; and
[0114] R 5 , R 6 and R 7 are selected from the group consisting of H and CH 3 .
[0115] In a yet more preferred embodiment the compound of the invention is
N-{[(2S)-7-BROMO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}PROPAN-1-AMINE; N-[(6,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE; N-[(7-CHLORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE; 3-[(PROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(PROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; N-[(7,8-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE; 1-{[(2S)-7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}PYRROLIDINE; 1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N-METHYLMETHANAMINE; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]BUTAN-1-AMINE; 2-{[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AMINO}ETHANOL; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-PROPYLPROPAN-1-AMINE; N-ETHYL-N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE; 1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PIPERIDINE; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]ETHANAMINE; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROP-2-EN-1-AMINE; 1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N,N-DIMETHYLMETHANAMINE; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLPROPAN-1-AMINE; 1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AZETIDINE; 4-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]MORPHOLINE; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-2-METHOXYETHANAMINE; N-ETHYL-N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]ETHANAMINE; N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLETHANAMINE; 3-[(METHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(ETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(BUTYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-{[(2-HYDROXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(DIPROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-{[ETHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-(PIPERIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(DIMETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-{[METHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-(MORPHOLIN-4-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(DIETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-(PYRROLIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(ALLYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-{[ETHYL(METHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-{[(2-METHOXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-(AZETIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE; 3-[(METHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-[(ETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-[(BUTYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-{[(2-HYDROXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-[(DIPROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-{[ETHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-(PIPERIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-[(DIMETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-(MORPHOLIN-4-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-[(DIETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-(PYRROLIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-[(ALLYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-{[ETHYL(METHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-{[(2-METHOXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-(AZETIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 3-{[METHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE; 1-[(6,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PYRROLIDINE; N-{[(2S)-7-(TRIFLUOROMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}PROPAN-1-AMINE; 1-(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N-METHYLMETHANAMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]ETHANAMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROP-2-EN-1-AMINE; 4-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]MORPHOLINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]BUTAN-1-AMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-PROPYLPROPAN-1-AMINE; 1-(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N,N-DIMETHYLMETHANAMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-ETHYLETHANAMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-2-AMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLPROPAN-1-AMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-ETHYLPROPAN-1-AMINE; 2-{[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AMINO}ETHANOL; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLETHANAMINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-2-METHOXYETHANAMINE; 1-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AZETIDINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-2-METHYLPROPAN-1-AMINE; 1-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PYRROLIDINE; 1-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PIPERIDINE; N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-3-FLUOROPROPAN-1-AMINE; 2-({[(2S)-7-(TRIFLUOROMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}AMINO)ETHANOL; or N-{[7-(FLUOROMETHYLSULFONYL)-3,4-DIHYDRO-2H-CHROMEN-2-YL]METHYL}-N-PROPAN-1-AMINE;
[0195] any of its stereoisomers or any mixture of its stereoisomers, or an N-oxide thereof, or a pharmaceutically acceptable salt thereof.
[0196] Any combination of two or more of the embodiments as described above is considered within the scope of the present invention.
DEFINITION OF SUBSTITUENTS
[0197] In the context of this invention C 1 -C 5 alkyl means a straight chain or branched chain of one to five carbon atoms, including but not limited to, methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, s-butyl, t-butyl, n-pentyl, i-pentyl, neo-pentyl.
[0198] C 3 -C 6 cycloalkyl designates a cyclic alkyl group containing of from three to six carbon atoms, including cyclopropyl, cyclobutyl and cyclopentyl.
[0199] The term “allyl” refers to the group —CH 2 —CH═CH 2 .
[0200] Four- to six-membered heterocyclic rings comprising at least one nitrogen atom include for example, but not limited to, acetidine, pyrrolidine, piperidine and morpholine.
Pharmaceutically Acceptable Salts
[0201] The chemical compound of the invention may be provided in any form suitable for the intended administration. Suitable forms include pharmaceutically (i.e. physiologically) acceptable salts, and pre- or prodrug forms of the chemical compound of the invention.
[0202] Examples of pharmaceutically acceptable addition salts include, without limitation, the non-toxic inorganic and organic acid addition salts such as the hydro-chloride, the hydrobromide, the nitrate, the perchlorate, the phosphate, the sulphate, the formate, the acetate, the aconate, the ascorbate, the benzenesulphonate, the benzoate, the cinnamate, the citrate, the embonate, the enantate, the fumarate, the glutamate, the glycolate, the lactate, the maleate, the malonate, the mandelate, the methanesulphonate, the naphthalene-2-sulphonate, the phthalate, the salicylate, the sorbate, the stearate, the succinate, the tartrate, the toluene-p-sulphonate, and the like. Such salts may be formed by procedures well known and described in the art.
[0203] Other acids such as oxalic acid, which may not be considered pharmaceutically acceptable, may be useful in the preparation of salts useful as intermediates in obtaining a chemical compound of the invention and its pharmaceutically acceptable acid addition salt.
[0204] Examples of pharmaceutically acceptable cationic salts of a chemical compound of the invention include, without limitation, the sodium, the potassium, the calcium, the magnesium, the zinc, the aluminium, the lithium, the choline, the lysinium, and the ammonium salt, and the like, of a chemical compound of the invention containing an anionic group. Such cationic salts may be formed by procedures well known and described in the art.
[0205] In the context of this invention the “onium salts” of N-containing compounds are also contemplated as pharmaceutically acceptable salts. Preferred “onium salts” include the alkyl-onium salts, the cycloalkyl-onium salts, and the cycloalkylalkyl-onium salts.
[0206] Examples of pre- or prodrug forms of the chemical compound of the invention include examples of suitable prodrugs of the substances according to the invention include compounds modified at one or more reactive or derivatizable groups of the parent compound. Of particular interest are compounds modified at a carboxyl group, a hydroxyl group, or an amino group. Examples of suitable derivatives are esters or amides.
[0207] The chemical compound of the invention may be provided in dissoluble or indissoluble forms together with a pharmaceutically acceptable solvent such as water, ethanol, and the like. Dissoluble forms may also include hydrated forms such as the monohydrate, the dihydrate, the hemihydrate, the trihydrate, the tetrahydrate, and the like. In general, the dissoluble forms are considered equivalent to indissoluble forms for the purposes of this invention.
Steric Isomers
[0208] It will be appreciated by those skilled in the art that the compounds of the present invention may exist in different stereoisomeric forms—including enantiomers, diastereomers or cis-trans-isomers.
[0209] The invention includes all such isomers and any mixtures thereof including racemic mixtures.
[0210] Racemic forms can be resolved into the optical antipodes by known methods and techniques. One way of separating the enantiomeric compounds (including enantiomeric intermediates) is—in the case the compound being a chiral acid—by use of an optically active amine, and liberating the diastereomeric, resolved salt by treatment with an acid. Another method for resolving racemates into the optical antipodes is based upon chromatography on an optical active matrix. Racemic compounds of the present invention can thus be resolved into their optical antipodes, e.g., by fractional crystallisation of D- or L- (tartrates, mandelates, or camphor-sulphonate) salts for example.
[0211] The chemical compounds of the present invention may also be resolved by the formation of diastereomeric amides by reaction of the chemical compounds of the present invention with an optically active carboxylic acid such as that derived from (+) or (−) phenylalanine, (+) or (−) phenylglycine, (+) or (−) camphanic acid or by the formation of diastereomeric carbamates by reaction of the chemical compound of the present invention with an optically active chloroformate or the like.
[0212] Additional methods for the resolving the optical isomers are known in the art. Such methods include those described by Jaques J, Collet A, & Wilen S in “ Enantiomers, Racemates, and Resolutions ”, John Wiley and Sons, New York (1981).
[0213] Optical active compounds can also be prepared from optical active starting materials.
N-Oxides
[0214] In the context of this invention an N-oxide designates an oxide derivative of a tertiary amine, including a nitrogen atom of an aromatic N-heterocyclic compound, a non-aromatic N-heterocyclic compounds, a trialkylamine and a trialkenylamine. For example, the N-oxide of a compound containing a pyridyl may be the 1-oxy-pyridin-2, -3 or -4-yl derivative.
[0215] N-oxides of the compounds of the invention may be prepared by oxidation of the corresponding nitrogen base using a conventional oxidizing agent such as hydrogen peroxide in the presence of an acid such as acetic acid at an elevated temperature, or by reaction with a peracid such as peracetic acid in a suitable solvent, e.g. dichloromethane, ethyl acetate or methyl acetate, or in chloroform or dichloromethane with 3-chloroperoxybenzoic acid.
Labelled Compounds
[0216] The compounds of the invention may be used in their labelled or unlabelled form. In the context of this invention the labelled compound has one or more atoms replaced by an atom having an atomic mass or mass number different from the atomic mass or mass number usually found in nature. The labelling will allow easy quantitative detection of said compound.
[0217] The labelled compounds of the invention may be useful as diagnostic tools, radio tracers, or monitoring agents in various diagnostic methods, and for in vivo receptor imaging.
[0218] The labelled isomer of the invention preferably contains at least one radio-nuclide as a label. Positron emitting radionuclides are all candidates for usage. In the context of this invention the radionuclide is preferably selected from 2 H (deuterium), 3 H (tritium), 11 C, 13 C, 14 C, 131 I, 125 I, 123 I and 18 F.
[0219] The physical method for detecting the labelled isomer of the present invention may be selected from Position Emission Tomography (PET), Single Photon Imaging Computed Tomography (SPECT), Magnetic Resonance Spectroscopy (MRS), Magnetic Resonance Imaging (MRI), and Computed Axial X-ray Tomography (CAT), or combinations thereof.
Methods of Preparation
[0220] The chemical compounds of the invention may be prepared by conventional methods for chemical synthesis, e.g. those described in the working examples. The starting materials for the processes described in the present application are known or may readily be prepared by conventional methods from commercially available chemicals.
[0221] Also one compound of the invention can be converted to another compound of the invention using conventional methods.
[0222] The end products of the reactions described herein may be isolated by conventional techniques, e.g. by extraction, crystallisation, distillation, chromatography, etc.
[0223] Persons skilled in the art will appreciate that, in order to obtain compounds of the invention in an alternative—and in some occasions, more convenient manner—the individual process steps mentioned hereinbefore may be performed in a different order, and/or the individual reactions may be performed at different stage in the overall route (i.e. chemical transformations may be performed upon different intermediates to those associated hereinbefore with a particular reaction).
Biological Activity
[0224] The typical pharmacological effects which are characteristic for dopaminergic stabilizers are an increased turnover of dopamine in the terminal areas of the ascending dopaminergic projections of the mammalian brain. This can be illustrated by measuring of changes in biochemical indices in the brain with the characteristic features of dopamine antagonists, e.g. producing increases in concentrations of dopamine metabolites such as 3,4-dihydroxyphenyl-acetic acid (DOPAC) in the striatum. The typical increase in DOPAC levels (striatum) possible to achieve is in the range of 350-400% of control.
[0225] Representative compounds of the invention are shown in Table 1.
[0000]
TABLE 1
Estimated ED 50 values on increase of DOPAC (3,4-
dihydroxyphenylacetic acid) in the rat striatum after systemic
adminstration of test compound. For methods and statistical
calculations see the enclosed tests.
ED 50 DOPAC*
Examples
μmol/kg
Example 1
3.4
(2.6-4.1)
Example 6
12
(10-16)
Example 7
3.1
(2.1-4.0)
Example 8
14
(9.2-21)
Example 58
<3.7
[0226] The compounds according to the present invention possess dopamine-modulating properties and both they and their pharmaceutical compositions are useful in treating numerous central nervous system disorders, including both psychiatric and neurological disorders. Particularly, the compounds and their pharmaceutical compositions may be used in the treatment of CNS disorders where the dopaminergic system is dysfunctional due to direct or indirect causes.
[0227] The compounds and compositions according to the invention can be used to improve all forms of psychosis, including schizophrenia and schizophreniform and bipolar disorders as well as drug induced psychotic disorders. Iatrogenic psychoses and hallucinoses and non-iatrogenic psychoses and hallucinoses may also be treated.
[0228] In a preferred embodiment the disease, disorder or condition contemplated according to the invention is a form of psychosis, in particular schizophrenia, a schizophreniform disorder, a bipolar disorder, or a drug induced psychotic disorder.
[0229] Mood and anxiety disorders, depression and obsessive-compulsive disease may also be treated with the compounds and compositions according to the invention.
[0230] Compounds with modulating effects on dopaminergic systems may also be used to improve motor and cognitive functions and in the treatment of emotional disturbances related to ageing, neurodegenerative (e.g. dementia and age-related cognitive impairment) and developmental disorders (such as Autism spectrum disorders, ADHD, Cerebral Palsy, Gilles de la Tourette's syndrome) as well as after brain injury. Such brain injury may be induced by traumatic, inflammatory, infectious, neoplastic, vascular, hypoxic or metabolic causes or by toxic reactions to exogenous chemicals, wherein the exogenous chemicals are selected from the group consisting of substances of abuse, pharmaceutical compounds and environmental toxins
[0231] The compounds and pharmaceutical compositions according to the invention may also be used in behavioural disorders usually first diagnosed in infancy, childhood, or adolescence as well as in impulse control disorders.
[0232] They can also be used for treating substance abuse disorders as well as disorders characterized by misuse of food. They are further useful for treatment of a condition selected from the group consisting of sleep disorders, sexual disorders, eating disorders, obesitas, and headaches and other pains in conditions characterized by increased muscular tone.
[0233] Neurological indications include the use of the compounds and their pharmaceutical compositions to improve mental and motor function in Parkinson's disease, and in related parkinsonian syndromes, dyskinesias (including L-DOPA induced dyskinesias) and dystonias. They may also be used to ameliorate tics and tremor of different origins. Moreover, they may be used to relieve pain in conditions characterized by increased muscle tone.
[0234] They can also be used in the treatment of Huntington's disease and other movement disorders as well as movement disorders induced by drugs. Restless legs and related disorders as well as narcolepsy may also be treated with compounds included according to the invention.
[0235] The compounds and their pharmaceutical compositions according to the present invention can be used for the treatment of Alzheimer's disease or related dementia disorders.
[0236] The effects of compounds of the invention on spontaneous locomotion is shown in Table 2.
[0000]
TABLE 2
Effects of compounds from the present invention on Locomotor activity
in drug-naive rats. The animals were placed in the motility meters
immediately after drug administration and locomotor activity was
recorded for 60 minutes (counts/60 min ± SEM).
Example
Control group
3.7 μmol/kg
11 μmol/kg
33 μmol/kg
Example 1
8702 ± 1053
6714 ± 601
5111 ± 620
1326 ± 131
Example 6
10941 ± 2360
9495 ± 2036
10705 ± 1903
8064 ± 707
Example 7
6996 ± 1381
7932 ± 2067
6884 ± 400
4408 ± 212
Example 8
8318 ± 2419
9266 ± 2706
8320 ± 2405
5457 ± 536
Example 9
11544 ± 3670
5419 ± 1414
2769 ± 647
1944 ± 482
[0237] The effects of compounds of the invention on the increase in activity induced by direct or indirect dopaminergic agonists, i.e. d-amphetamine and congeners are shown in Table 3.
[0000]
TABLE 3
Effect of compound of the present invention on reduction of
amphetamine-induced hyper-locomotion. For methods and
statistical calculations see the enclosed tests.
ED 50
Example
μmol/kg
Example 7
13
(10-15)
Pharmaceutical Compositions
[0238] In another aspect the invention provides novel pharmaceutical compositions comprising a therapeutically effective amount of the chemical compound of the invention.
[0239] The present invention relates to pharmaceutical compositions comprising the compounds of the present invention, and their use in treating CNS disorders. Both organic and inorganic acids can be employed to form non-toxic pharmaceutically acceptable acid addition salts of the compounds according to the invention. Suitable acid addition salts of the compounds of the present invention include those formed with pharmaceutically acceptable salts such as those mentioned above. The pharmaceutical composition comprising a compound according to the invention may also comprise substances used to facilitate the production of the pharmaceutical preparation or the administration of the preparations. Such substances are well known to people skilled in the art and may for instance be pharmaceutically acceptable adjuvants, carriers and preservatives.
[0240] In clinical practice, the compounds according to the present invention will normally be administered orally, rectally, nasally or by injection, in the form of pharmaceutical preparations comprising the active ingredient either as a free base or as a pharmaceutically acceptable non-toxic, acid addition salt, such as the hydrochloride, lactate, acetate or sulfamate salt, in association with a pharmaceutically acceptable carrier. The carrier may be a solid, semisolid or liquid preparation. Usually the active substance will constitute between 0.1 and 99% by weight of the preparation, more specifically between 0.5 and 20% by a weight for preparations intended for injection and between 0.2 and 50% by weight for preparations suitable for oral administration.
[0241] To produce pharmaceutical preparations containing the compound according to the invention in the form of dosage units for oral application, the selected compound may be mixed with a solid excipient, e.g. lactose, saccharose, sorbitol, mannitol, starches such as potato starch, corn starch or amylopectin, cellulose derivatives, a binder such as gelatine or polyvinyl-pyrrolidine, and a lubricant such as magnesium stearate, calcium stearate, polyethylene glycol, waxes, paraffin, and the like, and then compressed into tablets. If coated tablets are required, the cores (prepared as described above) may be coated with a concentrated sugar solution which may contain e.g. gum arabic, gelatine, talcum, titanium dioxide, and the like. Alternatively, the tablet can be coated with a polymer known to the man skilled in the art, dissolved in a readily volatile organic solvent or mixture of organic solvents. Dyestuffs may be added to these coatings in order to readily distinguish between tablets containing different active substances or different amounts of the active compound.
[0242] For the preparation of soft gelatine capsules, the active substance may be admixed with e.g. a vegetable oil or polyethylene glycol. Hard gelatine capsules may contain granules of the active substance using either the mentioned excipients for tablets e.g. lactose, saccharose, sorbitol, mannitol, starches (e.g. potato starch, corn starch or amylopectin), cellulose derivatives or gelatine. Also liquids or semisolids of the drug can be filled into hard gelatine capsules.
[0243] Examples of tablet and capsule formulations suitable for oral administration are given below:
[0000]
Tablet I
mg/tablet
Compound
100
Lactose Ph. Eur
182.75
Croscarmellose sodium
12.0
Maize starch paste (5% w/v paste)
2.25
Magnesium stearate
3.0
[0000]
Tablet II
mg/tablet
Compound
50
Lactose Ph. Eur
223.75
Croscarmellose sodium
6.0
Maize starch
15.0
Polyvinylpyrrolidone (5% w/v paste)
2.25
Magnesium stearate
3.0
[0000]
Tablet III
mg/tablet
Compound
1.0
Lactose Ph. Eur
93.25
Croscarmellose sodium
4.0
Maize starch paste (5% w/v paste)
0.75
Magnesium stearate
1.0
[0000]
Capsule
mg/capsule
Compound
10
Lactose Ph. Eur
488.5
Magnesium
1.5
[0244] Dosage units for rectal application can be solutions or suspensions or can be prepared in the form of suppositories comprising the active substance in a mixture with a neutral fatty base, or gelatine rectal capsules comprising the active substance in admixture with vegetable oil or paraffin oil. Liquid preparations for oral application may be in the form of syrups or suspensions, for example solutions containing from about 0.2% to about 20% by weight of the active substance herein described, the balance being sugar and mixture of ethanol, water, glycerol and propylene glycol. Optionally such liquid preparations may contain coloring agents, flavoring agents, saccharine and carboxymethylcellulose as a thickening agent or other excipients known to the man in the art.
[0245] Solutions for parenteral applications by injection can be prepared in an aqueous solution of a water-soluble pharmaceutically acceptable salt of the active substance, preferably in a concentration of from 0.5% to about 10% by weight. These solutions may also containing stabilizing agents and/or buffering agents and may conveniently be provided in various dosage unit ampoules. The use and administration to a patient to be treated would be readily apparent to an ordinary skill in the art.
[0246] For intranasal administration or administration by inhalation, the compounds of the present invention may be delivered in the form of a solution, dry powder or suspension. Administration may take place via a pump spray container that is squeezed or pumped by the patient or through an aerosol spray presentation from a pressurized container or a nebulizer, with the use of a suitable propellant, e.g., dichlorodifluoromethane, trichlorofluoromethane, dichlorotetrafluoroethane, carbon dioxide or other suitable gas. The compounds of the invention may also be administered via a dry powder inhaler, either as a finely divided powder in combination with a carrier substance (e.g. a saccharide) or as microspheres. The inhaler, pump spray or aerosol spray may be single or multi dose. The dosage may be controlled through a valve that delivers a measured amount of active compound.
[0247] The compounds of the invention may also be administered in a controlled release formulation. The compounds are released at the required rate to maintain constant pharmacological activity for a desirable period of time. Such dosage forms provide a supply of a drug to the body during a predetermined period of time and thus maintain drug levels in the therapeutic range for longer periods of time than conventional non-controlled formulations. The compounds may also be formulated in controlled release formulations in which release of the active compound is targeted. For example, release of the compound may be limited to a specific region of the digestive system through the pH sensitivity of the formulation. Such formulations are well known to persons skilled in the art.
[0248] Further details on techniques for formulation and administration may be found in the latest edition of Remington's Pharmaceutical Sciences (Maack Publishing Co., Easton, Pa.).
[0249] Depending upon the disorder and patient to be treated and the route of administration, the compositions may be administered at varying doses. The dosing will also depend upon the relation of potency to absorbability and the frequency and route of administration. Such doses may be administered once, twice or three or more times daily. The compounds of this invention can be administered to subjects in doses ranging from 0.01 mg to 500 mg per kg of body weight per day, although variations will necessarily occur depending upon the weight, sex and condition of the subject being treated, the disease state being treated and the particular route of administration chosen. However, a dosage level that is in the range of from 0.1 mg to 10 mg per kg of body weight per day, single or divided dosage is most desirably employed in humans for the treatment of diseases. Alternatively, the dosage level is such that a serum concentration of between 0.1 nM to 10 μM of the compound is obtained.
EXAMPLES
[0250] The invention is further illustrated in the examples below and as outlined below in Schemes 1-3, which in no way are intended to limit the scope of the invention.
[0000]
[0000]
[0000]
[0251] The substituents in Scheme 1-3, are as follows: z is a leaving group, G 1 is R 1 or a group that can be transformed into R 1 , A is alkyl, hydrogen or a protecting group. R 1 , R 2 , R 3 and R 4 are as defined above.
Example 1
N-{[(2S)-7-BROMO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}PROPAN-1-AMINE
[0252] A mixture of [(2R)-7-bromo-2,3-dihydro-1,4-benzodioxin-2-yl]methyl 4-methylbenzenesulfonate (3.1 g, 7.8 mmol) K 2 CO 3 (1.3 g, 9.3 mmol) and propan-1-amine (0.70 ml, 8.5 mmol) in ACN (15 ml) was split into 3 batches and heated under microwave radiation to 180° C. for 10 min. After cooling to ambient temperature, the reaction mixtures were brought together and then filtered through a pad of celite and evaporated to dryness. Purification by flash column chromatography (EtOAc) gave the title compound (1.79 g, 81%). The amine was converted to the hydrochloric acid salt and crystallized from EtOH/Et 2 O: M.p. 194° C. MS m/z (rel. intensity, 70 eV) 286 (M+, 4), 285 (M+, 5), 78 (13), 72 (bp), 51 (10). [α]=−75° (methanol).
Example 2
N-[(6,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE
[0253] A mixture of (6,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.44 g, 2.5 mmol), propan-1-amine (1.5 ml) and ACN (4 ml) was heated under microwave radiation to 140° C. for 20 min. Yield: 0.2 g, (32%). The amine was converted to the hydrobromic acid salt and crystallized from EtOH/diisopropyl ether: M.p. 262° C. MS m/z (rel. intensity, 70 eV) 243 (M+, 10), 117 (5), 116 (5), 88 (14), 72 (bp).
Example 3
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE
[0254] A mixture of (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.87 g, 2.6 mmol) and propan-1-amine (2 ml) in ACN (3 ml) was heated under microwave radiation at 130° C. for 12 min. The solution was evaporated to dryness and purified on a SCX-3 cation exchange column. Further purification on flash column chromatography (EtOAc/MeOH) gave the title product (0.32 g, 55%). The amine was converted to the hydrochloric acid salt and crystallized from EtOH/diethyl ether: M.p. 187° C. MS m/z (rel. intensity, 70 eV) 225 (M+, 23), 139 (4), 98 (8), 72 (bp), 70 (9).
Example 4
N-[(7-CHLORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE
[0255] A mixture of (7-chloro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (1.3 g, 3.7 mmol) and propan-1-amine (1 ml) in ACN (3 ml) was heated under microwave radiation to 120° C. for 20 min and then to 130° C. for 10 min. The reaction mixture was purified on a SCX-3 cation exchange column (MeOH/TEA 4:1) and filtered through a pad of silica (EtOAc/MeOH) to give the title compound (0.46 g, 52%). The amine was converted to the hydrochloric acid salt and crystallized from EtOH/Et 2 O: M.p. 191° C. MS m/z (rel. intensity, 70 eV) 241 (M+, 26), 243 (M+, 8), 106 (5), 73 (5), 72 (bp).
Example 5
3-[(PROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0256] A mixture of {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (1 g, 2.4 mmol) and propan-1-amine (1 ml) in ACN (6 ml) was heated under microwave radiation to 120° C. for 20 min. The mixture was evaporated to dryness, Na 2 CO 3 and EtOAc were added and the phases were separated. The combined organic phases were dried (Na 2 SO 4 ) and evaporated to dryness. Purification on flash column chromatography gave the title compound. Yield: 0.4 g (54%). The amine was converted to the fumaric acid salt and crystallized from EtOH/Et 2 O. M.p. 178° C. MS m/z (rel. intensity, 70 eV) 301 (M+, 28), 272 (5), 222 (4), 151 (5), 72 (bp).
Example 6
3-[(PROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0257] A mixture of (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.5 g, 1.1 mmol) and propan-1-amine (0.4 ml, 5.4 mmol) in ACN (3 ml) was heated under microwave radiation at 120° C. for 20 min and then evaporated to dryness. Na 2 CO 3 (10%) and EtOAc was added. The phases were separated and the organic phase dried (Na 2 SO 4 ) and evaporated to dryness. The product was purified on silica and mixed with another batch of the same compound. The amine was converted to the fumaric acid salt and crystallized from EtOH/Et 2 O. M.p. 163° C. MS m/z (rel. intensity, 70 eV) 355 (M+, 14), 326 (7), 222 (4), 72 (bp), 70 (6).
Example 7
N-[(7,8-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE
[0258] A mixture of (7,8-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.16 g, 0.4 mmol), propan-1-amine (3 ml) and ACN (3 ml) was heated under microwave radiation to 120° C. for 15 min. The solution was evaporated to dryness and the residue dissolved in EtOAc/Et 2 O. The solution was extracted with HCl (10%) and the combined water phases were basified and extracted with EtOAc. The combined organic phases were washed with brine, dried (MgSO 4 ) and evaporated to dryness. Purification together with another batch of the same compound (0.22 g) on flash column chromatography (EtOAc) gave the title compound (0.2 g, 59%). The amine was converted to the hydrochloric acid salt and crystallized from EtOH/EtO: M.p. 184° C. MS m/z (rel. intensity, 70 eV) 243 (M+, 11), 88 (6), 73 (5), 72 (bp), 70 (6).
Example 8
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE
[0259] A mixture of (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (1 g, 2.8 mmol), propan-1-amine (3 ml) and ACN (2 ml) was heated under microwave radiation at 120° C. for 20 min and then evaporated to dryness. Et 2 O and HCl (1%) was added and the phases were separated. The water phase was basified and extracted with EtOAc. The combined organic phases were dried and evaporated to dryness. Purification on flash column chromatography (isooctane/EtOAc) gave the title compound (0.4 g, 63%). The amine was converted to the hydrochloric acid salt and crystallized from EtOH/Et 2 O. M.p. 157° C. MS m/z (rel. intensity, 70 eV) 243 (M+, 8), 88 (6), 73 (5), 72 (bp), 70 (6).
Example 9
1-{[(2S)-7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}PYRROLIDINE
[0260] A mixture of [(2R)-7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl]methyl 4-methylbenzenesulfonate (0.22 g, 0.65 mmol), K 2 CO 3 (0.1 g, 0.71 mmol) and pyrrolidine (0.06 ml, 0.71 mmol) in acetonitrile (3 ml) was heated under microwave radiation to 180° C. for 5 min and filtered through a pad of celite. The resulting product was put together with another batch of the same product and purified on flash column chromatography (Isooctane/EtOAc/MeOH) to give the title compound (0.11 g, 34%). The amine was converted to the hydrochloric acid salt and crystallized from MeOH/Et 2 O: M.p. 215° C. MS m/z (rel. intensity, 70 eV) 237 (M+, 10), 110 (4), 85 (6), 84 (bp), 70 (5).
Example 10
1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N-METHYLMETHANAMINE
[0261] A solution of (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.032 g, 0.095 mmol) and methanamine (40% in H 2 O, 0.5 ml) in ACN (2 ml) was heated under microwave radiation at 120° C. for 20 min. MS m/z (rel. intensity, 70 eV) 197 (M+, bp), 166 (11), 139 (17), 109 (12), 70 (27).
Example 11
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]BUTAN-1-AMINE
[0262] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.023 g, 0.068 mmol), butan-1-amine (0.5 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 239 (M+, 47), 139 (5), 98 (9), 86 (bp), 70 (10).
Example 12
2-{[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AMINO}ETHANOL
[0263] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.026 g, 0.077 mmol), 2-aminoethanol (0.5 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 227 (M+, 14), 196 (7), 139 (5), 74 (bp), 56 (19).
Example 13
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-PROPYLPROPAN-1-AMINE
[0264] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.016 g, 0.047 mmol), N-propylpropan-1-amine (0.5 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 267 (M+, 1), 238 (5), 115 (8), 114 (bp), 86 (10).
Example 14
N-ETHYL-N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-1-AMINE
[0265] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.025 g, 0.074 mmol), N-ethylpropan-1-amine (0.5 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 253 (M+, 2), 101 (7), 100 (bp), 72 (9), 58 (8).
Example 15
1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PIPERIDINE
[0266] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.039 g, 0.12 mmol), piperidine (0.5 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 251 (M+, 5), 124 (3), 99 (8), 98 (bp), 70 (4).
Example 16
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]ETHANAMINE
[0267] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.062 g, 0.18 mmol), ethanamine (70% in H 2 O, 0.5 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 211 (34), 139 (4), 98 (5), 70 (7), 58 (bp).
Example 17
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROP-2-EN-1-AMINE
[0268] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.043 g, 0.13 mmol), prop-2-en-1-amine (0.5 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 223 (M+, 14), 139 (4), 99 (4), 71 (5), 70 (bp).
Example 18
1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N,N-DIMETHYLMETHANAMINE
[0269] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.034 g, 0.10 mmol), N-methylmethanamine (40% in H 2 O, 1 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 211 (M+, 11), 99 (3), 84 (3), 70 (5), 58 (bp).
Example 19
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLPROPAN-1-AMINE
[0270] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.037 g, 0.11 mmol), N-methylpropan-1-amine (1 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 239 (M+, 5), 210 (3), 87 (6), 86 (bp), 58 (11).
Example 20
1-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AZETIDINE
[0271] A mixture of (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.037 g, 0.11 mmol) and azetidine (0.2 ml) in ACN (1 ml) was heated under microwave radiation at 120° C. for 30 min. MS m/z (rel. intensity, 70 eV) 223 (M+, 14), 166 (2), 99 (3), 71 (5), 70 (bp).
Example 21
4-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]MORPHOLINE
[0272] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.089 g, 0.26 mmol), morpholine (1 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 253 (M+, 10), 101 (6), 100 (bp), 70 (5), 56 (5).
Example 22
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-2-METHOXYETHANAMINE
[0273] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.037 g, 0.11 mmol), 2-methoxyethanamine (1 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 241 (M+, 39), 196 (23), 88 (bp), 70 (10), 56 (12).
Example 23
N-ETHYL-N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]ETHANAMINE
[0274] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.021 g, 0.062 mmol), N-ethylethanamine (1 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 239 (M+, 2), 87 (6), 86 (bp), 72 (3), 58 (5).
Example 24
N-[(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLETHANAMINE
[0275] Preparation according to Example 10: (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.027 g, 0.080 mmol), N-methylethanamine (1 ml), ACN (2 ml). MS m/z (rel. intensity, 70 eV) 225 (M+, 5), 98 (3), 73 (5), 72 (bp), 70 (4).
Example 25
3-[(METHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0276] A solution of {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), methanamine (HCl-salt, 0.2 g, 2.4 mmol) and K 2 CO 3 (0.2 g) in ACN (3 ml) was heated under microwave radiation at 120° C. for 20 min. Methanamine (33% in EtOH, 1 ml) was added and the solution was further heated under microwave radiation at 120° C. for 20 min. MS m/z (rel. intensity, 70 eV) 273 (M+, bp), 230 (80), 151 (66), 79 (12), 70 (19).
Example 26
3-[(ETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0277] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), ethanamine (HCl-salt, 0.2 g, 2.4 mmol), K 2 CO 3 (0.2 g), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 287 (M+, 15), 230 (4), 151 (6), 84 (5), 58 (bp).
Example 27
3-[(BUTYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0278] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), butan-1-amine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 315 (M+, 13), 151 (4), 112 (5), 86 (bp), 70 (7).
Example 28
3-{[(2-HYDROXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0279] A solution of {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol) and 2-aminoethanol (0.1 ml) in ACN (3 ml) was heated under microwave radiation at 120° C. for 20 min. 2-aminoethanol (1 ml) was added and the mixture was heated for another 20 min at 120° C. under microwave radiation. MS m/z (rel. intensity, 70 eV) 303 (11), 272 (24), 151 (5), 74 (bp), 56 (14).
Example 29
3-[(DIPROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0280] Preparation according to Example 28: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), N-propylpropan-1-amine (0.3 ml+1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 314 (M+, 6), 115 (8), 114 (bp), 112 (5), 86 (6).
Example 30
3-{[ETHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0281] Preparation according to Example 28: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), N-ethylpropan-1-amine (0.3 ml+1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 329 (M+, 1), 101 (7), 100 (bp), 72 (5), 58 (6).
Example 31
3-(PIPERIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0282] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), piperidine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 327 (M+, 3), 124 (5), 99 (7), 98 (bp), 55 (4).
Example 32
3-[(DIMETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0283] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), N-methylmethanamine (40% in H 2 O, 1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 287 (M+, 8), 84 (4), 79 (3), 59 (4), 58 (bp).
Example 33
3-{[METHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0284] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), N-methylpropan-1-amine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 315 (M+, 3), 112 (6), 87 (6), 86 (bp), 84 (6), 58 (5).
Example 34
3-(MORPHOLIN-4-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0285] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), morpholine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 329 (M+, 6), 126 (2), 101 (6), 100 (bp), 56 (4).
Example 35
3-[(DIETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0286] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), N-ethylethanamine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 315 (M+, 3), 112 (3), 87 (6), 86 (bp), 58 (4).
Example 36
3-(PYRROLIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0287] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), pyrrolidine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 313 (M+, 4), 110 (5), 85 (6), 84 (bp), 55 (4).
Example 37
3-[(ALLYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0288] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), prop-2-en-1-amine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 299 (M+, 14), 220 (7), 151 (6), 96 (5), 70 (bp).
Example 38
3-{[ETHYL(METHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0289] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), N-methylethanamine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 301 (M+, 4), 98 (3), 84 (3), 73 (5), 72 (bp).
Example 39
3-{[(2-METHOXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0290] Preparation according to Example 10: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.1 g, 0.24 mmol), 2-methoxyethanamine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 317 (M+, 12), 272 (29), 88 (bp), 70 (9), 56 (9).
Example 40
3-(AZETIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL METHANESULFONATE
[0291] Preparation according to Example 20: {7-[(methylsulfonyl)oxy]-2,3-dihydro-1,4-benzodioxin-2-yl}methyl 4-methylbenzenesulfonate (0.05 g, 0.012 mmol), azetidine (0.1 ml), ACN (1.5 ml). MS m/z (rel. intensity, 70 eV) 300 (M+, 9), 299 (M+, 59), 220 (6), 192 (8), 70 (bp).
Example 41
3-[(METHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0292] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), methanamine (40% in H 2 O, 1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 327 (M+, bp), 163 (17), 123 (15), 70 (48), 69 (68).
Example 42
3-[(ETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0293] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), ethanamine (70% in H 2 O, 1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 341 (M+, 7), 84 (5), 69 (7), 59 (4), 58 (bp).
Example 43
3-[(BUTYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0294] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), butan-1-amine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 369 (M+, 5), 87 (6), 86 (bp), 70 (8), 69 (6).
Example 44
3-{[(2-HYDROXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0295] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), 2-aminoethanol (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 357 (M+, 8), 326 (19), 74 (bp), 69 (9), 56 (12).
Example 45
3-[(DIPROPYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0296] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), N-propylpropan-1-amine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 396 (M+, 1), 368 (41), 115 (41), 114 (bp), 112 (32).
Example 46
3-{[ETHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0297] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), N-ethylpropan-1-amine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 382 (M+, 1), 354 (11), 221 (6), 101 (7), 100 (bp).
Example 47
3-(PIPERIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0298] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), piperidine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 381 (M+, 4), 248 (9), 124 (5), 99 (6), 98 (bp).
Example 48
3-[(DIMETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0299] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), N-methylmethanamine (40% in H 2 O, 1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 341 (M+, 2), 84 (5), 69 (5), 59 (4), 58 (bp).
Example 49
3-(MORPHOLIN-4-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0300] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), morpholine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 383 (M+, 1), 101 (6), 100 (bp), 70 (5), 56 (5).
Example 50
3-[(DIETHYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0301] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), N-ethylethanamine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 368 (M+, 1), 112 (4), 87 (5), 86 (bp), 58 (4).
Example 51
3-(PYRROLIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0302] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), pyrrolidine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 367 (M+, 1), 110 (5), 85 (6), 84 (bp), 69 (4).
Example 52
3-[(ALLYLAMINO)METHYL]-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0303] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), prop-2-en-1-amine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 353 (M+, 5), 220 (3), 96 (5), 70 (bp), 69 (7).
Example 53
3-{[ETHYL(METHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0304] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), N-methylethanamine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 355 (M+, 1), 98 (4), 73 (5), 72 (bp), 69 (5).
Example 54
3-{[(2-METHOXYETHYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0305] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), 2-methoxyethanamine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 371 (M+, 2), 326 (17), 88 (bp), 70 (17), 56 (9).
Example 55
3-(AZETIDIN-1-YLMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0306] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.05 g, 0.1 mmol), azetidine (0.1 ml), ACN (1.5 ml). MS m/z (rel. intensity, 70 eV) 353 (M+, 1), 192 (2), 71 (5), 70 (bp), 69 (6).
Example 56
3-{[METHYL(PROPYL)AMINO]METHYL}-2,3-DIHYDRO-1,4-BENZODIOXIN-6-YL TRIFLUOROMETHANESULFONATE
[0307] Preparation according to Example 10: (7-{[(trifluoromethyl)sulfonyl]oxy}-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.1 g, 0.21 mmol), N-methylpropan-1-amine (1 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 369 (M+, 1), 340 (11), 207 (7), 86 (bp), 84 (7).
Example 57
1-[(6,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PYRROLIDINE
[0308] A mixture of (6,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.44 g, 1.2 mmol) and pyrrolidin (1.5 ml) in ACN (4 ml) was heated under microwave radiation at 140° C. for 15 min and then mixed with another batch of the same product (0.4 g sm). The combined batches were evaporated to dryness and dissolved in EtOAc and H 2 O. The organic phase was washed with H 2 O and extracted with HCl (10%). The waterphase was basified (Na 2 CO 3 ) and extracted with EtOAc. Yield: (0.2 g, 40%). The amine was converted to the hydrobromic acid salt and crystallized from EtOH/diisopropylether. MS m/z (rel. intensity, 70 eV) 255 (M+, 2), 88 (6), 85 (6), 84 (bp), 55 (7).
Example 58
N-{[(2S)-7-(TRIFLUOROMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}PROPAN-1-AMINE
[0309] A mixture of [(2R)-7-(trifluoromethyl)-2,3-dihydro-1,4-benzodioxin-2-yl]methyl 4-methylbenzenesulfonate (0.48 g, 1.23 mmol), propan-1-amine (1 ml) and ACN (2 ml) was heated under microwave radiation at 120° C. for 30 min. Propanamine (0.5 ml) was added and the mixture was heated under microwave radiation again at 120° C. for 30 min Purification on SCX-3 column (TEA/MeOH) and by preparative HPLC (MeOH/NH 3 buffer). Yield: 0.12 g, 40%. The amine was converted to the hydrochloric acid salt and crystallized from MeOH/Et 2 O. M.p. 166° C. MS m/z (rel. intensity, 70 eV) 275 (M+, 3), 120 (4), 73 (5), 72 (bp), 70 (6). [α]=−52° (methanol).
Example 59
1-(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N-METHYLMETHANAMINE
[0310] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), methanamine (33% in EtOH, 0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 215 (M+, bp), 145 (29), 117 (48), 88 (95), 70 (55).
Example 60
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]ETHANAMINE
[0311] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), ethanamine (2.0 M in MeOH, 0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 229 (M+, 10), 87 (11), 70 (5), 58 (bp), 56 (5).
Example 61
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROP-2-EN-1-AMINE
[0312] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), prop-2-en-1-amine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 241 (M+, 5), 117 (6), 88 (9), 70 (bp), 68 (7).
Example 62
4-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]MORPHOLINE
[0313] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), morpholine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 271 (M+, 3), 101 (7), 100 (bp), 88 (5), 70 (4), 56 (8).
Example 63
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]BUTAN-1-AMINE
[0314] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), butan-1-amine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 257 (M+, 11), 88 (14), 86 (bp), 70 (11), 57 (8).
Example 64
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-PROPYLPROPAN-1-AMINE
[0315] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), N-propylpropan-1-amine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 285 (M+, 1), 256 (10), 115 (8), 114 (bp), 86 (12), 72 (6).
Example 65
1-(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)-N,N-DIMETHYLMETHANAMINE
[0316] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), N-methylmethanamine (2.0 M in MeOH, 0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 229 (M+, 2), 117 (3), 88 (7), 84 (3), 59 (4), 58 (bp).
Example 66
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-ETHYLETHANAMINE
[0317] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), N-ethylethanamine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 257 (M+, 1), 88 (5), 87 (7), 86 (100), 58 (8), 56 (5).
Example 67
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PROPAN-2-AMINE
[0318] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), propan-2-amine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 243 (M+, 9), 88 (16), 84 (13), 72 (bp), 56 (10).
Example 68
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLPROPAN-1-AMINE
[0319] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), N-methylpropan-1-amine (N—,N—) (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 257 (M+, 1), 88 (9), 87 (6), 86 (bp), 84 (9), 58 (16).
Example 69
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-ETHYLPROPAN-1-AMINE
[0320] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), N-ethylpropan-1-amine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 271 (M+, 1), 101 (8), 100 (bp), 98 (6), 72 (13), 58 (13).
Example 70
2-{[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AMINO}ETHANOL
[0321] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), 2-aminoethanol (0.5 ml), ACN (3 ml). 1 H-NMR (400 MHz, CDCl 3 ): δ 6.43-6.49 (2H, m), δ 4.30-4.34 (2H, m), δ 4.04 (1H, dd, J=11.6 Hz, J 7.6), 3.68 (2H, t, J=5.2 Hz), δ 2.93 (2H, t, J=4.8 Hz), δ 2.84 (2H, t, J=4.8 Hz).
Example 71
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-N-METHYLETHANAMINE
[0322] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), N-methylethanamine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 243 (M+, 1), 117 (3), 88 (7), 84 (4), 73 (5), 72 (bp).
Example 72
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-2-METHOXYETHANAMINE
[0323] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), 2-methoxyethanamine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 259 (M+, 9), 214 (13), 88 (bp), 70 (11), 58 (10), 56 (19).
Example 73
1-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]AZETIDINE
[0324] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), azetidine (0.2 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 241 (M+, 6), 116 (5), 88 (9), 71 (5), 70 (bp).
Example 74
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-2-METHYLPROPAN-1-AMINE
[0325] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), 2-methylpropan-1-amine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 257 (M+, 11), 214 (14), 88(14), 86 (bp), 70 (12), 57 (15).
Example 75
1-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PYRROLIDINE
[0326] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), pyrrolidine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 255 (M+, 2), 110 (5), 88 (6), 84 (bp), 85 (6), 55 (5).
Example 76
1-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]PIPERIDINE
[0327] Preparation according to Example 10: (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), piperidine (0.5 ml), ACN (3 ml). MS m/z (rel. intensity, 70 eV) 269 (M+, 1), 99 (7), 98 (bp), 88 (5), 70 (4), 55 (6).
Example 77
N-[(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL]-3-FLUOROPROPAN-1-AMINE
[0328] A solution of (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (0.020 g, 0.0561 mmol), 3-fluoropropan-1-amine (0.23 M in MeOH 80%/TEA 20%, 1 ml), ACN (3 ml) was heated under microwave radiation at 120° C. for 1 h 20 min. MS m/z (rel. intensity, 70 eV) 261 (M+, 6), 91(5), 90 (bp), 88 (12), 70 (10).
Example 78
2-({[(2S)-7-(TRIFLUOROMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL}AMINO)ETHANOL
[0329] A mixture of [(2R)-7-(trifluoromethyl)-2,3-dihydro-1,4-benzodioxin-2-yl]methyl 4-methylbenzenesulfonate (0.25 g, 0.64 mmol), 2-aminoethanol (1 ml) and ACN (2 ml) was heated under microwave radiation at 120° C. for 30 min. Purification by preparative HPLC (MeOH/NH 3 buffer). Yield: 0.060 g, 34%. The amine was converted to the oxalic acid salt and crystallized from EtOH. M.p. 181.5-181.9° C. 1 H-NMR (400 MHz, CD 3 OD): δ 7.17 (1H, d, J 2.3), δ 7.13 (1H, dd, J 8.6, 2.3), δ 7.02 (1H, d, J8.69), δ 4.39 (1H, dd, J 11.5, 2.3), δ 4.34 (1H, m), δ 4.05 (1H, dd J 11.5, 7.2), δ 3.68 (2H, t, J 5.5), δ 2.91 (2H, dd, J 7.0, 5.0), δ 2.79 (2H, dd, J 7.0, 5.0) ppm (J-values are in Hz and shifts relative to solvent-peak at 3.31 ppm) [α]=−43° (methanol).
Example 79
N-{[7-(FLUOROMETHYLSULFONYL)-3,4-DIHYDRO-2H-CHROMEN-2-YL]METHYL}-N-PROPAN-1-AMINE
[0330] A mixture of (7-fluoro-3,4-dihydro-2h-chromen-2-yl)methyl 4-methylbenzenesulfonate (0.58 g, 1.5 mmol), propan-1-amine (2 ml) and acetonitrile (8 ml) was heated under microwave radiation at 120° C. for 30 min. The product was evaporated to dryness and was dissolved in EtOAc and extracted with HCl (10% in H 2 O). The combined water phases were basified using NaOH (20%). Extraction of the water phase using EtOAc gave the title compound (0.33 g, 99%). The amine was converted to the hydrochloric acid salt and recrystallized from MeOH. M.p. 212.8-213.6° C. MS m/z (rel. intensity, 70 eV) 223 (M+, 28), 194 (13), 125 (7), 96 (8), 72 (bp).
PREPARATIONS
Preparation 1
5-BROMO-2-[(2S)-OXIRAN-2-YLMETHOXY]BENZALDEHYDE
[0331] A mixture of 5-bromo-2-hydroxybenzaldehyde (10 g, 49.8 mmol), R-glycidyltosylate (11.4 g, 49.8 mmol) and K 2 CO 3 (6.9 g, 49.8 mmol) in DMF (120 ml) was heated at 100° C. for 4 h. The mixture was cooled to ambient temperature, water and EtOAc were added. The phases were separated and the combined organic phases were washed with brine, dried (MgSO 4 ), filtered and concentrated to give the title compound (10.9 g). MS m/z (rel. intensity, 70 eV) 258 (M+, 88), 256 (M+, 82), 200 (89), 198 (98), 63 (99), 57 (bp).
Preparation 2
5-BROMO-2-[(2S)-OXIRAN-2-YLMETHOXY]PHENYL FORMATE
[0332] To a solution of 5-bromo-2-[(2S)-oxiran-2-ylmethoxy]benzaldehyde (10.9 g, 42.2 mmol) in DCM (200 ml) was added m-CPBA (77%, 13.2 g, 59.1 mmol). The solution was heated at reflux over night and then brought to ambient temperature. Aqueous Na 2 CO 3 (10%) was added and the phases were separated. The organic phase was washed with brine, dried (MgSO 4 ), filtered and evaporated to dryness. The residue was purified by flash column chromatography (isooctane/EtOAc) to give the title compound (9.02 g). MS m/z (rel. intensity, 70 eV) 275 (M+, 4), 273 (M+, 4), 189 (46), 187 (48), 57 (bp), 51 (79).
Preparation 3
[(2S)-7-BROMO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHANOL
[0333] A mixture of 5-bromo-2-[(2S)-oxiran-2-ylmethoxy]phenyl formate (9 g, 33.0 mmol) and NaOH (2 M, 50 ml) was heated at reflux for 1 h 30 min and left at room temperature over night. The mixture was extracted with EtOAc. The combined organic phases were washed with water and dried (MgSO 4 ). The oily product was purified by flash column chromatography (isooctane/EtOAc) to give the title compound (4.9 g). MS m/z (rel. intensity, 70 eV) 245 (M+, 93) 244 (M+, bp), 188 (62), 79 (88), 51 (69).
Preparation 4
[(2R)-7-BROMO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL 4-METHYLBENZENESULFONATE
[0334] To a solution of [(2S)-7-bromo-2,3-dihydro-1,4-benzodioxin-2-yl]methanol (4.9 g, 20.0 mmol) in pyridine (10 ml) was added toluenesulfonyl chloride (6.7 g, 22.0 mmol). The mixture was split into six equal batches that were heated under microwave radiation to 100° C. for 60 sek. The batches were mixed, HCl (10% in H 2 O) and EtOAc was added and the phases were separated. The combined organic phases were washed with brine, dried (MgSO 4 ) and evaporated to dryness. The residue was purified by flash column chromatography to give the title compound (5.7 g). MS m/z (rel. intensity, 70 eV) 400 (M+, 44), 399 (M+, 41), 227 (50), 226 (52), 91 (bp).
Preparation 5
4,5-DIFLUORO-2-METHOXYPHENOL
[0335] To a solution of 1,2-difluoro-4,5-dimethoxybenzene (5 g, 28.7 mmol) in DMF (14 ml) was added sodium thiomethoxide (6.2 g, 88.5 mmol). After 30 min more DMF (4 ml) was added. The mixture was stirred in room temperature for 1 h 30 min and cooled on an icebath. Water was added and then HCl (10% in H 2 O). The solution was extracted with EtOAc and the combined organic phases were washed with water, dried (MgSO 4 ) and evaporated to dryness with EtOH. Purification on flash column chromatography (Isooctane/EtOAc) gave the title compound (1.5 g). MS m/z (rel. intensity, 70 eV) 160 (M+, 82) 145 (bp), 117 (63), 97 (8), 88 (9).
Preparation 6
2-[(4,5-DIFLUORO-2-METHOXYPHENOXY)METHYL]OXIRANE
[0336] 4,5-difluoro-2-methoxyphenol (0.4 g, 2.6 mmol) was dissolved in EtOH (20 ml). Epibromhydrin (0.3 ml, 3.4 mmol) was added, followed by KOH (0.2 g, 2.8 mmol) and water (0.5 ml). The resulting solution was heated at reflux for 1 h 45 min. HCl (10% in H 2 O) was added and the mixture was evaporated. Water and EtOAc was added and the phases were separated. The organic phase was evaporated to dryness with dry EtOH to give the title compound in a mixture with sideproducts that were not separated. Yield: 0.7 g. MS m/z (rel. intensity, 70 eV) 216 (M+, 78), 160 (77), 145 (bp), 88 (71), 57 (59).
Preparation 7
4,5-DIFLUORO-2-(OXIRAN-2-YLMETHOXY)PHENOL
[0337] 2-[(4,5-difluoro-2-methoxyphenoxy)methyl]oxirane (0.8 g, 3.6 mmol) was cooled on an icebath and HBr (48%, 10 ml) was added slowly. The reaction mixture was heated at 105° C. for 3 h and then brought to ambient temperature. Water and EtOAc was added and phases were separated. The combined organic phases were evaporated to dryness with dry EtOH to give the title compound in a mixture with sideproducts that were not separated. MS m/z (rel. intensity, 70 eV) 202 (M+, 68), 146 (bp), 117 (61), 88 (40), 57 (62).
Preparation 8
(6,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHANOL
[0338] A mixture of 4,5-difluoro-2-(oxiran-2-ylmethoxy)phenol (0.5 g, 2.6 mmol) and KOH (0.2 g, 2.8 mmol) in EtOH (50 ml) was heated at reflux for 3 h. Another (0.2 g, 2.2 mmol) of KOH was added and the mixture was heated at reflux for 2 h 30 min and then brought to ambient temperature. HCl (10% in H 2 O, 2 ml) and water was added and the solution was stirred over night and then evaporated to dryness with dry EtOH. The residue was purified on flash column chromatography (Isooctane/EtOAc/MeOH) to give the title compound (0.1 g). MS m/z (rel. intensity, 70 eV) 202 (M+, 86), 146 (bp), 145 (38), 88 (49), 57 (45).
Preparation 9
(6,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0339] (6,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methanol (0.8 g, 3.5 mmol), TEA (0.8 ml, 5.9 mmol) and p-toluenesulfonyl chloride (1.1 g, 5.9 mmol) was dissolved in DCM. The resulting solution was stirred in room temperature over night. H 2 O and HCl (10% in H 2 O) was added and the phases were separated. The organic phase was washed with Na 2 CO 3 (10% in H 2 O) and evaporated to dryness with dry EtOH to give the title compound. Yield: 1.8 g. MS m/z (rel. intensity, 70 eV) 356 (M+, 55), 184 (bp), 183 (40), 145 (28), 91 (69).
Preparation 10
5-FLUORO-2-(OXIRAN-2-YLMETHOXY)BENZALDEHYDE
[0340] A mixture of 5-fluoro-2-hydroxybenzaldehyde (10 g, 35.7 mmol), epibromhydrin (5.8 ml, 35.7 mmol) and K 2 CO 3 (9.8 g, 35.7 mmol) in DMF was heated at 100° C. for 20 min. After cooling to ambient temperature water and EtOAc were added. The phases were separated and the combined organic phases washed with LiCl (5% in H 2 O, 100 ml), dried (MgSO 4 ) and evaporated to dryness. Purification by flash column chromatography (isooctane/EtOAc) gave the title compound (8.8 g). MS m/z (rel. intensity, 70 eV) 196 (M+, 28), 139 (bp), 138 (65), 83 (38), 57 (54).
Preparation 11
5-FLUORO-2-(OXIRAN-2-YLMETHOXY)PHENOL
[0341] m-CPBA (77%, 4.6 g, 20.7 mmol) was slowly added to a solution of 5-fluoro-2-(oxiran-2-ylmethoxy)benzaldehyde (2.9 g, 14.8 mmol) in DCM (20 ml). The mixture was heated at reflux for 3 h and then brought to ambient temperature. Aqueous Na 2 CO 3 (10%) and EtOAc was added and the phases were separated. The combined organic phases were dried (MgSO 4 ) and purified with flash column chromatography to give the title compound (1.4 g). MS m/z (rel. intensity, 70 eV) 184 (M+, bp), 138 (32), 128 (88), 99 (40), 57 (32).
Preparation 12
(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHANOL
[0342] 5-fluoro-2-(oxiran-2-ylmethoxy)phenol (1.8 g, 9.8 mmol) in sodium hydroxide (15% in H 2 O, 15 ml) was heated at reflux for 1 h. The mixture was cooled to ambient temperature and extracted with diethyl ether. The combined organic phases were washed with water, dried (MgSO 4 ) and evaporated to dryness to give the title compound (2.2 g). MS m/z (rel. intensity, 70 eV) 184 (M+, bp), 153 (34), 138 (26), 128 (70), 127 (20).
Preparation 13
(7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0343] A mixture of (7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methanol (0.92 g, 5 mmol) p-toluenesulfonyl chloride (1.43 g, 7.5 mmol), TEA (1.04 ml, 7.5 mmol) and 4-DMAP (0.61 g, 5 mmol) in DCM was stirred in room temperature for 1 h. Water and EtOAc was added and the combined organic phases were dried (MgSO 4 ) and evaporated to dryness to give the title compound (1.19 g). MS m/z (rel. intensity, 70 eV) 338 (M+, bp), 166 (59), 165 (37), 139 (17), 91 (23).
Preparation 14
5-CHLORO-2-(OXIRAN-2-YLMETHOXY)BENZALDEHYDE
[0344] To a solution of 5-chloro-2-hydroxybenzaldehyde (8 g, 51.2 mmol) in DMF (30 ml) was added epibromhydrin (4.2 ml, 51.2 mmol) and K 2 CO 3 (7.1 g, 51.2 mmol) and the mixture was heated at 100° C. for 1 h. The mixture was cooled to ambient temperature and water and EtOAc was added. The phases were separated, and the combined organic phases washed with aqueous LiCl (10% in H 2 O), dried (MgSO 4 ) and evaporated to give the title product (15 g including impurities of DMF). MS m/z (rel. intensity, 70 eV) 212 (M+, 54), 169 (32), 156 (65), 155 (bp), 156 (64).
Preparation 15
5-CHLORO-2-(OXIRAN-2-YLMETHOXY)PHENOL
[0345] To a solution of 5-chloro-2-(oxiran-2-ylmethoxy)benzaldehyde [15 g (including impurities of DMF), 51.2 mmol] in DCM (40 ml) was added m-CPBA (77%, 16.1 g, 71.7 mmol) and the mixture was heated at reflux for 1 h and then brought to ambient temperature. The solution was washed with Na 2 CO 3 (10% in H 2 O) and extracted with EtOAc. The combined organic phases were dried (MgSO 4 ) and evaporated to dryness to give the title product in a mixture with sideproducts that were not separated (9.39 g). LC-MS m/z (ESI) 199 (M+1).
Preparation 16
(7-CHLORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHANOL
[0346] A mixture of 5-chloro-2-(oxiran-2-ylmethoxy)phenol (9.39 g, 41.4 mmol) and sodium hydroxide (15% in H 2 O, 30 ml) was heated at reflux for 30 min. The mixture was cooled to ambient temperature and extracted with Et 2 O and EtOAc. The combined organic phases were dried (MgSO 4 ), evaporated to dryness and purified on flash column chromatography (EtOAc/MeOH) to give the title compound (2.7 g). MS m/z (rel. intensity, 70 eV) 200 (M+, bp), 169 (40), 144 (83), 79 (42), 51 (46).
Preparation 17
(7-CHLORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0347] To a solution of (7-chloro-2,3-dihydro-1,4-benzodioxin-2-yl)methanol (2.7 g, 13.5 mmol) in DCM (30 ml) was added p-toluenesulfonyl chloride (3.9 g, 20.3 mmol), TEA (2.8 ml, 20.3 mmol) and 4-DMAP (1.65 g, 13.5 mmol). The mixture was stirred at ambient temperature for 45 min, water and EtOAc were added and the phases were separated. The combined organic phases were dried (MgSO 4 ) and evaporated to dryness. Purification on flash column chromatography (MeOH) gave the title compound (1.3 g). MS m/z (rel. intensity, 70 eV) 354 (M+, bp) 356 (M+, 38), 182 (92), 181 (45), 91 (50).
Preparation 18
1-[5-METHOXY-2-(OXIRAN-2-YLMETHOXY)PHENYL]ETHANONE
[0348] To a mixture of 1-(2-hydroxy-5-methoxyphenyl)ethanone (10 g, 60 mmol) and K 2 CO 3 (12.4 g) in DMF (50 ml) was added epibromhydrin (15 ml). The solution was heated at 80° C. and the reaction followed with GC/MS. H 2 O and EtOAc was added and the resulting solution was extracted several times with EtOAc. The combined organic layers were washed with aqueous LiCl (5%), HCl (1N) and brine. Drying (Na 2 SO 4 ) and evaporation of the solvent gave the title compound. Yield: 15 g (with impurities of DMF). MS m/z (rel. intensity, 70 eV) 222 (M+, 73), 180 (26), 166 (52), 151 (bp), 137 (27).
Preparation 19
5-METHOXY-2-(OXIRAN-2-YLMETHOXY)PHENYL ACETATE
[0349] To a solution of 1-[5-methoxy-2-(oxiran-2-ylmethoxy)phenyl]ethanone (13.3 g, 60 mmol) in DCM (100 ml) was slowly added m-CPBA (77%, 20.7 g, 50 mmol). The mixture was heated at reflux for 18 h and then brought to ambient temperature. The solution was washed with aqueous NaHCO 3 and with brine. The organic phase was dried (Na 2 SO 4 ) and evaporated to dryness to give the crude title compound that was used directly in the next step (Preparation 20) without further analysis.
Preparation 20
(7-METHOXY-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHANOL
[0350] 5-methoxy-2-(oxiran-2-ylmethoxy)phenyl acetate was dissolved in MeOH (50 ml) and KOH (10% in H 2 O, 40 ml) was added at 0° C. The solution was stirred for 30 min in room temperature and then evaporated to dryness. HCl (10% in H 2 O) was added and the solution was extracted with EtOAc. The combined organic phases were dried (Na 2 SO 4 ) and evaporated to dryness. The batch was mixed with another batch and then purified on flash column chromatography (isooctane/EtOAc) to give the title compound (9.3 g). MS m/z (rel. intensity, 70 eV) 196 (M+, bp), 139 (18), 125 (14), 110 (29), 69 (16).
Preparation 21
(7-METHOXY-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0351] (7-methoxy-2,3-dihydro-1,4-benzodioxin-2-yl)methanol (8.8 g, 44.9 mmol) was dissolved in DCM (150 ml) and TEA (12.5 ml, 89.8 mmol) was added. The solution was cooled to 0° C. and p-toluenesulfonyl chloride (17.1 g, 89.8 mmol) dissolved in DCM (25 ml) was added dropwise. The mixture was stirred for 30 min at 0° C. and then in room temperature. Na 2 CO 3 (10% in H 2 O) was added and the solution was stirred. The phases were separated and organic phase dried (Na 2 SO 4 ) and evaporated to dryness to give the title compound. Yield: 8.7 g. MS m/z (rel. intensity, 70 eV) 352 (M+, 7), 351 (M+, 20), 350 (M+, bp), 110 (10), 91 (7).
Preparation 22
(7-HYDROXY-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0352] A solution of (7-methoxy-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (8.5 g, 24.3 mmol) in DCM (200 ml) was cooled on icebath and BBr 3 (1 M in DCM, 48 ml, 48.5 mmol) was added dropwise. The solution was stirred for 45 min at 0° C. and then in room temperature. Aqueous Na 2 CO 3 (10%) was added and the solution was stirred in room temperature. The phases were separated and the organic phase was dried (Na 2 SO 4 ) and evaporated to dryness. The residue was purified on flash column chromatography (isooctane/EtOAc) to give the title compound (9.1 g). MS m/z (rel. intensity, 70 eV) 337 (M+, 19), 336 (M+, bp), 164 (28), 96 (19), 91 (27).
Preparation 23
{7-[(METHYLSULFONYL)OXY]-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL}METHYL 4-METHYLBENZENESULFONATE
[0353] A solution of (7-hydroxy-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (4.5 g, 13.4 mmol) and TEA (3.7 ml, 26.8 mmol) in DCM (150 ml) was cooled to 0° C. and methanesulfonyl chloride (1.6 ml, 20.1 mmol) dissolved in DCM was added dropwise. The resulting mixture was stirred at 0° C. for 45 min and then stirred at room temperature. Na 2 CO 3 (10% in H 2 O) was added and the solution was stirred. The phases were separated and the organic phase was dried (Na 2 SO 4 ) and evaporated to dryness to give the title compound (3.2 g). MS m/z (rel. intensity, 70 eV) 414 (M+, 65), 335 (bp), 163 (31), 155 (66), 91 (63).
Preparation 24
(7-{[(TRIFLUOROMETHYL)SULFONYL]OXY}-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0354] Preparation according to Preparation 23: (7-hydroxy-2,3-dihydro-1,4-benzodioxin-2-yl)methyl 4-methylbenzenesulfonate (4.5 g, 13.4 mmol), DCM (150 ml), TEA (3.7 ml, 26.8 mmol), trifluorosulfonyl chloride (2.1 ml, 20.1 mmol), DCM (20 ml): Yield: 4.6 g. MS m/z (rel. intensity, 70 eV) 468 (M+, 48), 335 (bp), 163 (39), 155 (87), 91 (89).
Preparation 25
3,4-DIFLUORO-2-HYDROXYBENZALDEHYDE
[0355] To a solution of magnesium methoxide (6-10% in MeOH, 40 ml, 31.1 mmol) was added 2,3-difluorophenol (6.7 g, 51.8 mmol). The mixture was heated at reflux for 40 min and MeOH (20 ml) was distilled from the solution. Toluene (50 ml+50 ml) was added and another 35 ml was distilled from the reaction mixture. Paraformaldehyde (5.6 g, 186 mmol) was added during 15 min. The resulting mixture was heated at 115° C. for 32 min and then cooled to ambient temperature. HCl (10% in H 2 O) was added and the solution stirred in room temperature over night. The phases were separated, the water phase was extracted with EtOAc and the combined organic phase was washed with brine, dried (MgSO 4 ) and evaporated to dryness to give the title compound (5.7 g). MS m/z (rel. intensity, 70 eV) 158 (M+, 87), 157 (M+, bp), 112 (28), 101 (57), 75 (25).
Preparation 26
3,4-DIFLUORO-2-(4-METHYLPHENOXY)BENZALDEHYDE
[0356] A mixture of 3,4-difluoro-2-hydroxybenzaldehyde (4.2 g, 26.4 mmol), benzylbromide (4.7 ml, 39.6 mmol) and TEA (7.3 ml, 52.7 mmol) in THF (25 ml) was put in 2 batches and heated under microwave radiation to 100° C. for 30 min. The batches were mixed and cooled to ambient temperature. HCl (10% in H 2 O) and EtOAc was added. The phases were separated and the organic phase dried (MgSO 4 ) and purified on flash column chromatography (isooctane/EtOAc) to give the title compound (2.0 g). MS m/z (rel. intensity, 70 eV) 248 (M+, 0.1), 157 (4), 92 (8), 91 (bp), 65 (12).
Preparation 27
3,4-DIFLUORO-2-(4-METHYLPHENOXY)PHENOL
[0357] A mixture of 3,4-difluoro-2-(4-methylphenoxy)benzaldehyde (2 g, 8.1 mmol) and m-CPBA (77%, 4.2 g, 24.2 mmol) in DCM (30 ml) was put in 2 batches and heated under microwave radiation to 80° C. for 1 h 10 min and then brought to ambient temperature. The batches were mixed. Aqueous Na 2 CO 3 (10%) was added and the solution was extracted with EtOAc. The combined organic phases were washed with brine, dried (MgSO 4 ) and evaporated to dryness. Purification on flash column chromatography (isooctane/EtOAc) gave the title compound (1.3 g). MS m/z (rel. intensity, 70 eV) 236 (M+, 2), 92 (8), 91 (bp), 69 (3), 65 (11).
Preparation 28
2-{[2-(BENZYLOXY)-3,4-DIFLUOROPHENOXY]METHYL}OXIRANE
[0358] A mixture of 3,4-difluoro-2-(4-methylphenoxy)phenol (1.9 g, 7.8 mmol), epibromhydrin (0.8 ml, 9.4 mmol), KOH (0.5 g, 8.6 mmol), H 2 O and EtOH was heated at 80° C. for 1 h. The solution was evaporated to dryness, dissolved in EtOAc and washed with aqueous Na 2 CO 3 (10%). The organic phase was dried (MgSO 4 ) and evaporated to dryness. Purification on flash column chromatography (isooctane/EtOAc) gave the title compound (1.6 g). MS m/z (rel. intensity, 70 eV) 292 (M+, 6), 117 (3), 92 (8), 91 (bp), 65 (9).
Preparation 29
(7,8-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHANOL
[0359] A mixture of 2-{[2-(benzyloxy)-3,4-difluorophenoxy]methyl}oxirane (0.9 g, 3.2 mmol) and Pd/C (0.1 g) in EtOH was hydrogenated in a Parr apparatus for 1 h. The reaction mixture was filtered through a pad of celite and washed with EtOH/MeOH (1:1, 100 ml). KOH (0.7 g, 12.7 mmol) was added and the solution was stirred in room temperature over night. Aqueous HCl (10%) was added and the solution was evaporated to dryness. HCl (10% in H 2 O) and EtOAc was added and the phases were separated. The organic phase was washed with brine, dried (MgSO 4 ) and evaporated to dryness to give the title compound (0.6 g). MS m/z (rel. intensity, 70 eV) 202 (M+, 69), 146 (bp), 145 (28), 88 (38), 57 (41).
Preparation 30
(7,8-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0360] A solution of (7,8-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methanol (0.6 g, 3.2 mmol), TEA (0.6 ml, 4.8 mmol) and p-toluenesulfonyl chloride (0.9 g, 4.8 mmol) in DCM was stirred in room temperature over night and aqueous HCl (10%) was added. The aqueous phase was extracted with EtOAc. The combined organic phases were dried (MgSO 4 ) and evaporated to dryness. Purification on flash column chromatography (isooctane/EtOAc) gave the title compound (0.4 g). MS m/z (rel. intensity, 70 eV) 356 (M+, 35), 184 (bp), 183 (39), 91 (71), 65 (27).
Preparation 31
1-[3,5-DIFLUORO-2-(4-METHYLPHENOXY)PHENYL]ETHANONE
[0361] A solution of 1-(3,5-difluoro-2-hydroxyphenyl)ethanone (9.8 g, 57 mmol), benzylbromide (10.7 g, 7.5 ml) and K 2 CO 3 (15.7 g, 114 mmol) in ACN (100 ml) was heated at reflux for 1 h and then filtered and washed with EtOAc. Purification on flash column chromatography gave the title compound (14.1 g). MS m/z (rel. intensity, 70 eV) 262 (M+, 1), 100 (6), 92 (8), 91 (bp), 65 (20).
Preparation 32
3,5-DIFLUORO-2-(4-METHYLPHENOXY)PHENYL ACETATE
[0362] To a solution of 1-[3,5-difluoro-2-(4-methylphenoxy)phenyl]ethanone (6.6 g, 25.2 mmol) in CHCl 3 (dry, 30 ml) was m-CPBA (77%, 21.7 g, 125 mmol) added in portions. The resulting solution was heated at reflux over night. DCM and aqueous Na 2 CO 3 (10%) was added and the phases were separated. The combined organic phases were washed with aqueous Na 2 CO 3 and brine, dried (MgSO 4 ) and evaporated to dryness. Yield: 15.9 g. MS m/z (rel. intensity, 70 eV) 278 (M+, 1), 236 (9), 92 (8), 91 (bp), 65 (17).
Preparation 33
3,5-DIFLUORO-2-(4-METHYLPHENOXY)PHENOL
[0363] A solution of 3,5-difluoro-2-(4-methylphenoxy)phenyl acetate (15.9 g), KOH (5.6 g, 99.6 mmol) in dioxan (100 ml) and H 2 O (30 ml) was heated at 60° C. After 40 min further KOH (1 g) was added and the solution was heated another 30 min. The resulting solution was mixed with two other batches of the same compound. HCl (10% in H 2 O), EtOAc and H 2 O was added and the phases were separated. The combined organic phases were washed with brine, dried (MgSO 4 ) and evaporated to dryness. Purification on flash column chromatography gave the title compound. MS m/z (rel. intensity, 70 eV) 236 (M+, 1), 92 (8), 91 (bp), 89 (3), 65 (12).
Preparation 34
1,5-DIFLUORO-3-METHOXY-2-(4-METHYLPHENOXY)BENZENE
[0364] A solution of 3,5-difluoro-2-(4-methylphenoxy)phenol (5.8 g, 23.3 mmol), K 2 CO 3 (6.8 g, 49.1 mmol) and methyliodide (1.8 ml, 29.5 mmol) in ACN was stirred in room temperature over night, filtered and evaporated to dryness. EtOAc, H 2 O and Na 2 CO 3 (10% in H 2 O) was added and the phases were separated. The combined organic phases were washed with brine, dried (MgSO 4 ) and evaporated to dryness. Yield 5.9 g. MS m/z (rel. intensity, 70 eV) 250 (M+, 6), 92 (8), 91 (bp), 88 (3), 65 (11).
Preparation 35
2,4-DIFLUORO-6-METHOXYPHENOL
[0365] A mixture of 1,5-difluoro-3-methoxy-2-(4-methylphenoxy)benzene (5.9 g, 23.6 mmol), Pd/C (10%, 0.9 g), HCl (konc, 10 drops) in MeOH/EtOH was hydrogenated in a Parr apparatus for 2 h, filtered and evaporated to dryness. EtOAc and HCl (1 M) was added and the phases were separated. The combined organic phases were washed with brine, dried (MgSO 4 ) and evaporated to dryness. Yield: 3.3 g. MS m/z (rel. intensity, 70 eV) 160 (M+, bp), 145 (91), 117 (64), 97 (24), 69 (19).
Preparation 36
2-[(2,4-DIFLUORO-6-METHOXYPHENOXY)METHYL]OXIRANE
[0366] Preparation according to Preparation 28 (heating at 70° C.): 2,4-difluoro-6-methoxyphenol (3.1 g, 19.4 mmol), epibromhydrin (1.8 ml, 21.4 mmol), KOH (1.2 g, 21.4 mmol), H 2 O (10 ml), EtOH (100 ml). Yield: 3.7 g (not pure). MS m/z (rel. intensity, 70 eV) 216 (M+, 71), 160 (bp), 158 (27), 145 (70), 57 (37).
Preparation 37
1-BROMO-3-(2,4-DIFLUORO-6-METHOXYPHENOXY)PROPAN-2-OL
[0367] A mixture of 2-[(2,4-difluoro-6-methoxyphenoxy)methyl]oxirane (3.6 g, 16.9 mmol) and HBr (48%, 16 ml) was heated at 100° C. over night. Further HBr (8 ml) was added and the solution was heated over night. Another 6 ml of HBr was added and after 6 h the solution was poured on ice. Et 2 O was added, the phases were separated and the organic phase was evaporated to dryness with EtOH. Yield: 4.4 g. MS m/z (rel. intensity, 70 eV) 284 (M+, 7), 160 (13), 146 (bp), 145 (14), 57 (9).
Preparation 38
(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHANOL
[0368] To a solution of 1-bromo-3-(2,4-difluoro-6-methoxyphenoxy)propan-2-ol (4.4 g) in EtOH (100 ml) and H 2 O (10 ml) was added KOH (5 g). The resulting mixture was stirred in room temperature over night. HCl (10% in H 2 O) was added and the solution was evaporated to dryness. Et 2 O and EtOAc were added and the phases were separated. The combined organic phase was washed with brine, dried (MgSO 4 ) and evaporated to dryness. Yield: 3.4 g. MS m/z (rel. intensity, 70 eV) 202 (M+, bp), 171 (24), 157 (22), 146 (60), 145 (20).
Preparation 39
(5,7-DIFLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0369] Preparation according to Preparation 30 (stirred in rt for 1 h): (5,7-difluoro-2,3-dihydro-1,4-benzodioxin-2-yl)methanol (3.4 g, 16.8 mmol), TEA (4 ml), p-toluenesulfonyl chloride (4.8 g, 25 2 mmol), DCM. Yield: 2.8 g. MS m/z (rel. intensity, 70 eV) 356 (M+, 73), 184 (bp), 183 (53), 155 (31), 91 (83).
Preparation 40
5-FLUORO-2-[(2S)-OXIRAN-2-YLMETHOXY]BENZALDEHYDE
[0370] Preparation according to Preparation 10 (heating for 1½ h at 100° C.): 5-fluoro-2-hydroxybenzaldehyde (6.77 g, 48.3 mmol), K 2 CO 3 (6.68 g, 48.4 mmol), R-glycidyltosylate (11.03 g, 48.3 mmol), DMF (50 ml). Yield: 8 g with impurities of DMF. MS m/z (rel. intensity, 70 eV) 196 (M+, 22), 139 (91), 138 (56), 83 (58), 57 (bp).
Preparation 41
5-FLUORO-2-[(2S)-OXIRAN-2-YLMETHOXY]PHENYL FORMATE
[0371] Preparation according to Preparation 11 (reflux at 1 h 30 min): 5-fluoro-2-[(2S)-oxiran-2-ylmethoxy]benzaldehyde [8 g (including impurities of DMF), 40.8 mmol], m-CPBA (77%, 12.8 g, 57.1 mmol), DCM (40 ml). MS m/z (rel. intensity, 70 eV) 212 (M+, 10), 184 (78), 139 (bp), 128 (75), 57 (56).
Preparation 42
[(2S)-7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHANOL
[0372] A mixture of 5-fluoro-2-[(2S)-oxiran-2-ylmethoxy]phenyl formate (2.2 g, 10.4 mmol) and aqueous sodium hydroxide (15%, 10 ml) was heated at reflux for 1 h 30 min. The mixture was cooled to ambient temperature and extracted with Et 2 O. The organic phase was washed with H 2 O, dried (MgSO 4 ), evaporated to dryness and purified on flash column chromatography (EtOAc/MeOH) to give the title compound. MS m/z (rel. intensity, 70 eV) 184 (M+, bp), 153 (35), 138 (23), 128 (73), 127 (25).
Preparation 43
[(2R)-7-FLUORO-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL 4-METHYLBENZENESULFONATE
[0373] To a solution of [(2S)-7-fluoro-2,3-dihydro-1,4-benzodioxin-2-yl]methanol (0.12 g, 0.64 mmol) in DCM (10 ml) was added dibutyltinoxide (3 mg, 0.012 mmol), p-toluenesulfonyl chloride (0.12 g, 0.64 mmol) and TEA (0.089 ml, 0.64 mmol). The mixture was stirred at room temperature for 15 h and then mixed with another batch of the same compound. Water and EtOAc were added and the phases were separated. The combined organic phases were dried (MgSO 4 ) and evaporated to dryness to give the title compound. Yield: 0.50 g. MS m/z (rel. intensity, 70 eV) 338 (M+, 82), 166 (bp), 165 (56), 139 (33), 91 (58).
Preparation 44
2-[4-(TRIFLUOROMETHYL)PHENOXY]TETRAHYDRO-2H-PYRAN
[0374] To a mixture of 4-(trifluoromethyl)phenol (0.5 g, 3.08 mmol), HCl in 1,4-dioxane (10 ml, 4 N), and DCM (30 ml) was added 3,4-dihydro-2H-pyran (0.65 g, 7.7 mmol). The mixture was stirred overnight at room temperature. Aqueous NaHCO 3 (sat.) was added and the organic phase was separated, dried (MgSO 4 ) and evaporated to dryness. Flash column chromatography (isooctane/EtOAc) yielded the title compound. Yield: 0.65 g. MS m/z (rel. intensity, 70 eV) 162 (14), 143 (17), 85 (bp), 67 (24), 57 (23).
Preparation 45
2-HYDROXY-5-(TRIFLUOROMETHYL)BENZALDEHYDE
[0375] n-BuLi (1.7 ml, 42 mmol) was added to a mixture of TMEDA (0.6 ml) and THF (25 ml) at −10° C. under N 2 . After 30 min a solution of 2-[4-(trifluoromethyl)phenoxy]tetrahydro-2H-pyran (0.7 g, 2.84 mmol) in dry THF (5 ml) was added dropwise. The mixture was stirred for 15 min at −10° C. and was then brought to room temperature. HCl (22% in water) was added, the organic phase was separated and was added to HCl in 1,4-dioxane (15 ml, 4N) and the resulting mixture was stirred at room temperature overnight. Water (50 ml) was added, the organic phase was separated, dried (MgSO 4 ) and evaporated to dryness. Flash column chromatography (isooctane/EtOAc) yielded the title compound. Yield: 0.12 g. MS m/z (rel. intensity, 70 eV) 190 (M+, 90), 189 (bp), 161 (33), 144 (28), 63 (23).
Preparation 46
2-[(2R)-OXIRAN-2-YLMETHOXY]-5-(TRIFLUOROMETHYL)BENZALDEHYDE
[0376] A mixture of 2-hydroxy-5-(trifluoromethyl)benzaldehyde (1.0 g, 5.25 mmol), (R)-glycidyltosylate (1.05 g, 4.6 mmol), K 2 CO 3 (1.3 g, 9.4 mmol) and DMF was stirred overnight at 60° C. The mixture was evaporated to dryness and EtOAc was added. The organic phase was washed with HCl (20 ml, 1 N), dried (MgSO 4 ) and evaporated to dryness. Flash column chromatography (isooctane/EtOAc) yielded the title compound. Yield 0.58 g. MS m/z (rel. intensity, 70 eV) 246 (M+, 3), 228 (33), 189 (bp), 188 (82), 160 (37).
Preparation 47
[(2S)-7-(TRIFLUOROMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHANOL
[0377] A mixture of 2-[(2R)-oxiran-2-ylmethoxy]-5-(trifluoromethyl)benzaldehyde (0.58 g, 2.36 mmol) m-CPBA (77%, 0.61 g, 3.5 mmol) and CHCl 3 (10 ml) was stirred overnight at reflux. m-CPBA (77%, 0.30 g, 1.7 mmol) was added and the mixture was refluxed for 3 h. Aqueous NaHCO 3 (sat.) was added and the organic phase was separated, washed with brine, dried (MgSO 4 ) and evaporated to dryness. KOH (10 ml, 10% in H 2 O) and 1,4-dioxane (10 ml) was added and the mixture was stirred for 1 h at room temperature. Aqueous NaHCO 3 (sat.) was added and the organic phase was separated, washed with brine, dried (MgSO 4 ) and evaporated to yield the title compound (0.40 g). MS m/z (rel. intensity, 70 eV) 234 (M+, 79, 203 (bp), 189 (37), 178 (93), 57 (67).
Preparation 48
[(2R)-7-(TRIFLUOROMETHYL)-2,3-DIHYDRO-1,4-BENZODIOXIN-2-YL]METHYL 4-METHYLBENZENESULFONATE
[0378] A mixture of [(2S)-7-(trifluoromethyl)-2,3-dihydro-1,4-benzodioxin-2-yl]methanol (0.40 g, 1.71 mmol), p-toluenesulfonyl chloride (0.35 g, 1.71 mmol), TEA (0.23 ml, 1.71 mmol) and 4-DMAP (0.21 g, 1.71 mmol) in DCM (15 ml) was stirred at room temperature for 1 h and 30 min. HCl (1 N) was added, the organic phase was separated, washed with brine, dried (MgSO 4 ) and concentrated to give the title compound (0.48 g). MS m/z (rel. intensity, 70 eV) 388 (M+, 27), 216 (bp), 215 (46), 203 (23), 91 (47).
Preparation 49
1-[2-(BENZYLOXY)-4-FLUOROPHENYL]ETHANONE
[0379] A mixture of 1-(4-fluoro-2-hydroxyphenyl)ethanone (2.7 g, 17.5 mmol), benzylbromide (3.60 g, 21.0 mmol) and K 2 CO 3 (3.63 g, 26.3 mmol) was stirred in dry DMF (15 ml) under N 2 at 80° C. overnight. The solution was brought to ambient temperature and water and EtOAc was added. The water phase was extracted with EtOAc. The combined organic phases were washed with LiCl (5%) and evaporated to dryness to give the crude title compound (4.5 g). MS m/z (rel. intensity, 70 eV) 244 (M+, 18), 139 (9), 92 (17), 91 (bp), 65 (26).
Preparation 50
ETHYL 4-[2-(BENZYLOXY)-4-FLUOROPHENYL]-2,4-DIOXOBUTANOATE
[0380] Sodium (2.15 g, 93.3 mmol) was dissolved in EtOH and the solution was filtrated and added to a mixture of 1-[2-(benzyloxy)-4-fluorophenyl]ethanone (4.56 g, 18.7 mmol) and diethyloxalate (12.63 ml, 93.3 mmol) in EtOH (200 ml). The mixture was heated at 80° C. for 2.5 h, followed by evaporation of EtOH, addition of HCl (10% in H 2 O) and addition of EtOAc. The phases were separated, the organic phase was dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash column chromatography (isooctane/EtOAc) to give the title compound (5.3 g). MS m/z (rel. intensity, 70 eV) 344 (M+, 1), 271 (16), 139 (11), 92 (11), 91 (bp), 65 (11).
Preparation 51
ETHYL 4-(4-FLUORO-2-HYDROXYPHENYL)-2-HYDROXYBUTANOATE
[0381] A mixture of ethyl 4-[2-(benzyloxy)-4-fluorophenyl]-2,4-dioxobutanoate (5.08 g, 14.75 g), palladium black (2.5 g) and EtOH was hydrogenated at 40 Psi for 3 h. The mixture was filtrated through Celite, palladium black (2.5 g) was added and the mixture was again hydrogenated at 40 Psi for 3+3 h. The procedure was repeated using palladium black (1.9 g) and hydrogenation at 40 Psi for 40 h. Filtration through Celite and evaporation gave the title compound (2.8 g). MS m/z (rel. intensity, 70 eV) 242 (M+, 24), 149 (27), 125 (bp), 104 (33), 76 (21).
Preparation 52
ETHYL 7-FLUOROCHROMANE-2-CARBOXYLATE
[0382] Ethyl 4-(4-fluoro-2-hydroxyphenyl)-2-hydroxybutanoate (2.20 g, 9.1 mmol) and triphenylphosphine (2.62 g, 10.0 mmol) were dissolved in dry THF (5 ml), using a sonic bath. Diispropylhydrazine-1,2-dicarboxylate (2.02 g, 10.0 mmol) was added and the mixture was stirred for 4 h. Water was added and the water phase was extracted with EtOAc. The combined organic phases were evaporated to dryness. Purification by flash chromatography (isooctane/EtOAc) gave the title compound (1.3 g). MS m/z (rel. intensity, 70 eV) 224 (M+, 74), 178 (32), 151 (bp), 149 (38), 123 (30).
Preparation 53
(7-FLUORO-3,4-DIHYDRO-2H-CHROMEN-2-YL)METHANOL
[0383] LiAlH 4 (0.41 g, 10.7 mmol) was added to ethyl 7-fluorochromane-2-carboxylate (1.2 g, 5.4 mmol) in THF (8 ml) at 0° C. The mixture was stirred at room temperature for 1 h. EtOH was added, followed by HCl (10% in H 2 O) and EtOAc. The organic phase was separated, washed with brine, dried (Na 2 SO 4 ), filtered and concentrated to give the title compound. Yield 0.90 g. MS m/z (rel. intensity, 70 eV) 182 (M+, 57), 151 (bp), 125 (40), 123 (32), 103 (32).
Preparation 54
(7-FLUORO-3,4-DIHYDRO-2H-CHROMEN-2-YL)METHYL 4-METHYLBENZENESULFONATE
[0384] A mixture of (7-fluoro-3,4-dihydro-2H-chromen-2-yl)methanol (0.9 g, 4.9 mmol), p-toluenesulfonyl chloride (1.41 g, 7.4 mmol), TEA (0.83 ml, 5.9 mmol), 4-DMAP (0.72 g, 5.9 mmol) and DCM (25 ml) was stirred at room temperature for 2 h. Water and DCM was added and the phases were separated. The organic phase was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated. Purification by flash chromatography (isooctane/EtOAc) gave the title compound (1.15 g). MS m/z (rel. intensity, 70 eV) 336 (M+, 57), 164 (bp), 163 (93), 151 (72), 149 (82), 91 (73).
Biological Activity
[0385] The following tests are used for evaluation of the compounds according to the invention.
In Vivo Test: Behaviour
[0386] Behavioural activity is measured using eight Digiscan activity monitors (RXYZM (16) TAO, Omnitech Electronics, Columbus, Ohio, USA), connected to an Omnitech Digiscan analyzer and an Apple Macintosh computer equipped with a digital interface board (NB DIO-24, National Instruments, USA). Each activity monitor consists of a quadratic metal frame (W×L=40 cm×40 cm) equipped with photobeam sensors. During measurements of behavioural activity, a rat is put in a transparent acrylic cage (W×L×H, 40×40×30 cm) which in turn is placed in the activity monitor. Each activity monitor is equipped with three rows of infrared photobeam sensors, each row consisting of 16 sensors. Two rows are placed along the front and the side of the floor of the cage, at a 90° angle, and the third row is placed 10 cm above the floor to measure vertical activity. Photobeam sensors are spaced 2.5 cm apart. Each activity monitor is fitted in an identical sound and light attenuating box containing a weak house light and a fan.
[0387] The computer software is written using object oriented programming (LabVIEW®, National instruments, Austin, Tex., USA).
[0388] Behavioural data from each activity monitor, representing the position (horizontal center of gravity and vertical activity) of the animal at each time, are recorded at a sampling frequency of 25 Hz and collected using a custom written LABView™ application. The data from each recording session are stored and analyzed with respect to distance traveled. Each behavioural recording session lasts 60 min, starting approximately 4 min after the injection of test compound. Similar behavioural recording procedures are applied for drug-naïve and drug pre-treated rats. Rats pre-treated with d-amphetamine are given a dose of 1.5 mg/kg i.p. 10 min before the recording session in the activity monitor. Rats pre-treated with MK-801 are given a dose of 0.7 mg/kg i.p. 90 min before the recording session in the activity monitor. The results are presented as counts/60 minutes, or counts/30 minutes, in arbitrary length units. Statistical comparisons are carried out using Student's t-test against the control group. In MK-801 or amphetamine pre-treated animals, statistical comparisons are made against the MK801 or d-amphetamine controls, respectively.
[0389] ED 50 values for reduction of amphetamine-induced hyper-locomotion are calculated by curve fitting. For most compounds, the evaluation is based on 16 amphetamine pre-treated animals over the dose range 0, 11, 33 and 100 μmol/kg s.c. in one single experiment, with complementary doses in separate experiments. Calculations are based on distance during the last 45 minutes of one hour of measurement. The distances are normalised to amphetamine-control and fitted by least square minimization to the function “End-(End-Control)/(1+(dose/ED 50 ) Slope )”. The four parameters (Control, End, ED 50 and Slope) are fitted with the restrictions: ED 50 >0, 0.5<Slope<3, End=0% of control. The restriction with locked End is made to focus on potency rather than efficacy. To estimate confidence levels for the parameters, the fit is repeated 100 times with a random evenly distributed squared weight (0 to 1) for every measurement value. Presented ED 50 -ranges cover 95% of these values.
In Vivo Test: Neurochemistry
[0390] After the behavioural activity sessions, the rats are decapitated and their brains rapidly taken out and put on an ice-cold petri-dish. The limbic forebrain, the striatum, the frontal cortex and the remaining hemispheral parts of each rat are dissected and frozen. Each brain part is subsequently analyzed with respect to its content of monoamines and their metabolites.
[0391] The monoamine transmitter substances (NA (noradrenaline), DA (dopamine), 5-HT (serotonin)) as well as their amine (NM (normethanephrine), 3-MT (3-methoxytyramine)) and acid (DOPAC (3,4-dihydroxyphenylacetic acid), 5-HIAA (5-hydroxyindoleacetic acid), HVA (homovanillic acid)) metabolites are quantified in brain tissue homogenates by HPLC separations and electrochemical detection
[0392] The analytical method is based on two chromatographic separations dedicated for amines or acids. Two chromatographic systems share a common auto injector with a 10-port valve and two sample loops for simultaneous injection on the two systems. Both systems are equipped with a reverse phase column (Luna C18(2), dp 3 μm, 50*2 mm i.d., Phenomenex) and electrochemical detection is accomplished at two potentials on glassy carbon electrodes (MF-1000, Bioanalytical Systems, Inc.). The column effluent is passed via a T-connection to the detection cell or to a waste outlet. This is accomplished by two solenoid valves, which block either the waste or detector outlet. By preventing the chromatographic front from reaching the detector, better detection conditions are achieved. The aqueous mobile phase (0.4 ml/min) for the acid system contains citric acid 14 mM, sodium citrate 10 mM, MeOH 15% (v/v) and EDTA 0.1 mM. Detection potentials relative to Ag/AgCl reference are 0.45 and 0.60V. The aqueous ion pairing mobile phase (0.5 ml/min) for the amine system contains citric acid 5 mM, sodium citrate 10 mM, MeOH 9% (v/v), MeCN 10.5% v/v), decane sulfonic acid 0.45 mM, and EDTA 0.1 mM. Detection potentials relative to Ag/AgCl reference are 0.45 and 0.65V.
[0393] ED 50 values for the increase of DOPAC in striatum are calculated by curve fitting. For most compounds, the evaluation is based on 20 animals over the dose range 0, 3.7, 11, 33 and 100 μmol/kg s.c. in one single experiment, with complementary doses in separate experiments. The DOPAC levels are normalised to control and fitted by least square minimization to the function “End-(End-Control)/(1+(dose/ED 50 ) Slope )”. The four parameters (Control, End, ED 50 and Slope) are fitted with the restrictions: ED 50 >0, 0.5<Slope<3, 350<End<400% of control. To estimate confidence levels for the parameters, the fit is repeated 100 times with a random evenly distributed squared weight (0 to 1) for every measurement value. Presented ED 50 -ranges cover 95% of these values.
In Vivo Test: Oral Bioavailability
[0394] Experiments are performed 24 hours after implantation of arterial and venous catheters. Test compound is administered orally at 12.5 μmol/kg or intravenously at 5 μmol/kg using the venous catheters, n=3 per group. Arterial blood samples are then taken during six hours at 0, 3, 9, 27, 60, 120, 180, 240, 300 and, 360 minutes after administration of the test compound. The oral bioavailability is calculated as the ratio of the AUC (Area under curve) obtained after oral administration over the AUC obtained after intravenous administration for each rat. The parameter AUC is calculated according to the following:
[0395] AUC: the area under the plasma concentration versus time curve from time zero to the last concentration measured (Clast), calculated by the log/linear trapezoidal method.
[0396] The levels of test compound are measured by means of liquid chromatography-mass spectrometry (LC-MS) (Hewlett-Packard 1100MSD Series). The LC-MS module includes a quaternary pump system, vacuum degasser, thermostatted autosampler, thermostatted column compartment, diode array detector and API-ES spray chamber. Data handling was performed with a HP ChemStation rev.A.06.03. system. Instrument settings: MSD mode: Selected ion monitoring (SIM) MSD polarity: Positiv Gas temp: 350° C. Drying gas: 13.0 l/min Nebulizer gas: 50 psig Capillary voltage: 5000 V Fragmentor voltage: 70 V.
[0397] Analytical column: Zorbax eclipse XDB-C8 (4.6*150 mm, 5 μm) at 20° C. The mobile phase is acetic acid (0.03%) (solvent A) and acetonitrile (solvent B). The flow rate of the mobile phase is 0.8 ml/min. The elution is starting at 12% of solvent β isocratic for 4.5 min, then increasing linearity to 60% over 4.5 min.
[0398] Extractions procedure: Plasma samples (0.25-0.5 ml) are diluted with water to 1 ml, and 60 pmol (100 μl) internal standard (−)-OSU6241 is added. The pH was adjusted to 11 by the addition of 25 μl saturated Na 2 CO 3 . After mixing, the samples are extracted with 4 ml dichloromethane by shaking for 20 min. The organic layer is after centrifugation transferred to a smaller tube and evaporated to dryness under a stream of nitrogen. The residue is then dissolved in 120 μl mobile phase (acetic acid (0.03%): acetonitrile, 95:5) for LC-MS analysis (10 μl injected). The selective ion (MH + ) is monitored for each Example, and MH + 296 for (−)-OSU6241 ((3-[3-(ethylsulfonyl)phenyl]-1-propylpiperidine).
[0399] A standard curve over the range of 1-500 pmol is prepared by adding appropriate amounts of test compound to blank plasma samples.
In Vitro Test: Metabolic Stability in Rat Liver Microsomes
[0400] Rat liver microsomes are isolated as described by Förlin [Förlin L: Effects of Clophen A50, 3-methylcholantrene, pregnenolone-16aq-carbonitrile and Phenobarbital on the hepatic microsomal cytochrome P-450-dependent monooxygenaser system in rainbow trout, salmo gairdneri , of different age and sex; Tox Appl Pharm. 1980 54 (3) 420-430] with minor modifications e.g. 3 mL/g liver of a 0.1 M Na/K*PO 4 buffer with 0.15M KCl, pH 7.4, (buffer 1) is added before homogenisation, the homogenate is centrifuged for 20 minutes instead of 15, the supernatant is ultracentrifuged at 100.000 g instead of 105.000 g and the pellet from the ultracentrifugation is resuspended in 1 mL/g liver of 20% v/v 87% glycerol in buffer 1.
[0401] 1 μL of, 0.2 or 1 mM test substance diluted in water, and 10 μL 20 mg/mL rat liver microsome are mixed with 149 μL 37° C. buffer 1 and the reaction is started by addition of 40 μL 4.1 mg/mL NADPH. After 0 or 15 minutes incubation at 37° C. in a heating block (LAB-LINE, MULTI-BLOK Heater or lab4you, TS-100 Thermo shaker at 700 rpm) the reaction is stopped by addition of 100 μL pure acetonitrile. The protein precipitation is then removed by rejecting the pellet after centrifugation at 10.000 g for 10 minutes (Heraeus, Biofuge fresco) in 4° C. The test compound is analysed using HPLC-MS (Hewlett-Packard 1100MSD Series) with a Zorbax SB-C18 column (2.1*150 mm, 5 μm) using 0.03% formic acid and acetonitrile as mobile phase (gradient) or a Zorbax Eclipse XDB-C18 (3*75 mm, 3.5 μm) using 0.03% acetic acid and acetonitrile as mobile phase (gradient). The 15 min turnover is calculated as the fraction of test compound eliminated after 15 minutes, expressed in percent of 0 min levels, i.e. 100*[conc test compound at 0 min−concentration at 15 min]/conc at 0 min.
[0402] Preparation of liver microsomes is performed as described in Förlin [Förlin L: Effects of Clophen A50, 3-methylcholantrene, pregnenolone-16aq-carbonitrile and Phenobarbital on the hepatic microsomal cytochrome P-450-dependent monooxygenaser system in rainbow trout, salmo gairdneri , of different age and sex; Tox Appl Pharm. 1980 54 (3) 420-430]. Protocols for incubation with liver microsomes are referred in Crespi et Stresser [Crespi C L, DM Stressser: Fluorometric screening for metabolism based drug-drug interactions; J. Pharm. Tox. Meth. 2000 44 325-331], and Renwick et al. [Renwick A B et al.: Metabolism of 2,5-bis(trifluoromethyl)-7-benzyloxy-4-trifluoromethylcoumarin by human hepatic CYP isoforms: evidence for selectivity towards CYP3A4; Xenobiotica 2001 31 (4) 187-204].
Microdialysis
[0403] Male Sprague-Dawley rats weighing 220-320 g are used throughout the experiments. Before the experiment the animals are group housed, five animals in each cage, with free access to water and food. The animals are housed at least one week after arrival prior to surgery and use in the experiments. Each rat is used only once for microdialysis.
[0404] We use a modified version Waters et al. [Waters N, Lofberg L, Haadsma-Svensson S, Svensson K, Sonesson C and Carlsson A: Differential effects of dopamine D2 and D3 receptor antagonists in regard to dopamine release, in vivo receptor displacement and behaviour; J. Neural. Transm. Gen. Sect. 1994 98 (1) 39-55] of the I-shaped probe as described by Santiago and Westerink [Santiago M, Westerink B H C: Characterization of the in vivo release of dopamine as recorded by different types of intracerebral microdialysis probes; Naunyn - Schmiedeberg's Arch. Pharmacol. 1990 342 407-414]. The dialysis membrane we use is the AN69 polyacrylonitrile/sodiummethalylsulfonate copolymer (HOSPAL; o.d./i.d. 310/220 μm: Gambro, Lund, Sweden). In the dorsal striatum we use probes with an exposed length of 3 mm of dialysis membrane and in the prefrontal cortex the corresponding length is 2.5 mm. The rats are operated under isoflurane inhalationanesthesia while mounted into a Kopf stereotaxic instrument. Co-ordinates are calculated relative to bregma; dorsal striatum AP+1, ML±2.6, DV−6.3; Pf cortex, AP+3.2, 8° ML±1.2, DV−4.0 according to Paxinos and Watson [Paxinos G, Watson C: The Rat Brain in Stereotaxic Coordinates; New York, Academic Press 1986]. The dialysis probe is positioned in a burr hole under stereotaxic guidance and cemented with phosphatine dental cement. The rats are housed individually in cages for 48 h before the dialysis experiments, allowing them to recover from surgery and minimizing the risk of drug interactions with the anaesthetic during the following experiments. During this period the rats have free access to food and water. On the day of experiment the rats are connected to a micro perfusion pump via a swivel and are replaced in the cage where they can move freely within its confinements. The perfusion medium is a Ringer's solution containing in mmol/l: NaCl; 140, CaCl2; 1.2, KCl; 3.0, MgCl2; 1.0 and ascorbic acid; 0.04 according to Moghaddam and Bunney [Moghaddam B, Bunney B S: Ionic Composition of Microdialysis Perfusing Solution Alters the Pharmacological Responsiveness and Basal Outflow of Striatal Dopamine; J. Neurochem. 1989 53 652-654]. The pump is set to a perfusion speed of 2 μl/min and 40 μl samples are collected every 20 min.
[0405] Each sample is analyzed at two HPLC systems. On an autoinjector (CMA 200) with a 10-port valve (Valco C10WE), holding two sample loops in series (4 μl and 20 μl), each brain dialysate sample is loaded in both loops simultaneously. At injection the 20 μl sample is introduced into a column switching system (reverse-phase combined with reverse-phase ion-pairing) for dopamine (DA), noradrenaline (NA), normetanephrine (NM), 3-methoxytyramine (3-MT) and serotonin (5-hydroxytryptamine, 5-HT) determination, while the 4 μl sample is introduced on a reverse-phase column for the chromatography of the acidic monoamine metabolites 3,4-di-hydroxyphenylacetic acid (DOPAC), homovanillic acid (HVA) and 5-hydroxyindoleacetic acid (5-HIAA). The currents generated by the two EC detectors are converted to digital data and evaluated using Chromeleon software (Dionex) on a PC. The method sample turn over time is 4.5 min and two parallel experiments are normally analyzed simultaneously on the system. After the experiment the rats are uncoupled from the perfusion pump and decapitated. Their brains are rapidly taken out and fixed in Neo-fix solution (Kebo-lab, Sweden) for subsequent inspection of probe localisation. The Animal Ethics Committee in Göteborg, Sweden approved the procedures applied in these experiments. | The present invention relates to novel 1-(2,3-dihydro-1,4-benzodioxin-2-yl)-methanamine derivatives, useful as modulators of dopamine neurotransmission, and more specifically as dopaminergic stabilizers. In other aspects the invention relates to the use of these compounds in a method for therapy and to pharmaceutical compositions comprising the compounds of the invention. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a manufacturing method for tires, more specifically a method for improving the uniformity of a tire by reducing the after cure radial force variation. In a tire, and more precisely, a radial tire, the after cure radial force variation (RFV) can be affected by many variables introduced from the process of assembly of the green (uncured) tire and during curing of the tire. When the radial force variation in a cured tire exceeds acceptable limits, the result may be unwanted vibrations affecting the ride and handling of the vehicle. For these reasons, tire manufacturers strive to minimize the level of radial force variation in the tires delivered to their customers.
A well-known and commonly practiced method to improve the after cure RFV is to grind the tread surface of the tire in the zones corresponding to excess radial force. This method is effective, but has the drawback of creating an undesirable surface appearance and of removing wearable tread rubber from the product. In addition, this method requires an extra manufacturing step and uses expensive equipment. Alternatively, the after cure RFV may be improved by the method described in U.S. Pat. No. 5,365,781 where the sidewalls of the cured tire are physically deformed in a controlled manner in response to a measured uniformity characteristic. This method eliminates the undesirable removal of tread rubber, but still requires an extra manufacturing step and high-cost equipment.
An alternative to after cure correction of RFV is to treat the sources of RFV in the tire before cure. For example, it is well known in the tire industry to stagger the starting points of the various tire products during the assembly process, followed by observing the effect on after cure RFV. These data are then used to specify an optimum arrangement of product start points for each of the tire building steps according to the configuration that best minimizes after cure RFV. Another approach is disclosed in U.S. Pat. No. 5,882,452 where the before cure radial runout (RRO) of the tire is measured, followed by a process of clamping and reshaping the uncured tire to a more circular form.
Still another approach to a manufacturing method for improved uniformity involves a method where the factors relating to tire building and tire curing that contribute to after cure RRO or RFV are offset relative to a measured before cure RRO. An example of a typical method is given in Japanese Patent Application JP-1-145135. In these methods a sample group of tires, usually four, are placed in a given curing mold with each tire rotated an equal angular increment. The angular increment is measured between a reference location on the tire, such as a product joint, relative to a fixed location on the curing mold. Next, the tires are vulcanized and their composite RFV waveforms recorded. The term “composite waveform” means the raw waveform as recorded from the measuring device. The waveforms are then averaged by superposition of each of the recorded waveforms upon the others. Superposition is a point by point averaging of the recorded waveforms accomplished by overlaying the measured composite waveform from each tire. The effects of the vulcanization are assumed to cancel, leaving only a “formation” factor related to the building of the tire. In like manner, another set of sample tires is vulcanized in a curing mold and their respective RFV waveforms are obtained. The respective waveforms are again averaged by superposition, this time with the staring points of the waveforms offset by the respective angular increments for each tire. In this manner, the effects of tire building are assumed to cancel, leaving only a “vulcanization factor.” Finally, the average waveforms corresponding to the formation factor and the vulcanization factor are superimposed. The superimposed waveforms are offset relative to each other in an attempt to align the respective maximum of one waveform with the minimum of the other waveform. The angular offset thus determined is then transposed to the curing mold. When uncured tires arrive at the mold, each tire is then placed in the mold at the predetermined offset angle. In this manner, the formation and vulcanization contributions to after cure RFV are said to be minimized. A major drawback to this method is its assumption that the formation and vulcanization contributions to after cure RFV are equivalent for each tire. In particular, the factors contributing to the formation factor can vary considerably during a manufacturing run. In fact, these methods contain contradictory assumptions. The methodology used to determine the vulcanization factor relies on an assumption that the step of rotation of the tires in the curing mold cancels the tire building (or formation) effects. This assumption is valid only when the contribution of before cure RRO is consistent from one tire to the next tire, without random contributions. If this assumption is true, then the subsequent method for determination of the formation factor will produce a trivial result.
Further improvements have been proposed in Japanese Patent Application JP-6-182903 and in U.S. Pat. No. 6,514,441. In these references, methods similar to those discussed above are used to determine formation and vulcanization factor waveforms. However, these methods add to these factors an approximate contribution of the before cure RRO to the after cure RFV. The two methods treat the measured before cure RRO somewhat differently. In the method disclosed in reference JP-6-198203 optimizes RRO effects whereas the method disclosed in U.S. Pat. No. 6,514,441 estimates RFV effects by application of a constant stiffness scaling factor to the RRO waveform to estimate an effective RFV. Both these methods continue to rely on the previously described process of overlapping or superpositioning of the respective waveforms in an attempt to optimize after cure RFV.
The most important shortcoming of all the above methods is their reliance of superpositioning or overlapping of the respective waveforms. It is well known in the tire industry that the vehicle response to non-uniformity of RFV is more significant in the lower order harmonics, for example harmonics one through five. Since, the above methods use composite waveforms including all harmonics, these methods fail to optimize the RFV harmonics to which the vehicle is most sensitive. In addition, a method that attempts to optimize uniformity using the composite waveforms can be shown, in some instances, to produce after-cure RFV that actually increases the contribution of the important lower order harmonics. In this instance, the tire can cause more vehicle vibration problems than if the process were not optimized at all. Therefore, a manufacturing method that can optimize specific harmonics and that is free of the aforementioned assumptions for determining the effects of tire formation and tire vulcanization would be capable of producing tires of consistently improved uniformity.
SUMMARY OF THE INVENTION
In view of the above background, the present invention provides a tire manufacturing method that can effectively reduce the after cure radial force variation (RFV) of each tire produced. The method of the present invention operates to independently optimize each harmonic of RFV. A composite RFV signal, such as those described above, is a scalar quantity that is the variation of the tire's radial force at each angular position around the tire from the average radial force corresponding to the vertical load applied to the tire. When this composite is decomposed into its respective harmonic components, each harmonic of RFV can be expressed in polar coordinates as an after cure RFV vector. This vector has a magnitude equal to the peak-to-peak magnitude of the force variation of the respective harmonic and an azimuth equal to the angular difference between the measuring reference point and the point of maximum RFV.
The method of the present invention provides a significant improvement over previous methods by employing a vectorial representation of the several factors that contribute to the measured after cure RFV for a tire produced by a given process. The after cure RFV vector is modeled as a vector sum of each of the vectors representing RFV contributions arising from the tire building steps—the “tire room effect vector” and a vector representing RFV contributions arising from the vulcanization and uniformity measurement steps—the “curing room effect vector.” In further detail, both the tire room and curing room vectors can be further decomposed into sub-vectors representing each RFV contribution for which a measurable indicator is available. For a series of tires, the method obtains such measurements as the before cure radial runout (RRO) at one or more stages of the building sequence, measurements of loading angles on the tire building equipment, and measurements made during vulcanization process. After vulcanization, the tires are mounted on a uniformity measurement machine and the measured after cure RFV harmonic components are obtained. At this point, none of the coefficients for the magnitude and azimuth of the sub-vector components is known.
The present invention further improves on previously described methods since it does not rely on manipulation of the measured, composite RFV waveforms to estimate the tire room and curing room effects and does not rely on any of the previously described assumptions. The present invention uses the aforementioned measured data as input to a single analysis step. Thus, the coefficients of all the sub-vectors are simultaneously determined. Once these coefficients are known, the tire room effect vector and curing room effect vector are easily calculated. The method of the invention accounts for the possible RRO of the building drum itself. When any of the previously described methods measure the RRO of a green tire, the measured RRO is the sum of the actual green tire RRO and the RRO of the measuring device upon which the tire is currently mounted, be it a building drum or a measurement apparatus. In summary, the first step of the method determines a set of vector coefficients corresponding to the after cure radial force variation of a tire and comprises the steps of:
(a) recording a loading angle of a tire carcass on a measurement fixture, (b) measuring the before cure radial runout of a plurality of finished tires, (c) recording a loading angle of said finished tires in a curing mold and curing said tires, (d) measuring the after cure radial force variation for each of said tires, (e) extracting at least one harmonic of radial runout and of the radial force variation of said tires, (f) determining a set of vector coefficients relating the before cure radial runout to the after cure radial force variation of said tires cured in said mold, (g) storing said vector coefficients,
Thereafter, as the individual tires are manufactured, the before cure RRO and other manufacturing data are measured and recorded. These data are then input to the vector model and the magnitude and azimuth of the tire room vector are calculated. Next, a second step requires estimating the after cure uniformity of an individual tire comprising the sub-steps of:
(h) recording a loading angle of a carcass of said individual tire on said measurement fixture, (i) measuring the before cure radial runout of said individual tire, (j) choosing a harmonic of radial force variation to be optimized, (k) extracting a harmonic of before cure radial runout of said individual tire, (l) estimating a tire room effect vector of the radial force variation corresponding to said harmonic, (m) estimating a curing room effect vector of the radial force variation corresponding to said harmonic, (n)
Finally, the estimated tire room and curing room effect vectors are used to calculate the angular orientation of the uncured tire in the curing mold that will minimize after cure RFV for that individual tire. The step of optimizing the after cure uniformity of an individual tire comprises the sub-steps of:
(a) Determining an azimuth of said tire room effect vector and of said curing-room effect vector, (b) Aligning the angular position of said individual tire in said curing mold such that said azimuth of said tire room effect vector opposes said curing room effect vector, and (c) Placing said individual tire so aligned in said curing mold and curing said tire.
The method of the invention just described further improves on previous methods in its treatment of the factors that relate before cure RRO to after cure RFV. It has been found that RRO variations on the before cure tire do not always produce an after cure RFV contribution that is a scalar multiple of the RRO vector either in magnitude or azimuth. Thus, a scalar representation that relies on a simple stiffness factor can lead to erroneous result. In the present invention method, the contribution to after cure RFV is modeled as the vector product of a gain vector and the RRO vector. The gain vector correctly models the transformation from before cure RRO to after cure RFV. At least one pair of vector coefficients corresponds to the gain vector.
The method of the invention has an additional advantage owing to its simultaneous determination of the sub-vectors. Unlike previous methods, the method of the invention does not require any precise angular increments of the loading positions to determine the sub-vectors. This opens the possibility to continuously update the sub-vector coefficients using the measured data obtained during the production runs. Thus, the method will take into account production variables that arise during a high volume production run.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by means of the drawing accompanying the description, illustrating a non-limitative example of the execution of the tire manufacturing method for improving the uniformity of a tire according to the invention.
FIG. 1 is a schematic representation of a tire manufacturing process equipped to practice the method of the invention.
FIG. 2 A- FIG. 2C depicts schematic representations of a uniformity measurement of the radial force variation of tire showing the original composite waveform as well as several harmonic components.
FIG. 3 is a vector polar plot of the method of the invention showing the contributions of the tire room and curing room vectors to the after cure radial force variation of a tire.
FIG. 4 is a vector polar plot of the method of the invention demonstrating the optimization of cured tire uniformity.
FIG. 5 is a vector polar plot of the method of the invention showing the contribution of green tire radial runout to the tire room effect vector.
FIG. 6 is a vector polar plot of the method of the invention showing the effect on the green tire vector of the measurement drum used to measure green radial runout.
FIG. 7 is a vector polar plot of the method of the invention adding the effect of the after cure uniformity measurement machine.
DETAILED DESCRIPTION
Reference will now be made in detail to exemplary versions of the invention, one or more versions of which are illustrated in the drawings. Each described example is provided as an explanation of the invention, and not meant as a limitation of the invention. Throughout the description, features illustrated or described as part of one version may be usable with another version. Features that are common to all or some versions are described using similar reference numerals as further depicted in the figures.
Modern pneumatic tires are generally manufactured with great care and precision. The tire designer's goal is that the finished tire is free of non-uniformity in either the circumferential or lateral directions. However, the designer's good intentions notwithstanding, the multitude of steps in the tire manufacturing process can introduce a variety of non-uniformities. An obvious non-uniformity is that the tire may not be perfectly circular (radial runout or RRO). Another form of non-uniformity is radial force variation (RFV). Consider a tire mounted on a freely rotating hub that has been deflected a given distance and rolls on a flat surface. A certain radial force reacting on the flat surface that is a function of the design of the tire can be measured by a variety of known means. This radial force is, on average, equal to the applied load on the tire. However, as the tire rolls, that radial force will vary slightly due to variations in the internal tire geometry that lead to variations in the local radial stiffness of the tire. These variations may be caused on the green tire by localized conditions such as product joints used in the manufacture of the green tire, inaccurate placement of certain products. The process of curing the tire may introduce additional factors due to the curing presses or slippage of products during curing.
FIG. 1 depicts is a simplified depiction of the tire manufacturing process. A tire carcass 10 is formed on a building drum 15 . In a unistage manufacturing process, the carcass 10 remains on the drum 15 . In a two-stage process, the carcass 10 would be removed from the drum 15 and moved to a second stage finishing drum. In either case, the carcass 10 is inflated to receive a finished tread band 20 to produce the finished green tire 30 . In one variation of the invention, the RRO of the green tire 30 is measured by a measurement system 70 using a barcode 35 as a reference point. The RRO waveform is stored, here in a computer 80 . The green tire 30 is moved to the curing room where the orientation angle of the tire CAV_REF is recorded. The tire is then loaded into a curing cavity 40 and cured. The cured tire 30 ′ is moved to a uniformity measurement machine 50 for measurement and recording of the tire RFV.
FIG. 2A shows a schematic of the measured RFV for a cured tire 30 ′. The abscissa represents the circumference of the tire and the ordinate the radial force variations. FIG. 2A is the as-measured signal and is referred to as a composite waveform. The composite waveform may comprise an infinite series of harmonics. The individual harmonics may be obtained by applying Fourier decomposition to the composite signal. FIGS. 2B and 2C depict the resulting first and second harmonics, respectively, extracted form the composite signal. The magnitude of the first harmonic of radial force VRM1 is defined as the difference between the maximum and minimum force. The phase angle or azimuth of the first harmonic VRA 1 is defined as the angular offset between the reference location for the measurement and the location of maximum radial force. Thus, the sine wave depicted by Cartesian coordinates in FIG. 2B can be equally shown as a vector in a polar coordinate scheme. Such a vector polar plot is shown in FIG. 2C immediately to the right of the sine wave plot. The RFV vector of the first harmonic VRH 1 has a length equal to VRM1 and is rotated to an angle equal to the azimuth VRA 1 . In a similar manner, one can extract the second harmonic vector VRH 2 shown in FIG. 1C that has a force magnitude VRM2 and an azimuth VRA 2 . The corresponding polar plot for the H2 vector resembles the H1 vector, except that the angular coordinate is now two times the azimuth angle.
In the description of an example of the method that follows, the particular example is confined to the optimization of the first harmonic H 1 . However, it is within the scope of the present invention to apply the method to optimize a different harmonic such as H 2 , H 3 , etc. Likewise, the following example describes the optimization of radial force variation, whereas it is within the scope of the invention to apply the method to the correction of other uniformity characteristics such as cured tire radial runout or lateral force variation. In brief, the method may be used to optimize the harmonics of any measurable uniformity characteristic with suitable modifications to the vector equations described below.
FIG. 3 is a vector polar plot showing the two major contributions to first harmonic of the after cure radial force variation, the tire room effects vector TR 1 , and the curing room effects vector CR 1 when no optimization has been applied. The cured tire result VRH 1 is the vector sum of these two components. A unique attribute of the invention is the ability to optimize the after cure uniformity by manipulation of these two component vectors. The ability to treat these effects in vector space is possible only when each harmonic has been extracted.
FIG. 4 now shows a schematic of the optimization step. In this view the green tire 30 has been physically rotated by a pre-determined angle CAV_REF so that its tire room effect vector (TR 1 ) now directly opposes the curing room effect vector CR 1 , the latter being fixed if there are no changes to the setup or state of the curing equipment 40 . It is readily apparent that this optimization greatly reduces the after cure result VRH 1 .
The foregoing is a greatly simplified view of the factors affecting after cure uniformity. Both the tire room and curing room component vectors are the result of many individual factors, or sub-vectors. Each sub-vector is a contribution to the cured tire RFV and these vectors have units that correspond to radial force variation, i.e. kilograms. FIG. 5 demonstrates one such sub-vector, the effect of green tire radial runout indicated as Green RRO*gain. This sub-vector represents the vector product of the Green RRO (mm) and a gain vector that models the localized radial stiffness (Kg/mm). However, the gain vector is not a simple scalar factor as used in previous methods, but is a true vector that accounts for circumferential radial stiffness variation around the green tire 30 . The remaining, unidentified factors are consolidated in the Intercept vector 11 . If all factors were known, then the Intercept vector 11 would not exist. Throughout this disclosure, the Intercept vector 11 accounts for the unidentified effects. Thus, the tire room effect vector, TR 1 , will always be the vector sum of the specific sub-vectors and the Intercept vector 11 .
FIG. 6 further declinates the tire room sub-vectors. The measurement of green tire RRO is preferably at the completion of tire building and before the green tire is removed from the building drum 15 . In the preferred method, the measurement drum is the tire building drum 15 or whether it is the single drum of a unistage machine or the finishing drum of a two-stage machine. The green tire RRO measurement may also be performed offline in a dedicated measurement apparatus. In either case, the radial runout of the measurement drum can introduce a false contribution to the Green RRO vector. When the green tire RRO is measured, the result is the sum of true tire runout and the runout of the drum used for measurement of RRO. However, only the green tire RRO has an affect on the after cure RFV of the tire. As shown in FIG. 6 , the method of the invention includes a measurement drum sub-vector T 1 to account for this false RRO effect.
The sub-vector advantage can also be use to improve the curing room effects. An effect similar to the foregoing false RRO exists for measurement of after cure RFV. That is, the measurement machine itself introduces a contribution to the as-measured tire RFV. FIG. 8 depicts an additional sub-vector UM 1 to account for this effect showing the difference between the measured radial force vector VRH 1 and the true radial force vector TVRH 1 . This sub-vector imparts a small, but significant correction to the rotation angle CAV_REF shown in FIG. 4 for optimizing VRH 1 . Studies have shown that the inclusion of the UM 1 sub-vector can improve the magnitude VRM1 of the true radial force vector VRH 1 by about 0.5 to 1.0 Kg.
The foregoing graphical representations in vector space can now be recast as equation (1) below where each term represents the vectors and sub-vectors shown in the example of FIG. 6 . The method can be applied to additional effects not depicted in FIG. 6 nor described explicitly herein without departing from the scope of the invention.
VRH 1 =Tire Room RH 1 +Curing Room RH 1 (1)
Substituting the sub-vectors for the tire room yields the final modeling equation:
VRH 1 =(Green RRO*gain+Building Drum+Intercept)+Curing Room RH 1 (2)
or
VRH 1 = GR 1 * gn+T 1 + I 1 + CR 1 (3)
The first step in implementation of the method is to gather data to build the modeling equation. The Green RRO and VRH 1 vectors are measured quantities. The challenge is to estimate the gain vector gn, the building drum vector T 1 , the intercept vector 11 , and the curing room effect vector CR 1 . This is accomplished by vector rotation and regression analysis.
First, a reference point on the tire, such as a barcode applied to the carcass or a product joint that will be accessible through then entire process is identified. In the specific example described herein, the invention contains an improvement to account for the radial runout of the measurement drum itself. This effect may be significant when the tire building drum 15 is used as the measurement drum. The loading angle BD_REF of the tire carcass on the measurement drum is recorded. For this specific example, the loading angle is measured as the carcass 10 is loaded on either the first stage of a unistage or a second stage of a two-stage machine. It is advantageous to ensure a wide variation of the loading angle BD_REF within a given sample of tires to ensure accurate estimation of the effect of the measurement drum runout on the vector coefficients.
Next, the RRO of the finished, green tire 30 is measured by a measurement device 70 while the tire is mounted on the finishing stage building drum 15 . Alternatively, the finished, green tire may be moved to separate measurement apparatus and the RRO measurement made there. This RRO measurement is repeated for multiple tires to randomize the effects that are not modeled. There are many known devices 70 to obtain the RRO measurement such as a non-contact system using a vision system or a laser. It has been found that systems for measurement of radial runout that are based on tangential imaging are preferred to those using radial imaging. The RRO data thus acquired are recorded in a computer 80 .
Next, each green tire 30 is transferred to the curing room and the identification of the curing cavity 40 where each green tire is to be cured or vulcanized is recorded as well as the orientation azimuth CAV_REF at which each green tire is loaded into the curing cavity. It is advantageous to ensure a wide variation of the orientation azimuth within a given sample of tires to ensure accurate estimation of the curing cavity effect on the vector coefficients. After each tire has been cured, the cured tire 30 ′ is moved to the uniformity measurement machine 50 to acquire the radial force variation RFV for each tire. The RFV data thus acquired are also recorded in a computer 80 .
If the model is extended to include a uniformity machine sub-vector UM 1 , then similar steps to those outlined above for the building drum vector are applied at the uniformity measurement machine. A loading angle for the cured tire on the uniformity measurement machine UM_REF, similar to the carcass loading angle BD_REF, is recorded and stored in the computer 80 with the associated RFV data for a sample of tires. The sub-vector UM 1 can then be added to the model using the same vector analysis procedure as described herein to obtain the building drum sub-vector T 1 . The model will contain an additional pair of coefficients to obtain a magnitude UMM 1 and an azimuth UMA 1 of the sub-vector UM 1 to improve the estimation of after cure RFV.
Once these data have been acquired for a suitable sample of tires, the harmonic data are extracted from the RRO and RFV waveforms. In the present example the first harmonic data of the green radial runout GR 1 (magnitude FRM 1 and azimuth FRA 1 ) and radial force variation VRH 1 (magnitude VRM1 and azimuth VRA 1 ), respectively are extracted and stored. Each vector in equation (2) above has a magnitude and an azimuth as previously defined. The following table indicates the specific terminology.
Vector Magnitude Azimuth Radial Force (VRH1) VRM1 VRA1 Green RRO (GR1) FRM1 FRA1 Gain (gn) g θ Building Drum (T1) TM1 TA1 Intercept (I1) IM1 IA1 Tire Room Effect TRM1 TRA1 (TR1) Curing Room Effect CMI CA1 (CR1) Building Drum — BD_REF Loading Angle Curing Cavity — CAV_REF Loading Angle
Note that the BD_REF and CAV_REF are scalar quantities for the two reference angles that are recorded during the tire manufacturing steps.
To facilitate rapid application of equation (3) in a manufacturing environment, it is advantageous to use a digital computer to solve the equation. This requires converting the vector equations above to a set of arithmetic equations in Cartesian coordinates. In Cartesian coordinates, each vector or sub-vector has an x-component and a y-component as shown in the example below:
VRH 1 X =( VRM 1 )*COS( VRA 1 ), and VRH 1 Y =( VRM 1 )*SIN( VRA 1 ) (4)
where the parentheses indicate the scalar values of magnitude and azimuth of the quantity within. In like manner the independent factors are converted from polar to Cartesian coordinates:
GR 1 X =FRM 1 ·COS( FRA 1 )
GR 1 Y =FRM 1 ·SIN( FRA 1 ) (5)
CAV — REF X =COS( CAV — REF )
CAV — REF Y =SIN( CAV — REF ) (6)
BD — REF X =COS( BD — REF )
BD — REF Y=SIN( BD — REF ) (7)
I 1 X =IM 1 ·COS( IA 1 )
I 1 Y =IM 1 ·SIN( IA 1 ) (8)
The dependent vector (VRH 1 X , VRH 1 Y ) is sum of the vectors in the equations below.
VRH1 x = g · FRM1 · COS ( θ + FRA1 ) + CM1 · COS ( CA1 + CAV_REF ) + TM1 · COS ( TA1 + BD_REF ) + IM1 · COS ( IA1 ) ( 9 ) VRH1 y = g · FRM1 · SIN ( θ + FRA1 ) + CM1 · SIN ( CA1 + CAV_REF ) + TM1 · SIN ( TA1 + BD_REF ) + IM1 · SIN ( IA1 ) ( 10 )
Expanding these equations with standard trigonometric identities yields:
VRH1 x = g · COS ( θ ) · FRM1 · COS ( FRA1 ) - g · SIN ( θ ) · FRM1 · SIN ( FRA1 ) + CM1 · COS ( CA1 ) · COS ( CAV_REF ) - CM1 · SIN ( CA1 ) · SIN ( CAV_REF ) + TM1 · COS ( TA1 ) · COS ( BD_REF ) - TM1 · SIN ( TA1 ) · SIN ( BD_REF ) + IM1 · COS ( IA1 )
VRH1 y = g · COS ( θ ) · FRM1 · SIN ( FRA1 ) + g · SIN ( θ ) · FRM1 · COS ( FRA1 ) + CM1 · COS ( CA1 ) · SIN ( CAV_REF ) + CM1 · SIN ( CA1 ) · COS ( CAV_REF ) + TM1 · COS ( TA1 ) · SIN ( BD_REF ) + TM1 · SIN ( TA1 ) · COS ( BD_REF ) + IM1 · COS ( IA1 )
To simplify the expanded equation, introduce the following identities:
a=g ·COS(θ), b=g ·SIN(θ) (11)
c=CM 1·COS( CA 1 ), d=CM 1·SIN( CA 1 ) (12)
Substituting these identities into the expanded form of equations (9) and (10) yields:
VRH1 X = a · GR1 X - b · GR1 Y + c · CAV_REF X - d · CAV_REF Y + e · BD_REF X - f · BD_REF Y + I1 X ( 13 ) VRH1 Y = a · GR1 Y + b · GR1 X + c · CAV_REF Y + d · CAV_REF X + e · BD_REF Y + f · BD_REF X + I1 Y ( 14 )
The equations (13) and (14) immediately above can be written in matrix format:
VRH1 X VRH1 Y = GR1 X - GR1 Y CAV_REF X - CAV_REF Y BD_REF X - BD_REF Y 1 0 GR1 Y GR1 X CAV_REF Y CAV_REF X BD_REF Y BD_REF X 0 1 × a b c d e f I X I Y ( 15 )
When the predictive coefficients vectors (a,b), (c,d), (e,f), and (I 1 X ,I 1 Y ) are known, the equation (15) above provides a modeling equation by which the VRH1 vector for an individual tire may be estimated. This basic formulation can also be modified to include other process elements and to account for different production organization schemes. These coefficient vectors may be obtained by various known mathematical methods to solve the matrix equation above.
In a manufacturing environment and to facilitate real-time use and updating of the coefficients, the method is more easily implemented if the coefficients are determined simultaneously by a least-squares regression estimate. All coefficients for all building drums and cavities may be solved for in a single regression step. Finally the vector coefficients are stored in a database for future use. For the example of a single mold and single curing cavity, the coefficients have a physical significance as follows: (a,b) is the gain vector gn in units of kgf/mm, (c,d) is the curing room effect vector CR 1 in units of kgf, (e,f) is the building drum vector T 1 in units of kgf, and (I X , I Y ) is the Intercept vector I 1 in units of kgf.
The equations listed above are for one curing cavity and one building drum. The curing cavity and building drum are nested factors meaning that although the actual process contains many building drums and many cavities, each tire will see only one of each. Thus the complete equation may include a vector for each building drum and each curing cavity as shown below. To expand the model first requires the creation of the following matrices V ij , C ij , and X ij , where the subscript “i” denotes mold i and the where the subscript “j” denotes building machine drum j, the subscript pair “i,j” denotes a tire manufactured on building drum “j” and cured in curing cavity “i”:
V i , j = VRM1 x VRM1 y C i , j = a b c d e f I x I y
X i , j = FRM1 x - FRM1 y CAV_REF x - CAV_REF y BD_REF x BD_REF y 1 0 FRM1 y FRM1 x CAV_REF y CAV_REF x BD_REF y BD_REF x 0 1
Then the equations above can be expressed in the succinct matrix form below for a given combination of mold and building machine drum (indexed by i and j):
V i,j =X i,j ×C i,j (16)
This equation can be expanded to accommodate multiple molds and multiple building machine drums simultaneously in matrix formula below:
V 1 , 1 V 1 , 2 . . V 1 , m V 2 , 1 . . V n , m = X 1 , 1 0 . . 0 0 . . 0 0 X 1 , 2 . . 0 0 . . 0 . . . . . . . . . . . . . . . . . . 0 0 . . X 1 , m 0 . . 0 0 0 . . 0 X 2 , 1 . . 0 . . . . . . . . . . . . . . . . . . 0 0 . . 0 0 0 0 X n , m × C 1 , 1 C 1 , 2 . . C 1 , m C 2 , 1 . . C n , m ( 18 )
The final step is to apply the model to optimize the RFV of individual tires as they are manufactured according to the illustration shown in FIG. 4 . Each tire building drum carriers an identification “j” and each curing cavity an identification “i.” Each tire carries a unique identification device, such as a barcode. These identification tags allow the information recorded for an individual tire may be retrieved at a later step. At the completion of tire building, the green RRO is measured and its harmonic magnitude FRM 1 and azimuth FRA 1 are recorded along with the loading angle BD_REF of the tire on the building or measurement drum. When the green tire arrives in curing room, the curing cavity in which it will be cured will be predetermined and the curing room effect vector information for that cavity may be retrieved from the database. A reading device scans the unique barcode to identify the tire, to facilitate polling the database to find the measured and recorded tire information: FRM 1 and FRA 1 , the building drum identification, and the loading angle BD_REF. Next, a calculation is performed to estimate the tire room effect vector by the equations below. Note that equations (17) and (18) are identical in form to equations (9) and (10) above, but now are being used in a predictive fashion to estimate the tire room contribution to cured RFV.
TR1 x = a · GR1 x - b · GR1 y + e · BD_REF x - f · BD_REF y + e · BD_REF X - f · BD_REF Y + I x ( 19 ) TR1 y = a · GR1 y - b · GR1 x + e · BD_REF y - f · BD_REF x + e · BD_REF Y + f · BD_REF X + I y ( 20 )
The azimuth TRA 1 of the tire room effect vector TR 1 is the inverse tangent of the quantity (TR 1 Y /TR 1 X ), and the azimuth CA 1 of the curing room effect vector CA 1 is the inverse tangent of the quantity (d/c). Again referring to FIG. 4 , the green tire 30 is rotated so that its orientation angle CA 1 _REF relative to the curing cavity 40 is such that azimuth TRA 1 of the predicted tire room effect vector is opposed to the azimuth CA 1 of the curing room effect vector. This operation may be expressed in the equation below:
CAV — REF= 180 +TRA 1 − CA 1 (21)
The green tire 30 is then loaded into the curing cavity 40 at the orientation angle CAV_REF that minimizes RFV in the cured tire 30 ′.
When the above method is practiced with multiple tire building drums and multiple curing cavities, then all steps of the method, determining the vector coefficients, estimating the after cure RFV, and optimizing the after cure uniformity, are carried out using the specific identifiers of the process equipment. In this manner, a tire produced on any building machine can be cured in a curing cavity with an optimized level of RFV.
In the case where the tire does not have a unique identifying barcode, it is not possible to perform the entire optimization process at the curing room. In this case, the tire must be marked to indicate the azimuth TRA 1 of the tire room effect vector TR 1 while the tire is at the tire building machine. The azimuth of the tire room effect vector of the green tire is calculated using the vector-regression method, and a mark is placed on the tire corresponding to the azimuth angle TRA 1 . In addition, the curing cavity 40 has been previously marked at an azimuth (CA 1 - 180 ) diametrically opposed to the curing room effect vector CA 1 . When the green tire 30 is transferred to the curing room and arrives at the curing cavity 40 , the pre-applied mark on the tire 30 indicating the azimuth TRA 1 is aligned with the pre-applied mark on the curing cavity 40 . In this manner, the tire room effect vector TR 1 and the curing room effect vector oppose each other and the after cure VRH 1 will be optimized.
Another advantageous and unique feature of the invention is the ability to update the predictive coefficients vectors (a,b), (c,d), (e,f), and (I X ,I Y ) with the data measured from each individual tire to account for the constant variations associated with a complex manufacturing process. Because the green RRO and cured RFV of individual tires are continuously measured, the model may be updated at periodic intervals with these new production data so as to adjust the predictive equations for changes in the process. These updates may be appended to the existing data or used to calculate a new, independent set of predictive coefficient vectors which may replace the original data.
It should be understood that the present invention includes various modifications that can be made to the tire manufacturing method described herein as come within the scope of the appended claims and their equivalents. | A tire manufacturing method includes a method for optimizing the uniformity of a tire by reducing the after cure radial force variation. The after cure radial force variation vector is modeled as a vector sum of each presenting contributions arising from the tire building steps—the “tire room effect vector” and a vector representing contributions arising from the vulcanization and uniformity measurement steps—the “curing room effect vector.” In further detail, both the tire room and curing room effect vectors can be further decomposed into sub-vectors representing each radial force variation contribution for which a measurable indicator is available. For a series of tires, the method obtains such measurements as the before cure radial runout (RRO) at one or more stages of the building sequence, measurements of loading angles on the tire building equipment, and measurements made during vulcanization process. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a control system, and more particularly to a control system for an internal combustion engine.
Determining an accurate camshaft angular position or simply a camshaft position is an important factor in obtaining maximum torque from an engine equipped with a variable camshaft. Position sensors attached to the camshaft are typically used to measure the camshaft angular position. The measured camshaft position with respect to a crankshaft angular position is then calculated. However, manufacturing tolerances of the engine and of the sensors often lead to inaccurate measurement of the real camshaft position. This results in a camshaft measurement deviation.
As a consequence, different adaptation algorithms are employed to compensate for the camshaft deviation. Generally, these adaptation algorithms first lock the camshaft in a well-defined reference position, measure the camshaft position, and then compare the measured camshaft position with the well-defined reference position to obtain a measured camshaft deviation. The measured camshaft deviation is then stored in a memory. When an engine control system obtains a current camshaft position from the position sensors, the adaptation algorithm adds the measured camshaft deviation from the memory to the measured camshaft position to obtain a more accurate camshaft position. The correction of camshaft position based on these adaptation algorithms is generally time consuming, even under well-defined engine operating conditions, for example, 15 seconds during idle. Consequently, these adaptation algorithms are run only occasionally during a normal drive cycle.
In addition to manufacturing tolerances of engines and sensors, other factors such as operating temperature, also affect the accuracy of the camshaft measurement. Changes in operating temperature can cause engine expansion, and chain elongation, which, in turn, can increase camshaft measurement deviations. The inaccuracy due to the change of operating temperature also varies depending on the engine drive cycle. Using a temperature compensation look-up table, a rough estimate of the additional camshaft deviation is used to obtain the current camshaft position. However, the same engine and sensor manufacturing tolerances will also affect individual engines differently. Furthermore, the camshaft deviation due to the temperature changes also affects other diagnostic functions used by the engine control system, such as fault recognition. Thus, camshaft deviation caused by temperature changes also reduces fault recognition accuracy, which also results in a higher risk of detecting false errors and a lower detection rate of real faults.
SUMMARY OF THE INVENTION
Accordingly, there is a need for improved methods and systems for determining camshaft position. In one embodiment, the present invention provides a method of determining a camshaft position. The method includes determining a plurality of temperatures that includes a current temperature, measuring a camshaft deviation at each of the temperatures, determining a camshaft deviation gradient based on the temperatures, and updating the camshaft position based on the camshaft position measured at (a) the current temperature, (b) at least one of the camshaft deviations, (c) the camshaft deviation gradient, and (d) the current temperature.
In another embodiment, the invention provides a second method of determining a camshaft position. The method includes retrieving camshaft position data from a memory, determining a rate of change of camshaft position using the camshaft position data, approximating a camshaft deviation based on the rate of change of camshaft position, measuring a camshaft position at a current temperature, and updating the camshaft position based on the approximated camshaft deviation, and the current temperature.
In yet another embodiment, the present invention provides a camshaft position temperature compensation system. The system includes a memory that stores a plurality of camshaft positions, and a gradient processing module that is coupled to the memory. The gradient processing module determines a rate of change of camshaft position. The system also includes a temperature sensor that measures a current temperature, a camshaft position sensor that measures a camshaft position, and an approximation module coupled to the temperature sensor, the camshaft position sensor, and the gradient processing module. The approximation module approximates a camshaft position based on the current temperature, the current camshaft position, and the rate of change of camshaft position.
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims, and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 shows a vehicle with a camshaft temperature compensation system of one embodiment of the invention;
FIG. 2 is a data preparation flow chart used in one embodiment of the invention;
FIG. 3 shows a plot of camshaft deviations against temperature used in an embodiment of the invention;
FIG. 4 is a flow chart illustrating updating and approximating a camshaft position according to one embodiment of the invention.
FIG. 5 illustrates an alternative embodiment of the invention.
Before any 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 embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.
DETAILED DESCRIPTION
FIG. 1 shows a vehicle 100 with a camshaft temperature compensation system 104 . The vehicle 100 includes an engine 108 , a temperature sensor 12 positioned to measure engine temperature, and a position sensor 116 also positioned to measure a camshaft position of the camshaft (not shown) of engine 108 . Generally, the temperature sensor 112 is disposed to measure an engine oil temperature. However, other engine temperatures, such as the water or coolant temperature, can also be used. As noted, the position sensor 116 is generally positioned near the camshaft. Depending on the engine 108 used, the number of position sensors may be different. For example, there are four position sensors 116 in an engine with four camshafts. Therefore, the embodiment shown in FIG. 1 only illustrates an exemplary system.
The camshaft temperature compensation system 104 uses an adaptation algorithm module (“AAM”) 120 to calculate a camshaft difference or camshaft deviation between a known or locked reference camshaft position and the measured camshaft position from the position sensor 116 . For example, after the engine 108 is started, the AAM 120 receives a measured camshaft position from the position sensor 116 . The AAM 120 then determines a first deviation (D 1 ) based on the difference between the known or locked reference camshaft position and the measured camshaft position. The first deviation (D 1 ) along with a first temperature (T 1 ) at which the camshaft position was measured by the temperature sensor 112 , are sent to and stored in a memory 124 as a first set of camshaft position data. Similarly, a second set of camshaft position data (at a second time) including a second deviation (D 2 ) and a second temperature, (T 2 ) are also determined by the AAM 120 , and stored in the memory 124 . The number of camshaft position data sets collected and stored depends on the accuracy desired and the requirements of the vehicle 100 . For example, in a typical application or implementation five or more sets of camshaft position data are collected during the warm up cycle of the engine.
Referring back to FIG. 1 , the system 104 also includes a data preparation module (“PREP”) 126 . When the system 104 requests an update of the current camshaft position, the PREP 126 prepares the position data to be further processed by a curve fitting module (“CFM”) 128 . For example, the position data from the memory 124 can be prepared by the CFM 128 to generate a set of curve coefficients. Details of the processing performed by the PREP 126 and the CFM 128 will be described hereinafter. The system 104 also includes an updating and approximation module (“UAM”) 132 coupled to the PREP 128 . Together with the curve coefficients generated, a current temperature measured by the temperature sensor 112 , a measured camshaft position measured by the position sensor 116 , the UAM 132 then generates an updated camshaft position.
FIG. 2 shows a first flow chart 200 used in the PREP 126 ( FIG. 1 ) according to the present invention. At block 204 , a set of current position data including a current camshaft deviation (D current ) generated by the AAM 120 and a current temperature (T current ) (at which D current is measured) from the temperature sensor 112 is obtained. A set of pre-determined position data are then compared with the current position data subsequently. For example, at block 206 , at least two sets of pre-determined position data measured prior to the current position data and stored in the memory 124 are retrieved. The two sets of pre-determined position data typically include a minimum deviation (D min ), a minimum temperature (T min ) at which D min is determined, a maximum deviation (D min ) and a maximum temperature (T min ) at which D max is measured. At block 208 , T current is compared with T min threshold . If T current is less than T min threshold , T min is set to (or assigned to) T current and D min is set to D current at block 212 . Otherwise, that is, when T current is at least equal to T min threshold , T current is compared to T min threshold at block 220 . If T current is greater than T max threshold, T max is set to (or assigned to) T current , and D max is set to D current at block 224 . Potentially, as a result, a new minimum set of position data or a new maximum set of position data is obtained after block 212 or block 224 . Once the minimum or the maximum position data has been reset or determined, a plurality of curve fittings coefficients are generated. It should be understood that the minimum set of position data or the maximum set of position data can be repeatedly updated, or determined based on demand, and that multiple sets of minimum and maximum position data can also be obtained. A typical value of T min threshold is 40° C., and a typical value of T max threshold is 80° C.
At block 228 , some curve fitting coefficients required by the CFM 128 are generated based on the pre-determined or the updated position data sets. More specifically, once the pre-determined minimum temperature (T min ) or the pre-determined maximum temperature (T max ) are updated, or when the pre-determined minimum camshaft (D min ) and the pre-determined maximum camshaft deviation (D max ) are updated, the pre-determined values are used to fit a curve by a numerical method. For example, the desired curve may be a first order curve, or a straight line, and the numerical method can be a linear interpolating polynomial. Other numerical methods may be used including a least square approximation technique with a regression line. For high accuracy, regression models such as a second or a third order regression can also be used.
When the desired regression curve is a linear interpolation, a camshaft deviation due to a change of temperature is determined at block 228 as follows. After the position data from the memory 124 has been retrieved and updated as described above, curve fitting coefficients such as a rate of change of camshaft position
( “ ∂ D ∂ T ” )
with respect to temperature changes using the camshaft position data is determined as follows:
∂ D ∂ T = D max - D min T max - T min .
That is, a first difference between D max and D min , a second difference between T max and T min , and a gradient from dividing the first difference by the second difference are generated at block 228 . Using the generated gradient in the case of a linear interpolation, a deviation offset (D offset ) is also obtained at block 228 . This may be better understood by reference to FIG. 3 , which illustrates a deviation-temperature curve, a curve, or a line 300 crossing points (T max , D max ) 304 and (T min , D min ) 308 , and having a gradient 310 . The line 300 extends to an intercept at a point (0, D offset ) 312 on a deviation axis 316 . The gradient
( ∂ D ∂ T )
310 , and D offset 312 , which constitute a set of curve fitting coefficients are obtained. The sets of curve fitting coefficients are then optionally weighted depending on different determining factors such as the rotational speed or velocity and the time the last set of curve fitting coefficients was generated.
Once the curve fitting coefficients such as the gradient
( ∂ D ∂ T )
310 , and D offset 312 have been determined, the camshaft position can be updated and approximated as shown in FIG. 4 . Specifically, FIG. 4 shows a flow chart 250 of updating and approximating a camshaft position due to a change of temperature. When the system 104 requests a camshaft position update and approximation, the system 104 will also obtain a temperature reading (“T sensed ” or “7”) from the temperature sensor 112 , and a camshaft position (“P T ”) reading from the AAM 120 or the position sensor 116 , as shown in block 254 . P T is either a manufacturing tolerance compensated camshaft position when obtained from the AAM 120 , or a non-compensated position, or simply a sensed position when obtained from the position sensor 116 . UAM 132 then reads the curve fitting coefficients from PREP 126 , and approximates a camshaft deviation (“D T ”) due to the change of temperature with the curve fitting coefficients, as shown in block 258 . When a linear regression is used, the camshaft deviation due to the change of temperature is approximated as follows:
D T = D offset + ∂ D ∂ T · T sensed .
That is, the deviation due to the sensed temperature (T sensed ) is equal to a sum of D offset 312 and the product between the gradient 310 and T sensed . Alternatively, referring back to FIG. 3 , when a camshaft deviation point (T sensed , D T ) 318 is requested, T sensed is first sensed, and located on the curve 300 . The corresponding deviation D T can also be determined from a line 320 normal to the deviation axis 316 and crossing the curve 300 at the temperature T sensed . Once the camshaft deviation due to temperature change has been determined or approximated, the camshaft position, P T , is updated by summing the measured P T and the approximated temperature deviation D T , as shown in block 262 of FIG. 4 . Generally, when a camshaft deviation point (T sensed , D T ) is requested, the T sensed is first sensed. The corresponding camshaft deviation is then obtained by plugging the sensed temperature T sensed into the curve that encompasses the curve fitting coefficients.
In an alternative embodiment, the measured deviations such as D min , and D max are averaged over a number of times and temperatures, or filtered over several measurements. In yet another embodiment, a temperature threshold is used to set up the regressive curve. For example, the temperature threshold may require that an absolute difference between T min and T max is greater than a pre-determined minimum. In yet another example, the temperature threshold may require that an absolute difference between T min and T max is less than a predetermined maximum. In this way, the deviations produced by the system 100 will have a higher accuracy.
Once the temperature maximum and minimum, and the deviation maximum and minimum have been determined, a deviation threshold can be set up to validate the fault recognition. For example, when D T is beyond the deviation threshold developed, a fault recognition can be invalidated. Furthermore, with the line 300 (FIG. 3 ), a hypothetical deviation (D HYPO ) at an exemplary temperature can be determined. Once D HYPO has been determined, if T sensed does not exceed some pre-determined threshold, D T can be optionally set to D HYPO to reduce the systems response time. For example, when a hypothetical deviation is calculated at 20° C., a fault is detected only when T sensed is significantly higher than 20° C.
FIG. 5 shows an alternative system 500 embodying the present invention. System 500 includes a temperature compensation enable 504 configured to receive a temperature reading from a temperature sensor 508 (or 112 of FIG. 1 ), and a fault validity enable 512 . When the enable 504 is activated, the temperature reading is compared with an existing minimum temperature or an existing maximum temperature, as described in block 208 or block 220 of FIG. 2 , respectively. If the existing temperature limits requires an update, the enable 504 will send an enable signal to an update module 516 . Using a camshaft position reading from a camshaft position sensor 520 , a camshaft deviation is determined at a deviation determination module 524 . A temperature compensation module 526 then processes the determined deviation from module 524 , the temperature reading from sensor 508 , and the updated temperature limits, to generate a gradient 528 ( 310 of FIG. 3 ) and offset 532 ( 312 of FIG. 3 ) and a deviation validity 536 . The deviation validity 536 from the temperature compensation module 526 then controls whether the updated camshaft position, as determined in block 262 (of FIG. 2 ) (for example), should be released.
The system 500 also includes a fault threshold module 540 . When the enable 512 is activated, the fault threshold module 540 sets up a deviation threshold in which fault recognition is considered faulty. A comparison module 544 then compares the deviation reading from module 524 with the threshold. A fault validity is generated based on the comparison results. For example, a fault is valid when the deviation is within the threshold.
For ideal engine operation, the deviation should be as small as possible. Generally, the smaller the deviation, the greater or higher the alignment is between the camshaft and crankshaft. The alignment is also sometimes referred to as a timing of opening and closing of valves relative to a piston position. As described earlier, many factors affect alignment deviation (D current ). These factors include actual deviations from manufacturing tolerances and increasing wear, virtual deviations such as sensor tolerances, mounting mistakes such as misalignment of the belt or chain that drives the camshaft from a crank, and temperature effects due to sensor characteristic or different expansion within the engine 108 .
Diagnostic functions that check errors such as mounting mistakes generally compare D current with a diagnostic threshold D diagnosis to determine if, for example, the mounting mistakes are acceptable. If D current is greater than D diagnosis , a fault code is generated. To accurately generate a fault code, tolerance factors such as manufacturing, aging, and temperature are considered in determining D diagnosis . As a result, D T as determined earlier can be used to compensate for the effect of the engine temperature of the engine 108 . Specifically, D T can be used to calculate D HYPO at a defined temperature, for example 20° C. Thereafter, D HYPO at the defined temperature can be compared to D diagnosis at block 544 . In that way, the diagnostic threshold (D diagnosis ) can be lowered, and therefore the fault detection can be improved.
As should be apparent to one of ordinary skill in the art, the systems shown in FIGS. 1 and 5 are models of actual systems. In fact, the system shown in FIG. 5 is based on a model made using ASCET-SD modeling simulation software, which will automatically generate software code, and documentation based on the logical constructs created by the designer. Many of the modules and logical structures described are capable of being implemented in software executed by a microprocessor or a similar device or of being implemented in hardware using a variety of components including, for example, application specific integrated circuits (“ASICs”). Thus, the claims should not be limited to any specific hardware or software implementation or combination of software or hardware.
Various features and advantages of the invention are set forth in the following claims. | A method of determining a camshaft position. The method comprises determining temperatures, measuring camshaft deviations, and determining a camshaft deviation gradient. Embodiments of the invention may also take the form of a camshaft position temperature compensation system having a memory, a gradient processing module, a temperature sensor, a camshaft position sensor, and an approximation module. | 5 |
RELATED APPLICATIONS
[0001] This application (Attorney's Ref. No. P216567) is a continuation of pending U.S. patent application Ser. No. 12/332,272 filed December 10, 2008.
[0002] U.S. application Ser. No. 12/332,272 is a continuation of U.S. patent application Ser. No. 11/810,587 filed Jun. 5, 2007, which is now abandoned.
[0003] U.S. patent application Ser. No. 11/810,587 is a continuation of U.S. patent application Ser. No. 11/175,777 filed Jul. 5, 2005, now U.S. Pat. No. 7,226,232 issued Jun. 5, 2007.
[0004] U.S. patent application Ser. No. 11/175,777 is a continuation of U.S. patent application Ser. No. 10/215,530 filed Aug. 8, 2002, now U.S. Pat. No. 6,913,407 issued Jul. 5, 2005.
[0005] U.S. patent application Ser. No. 10/215,530 claims benefit of U.S. Provisional Patent Application Ser. No. 60/311,424 filed Aug. 10, 2001.
[0006] The contents of all related applications listed above are incorporated herein by reference.
TECHNICAL FIELD
[0007] The present invention relates to the application of coating materials and, in particular, to the systems and methods for dispensing texture material containing particulate material to a surface such as a wall or ceiling.
BACKGROUND OF THE INVENTION
[0008] To form walls, modern building methods typically employ sheets of wall material nailed and/or screwed to wall studs. The wall material may be coated with a texture material appropriate for either interior or exterior walls.
[0009] Texture materials can be applied to a destination surface in a number of different ways. For large surface areas, the texture material is typically applied with a sprayer system. Sprayer systems may be airless or may mix the texture material with a stream of pressurized air. The source of pressurized air may be a compressor, storage tank, or hand operated pump.
[0010] In other cases, such as touch up or repair of a wall or ceiling surface, only a small area need be covered with texture material. For small surfaces areas, the texture material is preferably dispensed using an aerosol system. Aerosol systems typically employ a container assembly, valve assembly, nozzle assembly, and propellant. The propellant pressurizes the texture material within the container such that, when the valve is opened, the texture material flows out of the nozzle assembly. The nozzle assembly is typically designed to deposit the texture material on the destination surface in selected one of a plurality of predetermined texture patterns.
[0011] The present invention is of particular relevance to the application of stucco or “sand texture” texture materials to small surface areas, and those applications will be described herein in detail. Stucco texture materials contain, in addition to a carrier and base, what will be referred to herein as a “particulate” material. The particulate material in stucco is typically formed by sand or other similar materials.
[0012] The need exists for improved systems and methods for applying stucco texture material to relatively small surface areas.
SUMMARY OF THE INVENTION
[0013] The present invention may be embodied as a method of applying texture material to a destination surface defining a pre-textured portion formed by a spray system and an untextured portion comprising the following steps. A flexible container defining a container opening, a container chamber, a first threaded surface, and a dispensing axis is provided. Texture material comprising a base, a carrier, and particulate material, where the particulate material is at least one of sand, perlite, cork, polystyrene chips, and foam is also provided. A sponge base defining a base opening and a second threaded surface and a resilient sponge member defining a substantially planar applicator surface and a sponge opening are provided. A sponge assembly is formed by adhering the sponge member to the sponge base such that the base opening and sponge opening are substantially aligned along the dispensing axis and the dispensing axis is substantially perpendicular to the applicator surface. The texture material is arranged within the container chamber. The sponge assembly is displaced such that the first threaded surface engages the second threaded surface to fix the sponge member relative to the container. Deliberate manual force is applied to the container to force the texture material in the container chamber out of the container member and onto the applicator surface through the container opening. At least a portion of the texture material on the applicator surface is transferred to the untextured portion of the destination surface by displacing the container member along the dispensing axis towards the destination surface with the applicator surface substantially parallel to the destination surface. The container member is then displaced away from the destination surface along the dispensing axis with the applicator surface substantially parallel to the destination surface such that an exposed portion of the particulate material on the untextured portion of the destination surface stands out from the destination surface and is visually perceptible. The carrier is allowed to evaporate such that the base adheres the particulate material to the destination surface to form a coat of new texture material that substantially matches an appearance of the textured portion of the destination surface formed by the spray system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an elevational view depicting a dispensing system constructed in accordance with, and embodying the principals in the present invention;
[0015] FIGS. 2 and 3 depict a method of using the system shown in FIG. 1 to apply texture material to a wall or ceiling surface;
[0016] FIG. 4 is an exploded section view depicting a portion of the dispensing system of FIG. 1 ; and
[0017] FIG. 5 is a section view depicting a portion of the dispensing system of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring initially to FIG. 1 , depicted therein is a dispensing system 20 constructed in accordance with, and embodying, the principals of the present invention. As shown in FIGS. 2 and 3 , the dispensing system 20 is used to apply new texture material 22 to a wall or ceiling surface 24 . Existing material 26 is present on the exemplary surface 24 , and an area 28 to be patched is shown in FIG. 2 . The dispensing system 20 is of particular significance in the context of patching the area 28 of the wall surface 24 to match the existing texture material 26 .
[0019] FIG. 2 also shows new texture material, indicated by reference character 22 a , in the process of being dispensed from the system 20 . FIG. 3 shows, as indicated by reference character 22 b , the new texture material 22 applied to the surface 24 over the area 28 to be patched.
[0020] Texture material typically comprises a base 36 , a particulate 38 , and a carrier 40 . The base 36 typically comprises a binder, a pigment, and filler material. The binder binds the remaining materials together and to the surface 24 to be coated. The pigment provides color to the applied coating. The filler is typically an inexpensive material that provides bulk to the coating without interfering with the function of the pigment or binder.
[0021] The particulate 38 in the texture material of the present invention is large enough to be visible to the unaided eye. The particulate 38 is typically sand, perlite, cork, polystyrene chips, foam, or the like. The particulate 38 provides a desirable aesthetic “look” and in some cases a functional purpose such as wear resistance or sound deadening.
[0022] The carrier 40 is typically oil or water that forms a solvent for the base 36 and thus allows the materials 22 to be in a liquid or plastic form when not exposed to air. Exposure to air causes the carrier 40 to evaporate or dry, leaving the base in a hardened form. The carrier 40 is represented by dots in the drawings; no dots are used when the texture material depicted has hardened.
[0023] The present invention is most significant in the context of patching a ceiling surface with what is referred to as stucco texture material. The dispensing system 20 may be used to dispense other texture materials, such as sand texture or stucco, but is of primary significance when applying acoustic texture material, and that application of the present invention will be described below in detail.
[0024] In the following discussion, the physical structure of the dispensing system 20 will be described in further detail. Following that, a method of using the dispensing system 20 to apply the new texture material 22 to the surface 24 will be described in detail.
[0025] Referring now to FIGS. 4 and 5 , it can be seen that the exemplary dispensing system 20 comprises a container 30 , a sponge assembly 32 , and a cap member 34 . The exemplary sponge assembly 32 comprises a sponge base 42 and sponge member 44 . The sponge member 44 defines a sponge opening 46 and an applicator surface 48 . The exemplary sponge base 42 is made of rigid plastic and is adapted to engage both the container 30 and the cap member 34 . The sponge member 44 is relatively resilient and is secured by adhesive or the like to the sponge base 42 .
[0026] The sponge base 42 and sponge member 44 of the exemplary sponge assembly 32 are made of different materials. In particular, the sponge base 42 is made of a relatively rigid plastic and the sponge member 44 is made of a resilient material such as synthetic or natural sponge or foam. This use of two different materials for the parts 42 and 44 simplifies the manufacturing process and reduces cost, but one of ordinary skill in the art will recognize that certain materials and manufacturing techniques may be used to manufacture the sponge assembly 32 out of a single piece of material. In this case, the sponge base 42 and sponge member 44 would be integrally formed and not separate members secured together as in the exemplary embodiment described herein. The exemplary sponge base 42 and sponge member 44 will be described in further detail below.
[0027] Referring now for a moment to FIG. 1 , it can be seen that the container 30 comprises a main portion 50 , a shoulder portion 52 , and a closed end 54 . FIGS. 4 and 5 show that the container 30 also comprises an opening portion 56 .
[0028] The container 30 is preferably made of a soft or resilient plastic material that is substantially impermeable to air and can be deformed by squeezing by hand. Other materials, such as paper, paperboard, metal, or the like may be used.
[0029] The exemplary main portion 50 starts out during manufacture as a cylindrical tube having a fill opening at one end and the shoulder and opening portions 52 and 56 at the other end. The new texture material 22 is introduced into a container chamber 58 defined by the container 30 . The fill opening is then closed to form the closed end 54 .
[0030] Formed on the opening portion 56 is an external threaded surface 60 and a dispensing surface 62 . A container opening 64 is formed in the dispensing surface 62 . When the closed end 54 is formed, the new texture material 22 in the material chamber 58 may thus exit the container 30 only through the container opening 64 . A dispensing axis 66 extends through the container opening 64 . In the exemplary system 20 , the opening portion 56 and container opening 64 are generally cylindrical and their longitudinal axes are aligned with each other and with the dispensing axis 66 .
[0031] As shown in the drawing, again with reference to FIGS. 4 and 5 , the sponge base 42 comprises a plate portion 70 , a mounting portion 72 , and a skirt portion 74 . The plate portion 70 defines a sponge surface 76 to which is attached the sponge member 44 .
[0032] The mounting portion 72 defines a mounting cavity 78 having an internal threaded surface 80 . The external threaded surface 60 and internal threaded surface 80 are complimentary such that the sponge base 42 may be threaded onto the container 30 to attach the sponge assembly 32 to the container 30 .
[0033] A base opening 82 is formed in the sponge base 42 . In particular, the base opening 82 extends from the sponge surface 76 to the mounting cavity 78 . When the threaded surfaces 60 and 80 are engaged with each other, the base opening 82 is substantially aligned with the container opening 64 . In addition, with the sponge member 44 secured to the sponge surface 76 , the sponge opening 46 is also substantially aligned with the base opening 82 .
[0034] The skirt portion 74 of the sponge base 42 comprises a side wall 84 defining a skirt edge 86 . The side wall 84 extends downwardly from the plate portion 70 around the mounting portion 72 . A cap surface 88 is formed on the side wall 84 . A stop portion 90 of the cap surface 88 extends radially outwardly from the side wall 84 .
[0035] The exemplary cap member 34 is or may be conventional in that it comprises a disc portion 92 and a wall portion 94 . The exemplary cap member 34 further comprises a pin portion 96 that extends from the disc portion 92 within the wall portion 94 . The wall portion 94 further defines an edge portion 98 .
[0036] The cap member 34 may be selectively attached to or detached form the sponge assembly 32 by engaging the edge portion 98 of the cap member wall portion 94 with the side wall 84 formed on the skirt portion 74 of the sponge base 42 . The edge portion 98 engages the stop portion 90 when the cap member 34 is secured to the sponge assembly 32 . However, the edge portion 98 engages the cap surface 88 such that deliberate application of manual force on the cap member 34 can remove the cap member 34 from the sponge assembly 32 .
[0037] Other systems and methods may be used to secure the cap member 34 relative to the sponge assembly 32 . For example, complimentary threaded portions may be formed on the cap surface 88 and the edge portion 98 such that the cap member 34 is threaded onto the sponge assembly 32 . Alternatively, the cap member 34 may be oversized such that it extends completely over the sponge assembly 32 and directly engages the container 30 , preferably at the transition between the shoulder portion 52 and the main portion 50 of the container 30 . If the cap member 34 directly engages the container 30 , the skirt portion 74 of the sponge base 42 may be eliminated. The cap member 34 is not essential to the principals of the present invention, and the present invention may be embodied in a dispensing system 20 without a cap member.
[0038] When the edge portion 98 of the cap member 34 engages the cap surface 88 of the sponge base 42 , the pin portion 96 extends into the sponge opening 46 in the sponge member 44 . The pin portion 96 removes at least a portion of the dried texture material 22 within the sponge opening 46 and thus facilitates re-use of the system 20 after it has initially been opened.
[0039] With the sponge member 44 secured to the sponge surface 76 and the complimentary threaded surfaces 60 and 80 securing the sponge assembly 32 onto the container 30 , the aligned sponge opening 46 , base opening 82 , and container opening 64 define a dispensing passageway 100 that allows material to flow out of the material chamber 58 .
[0040] With the foregoing understanding of the dispensing system 20 in mind, the method of use of this system 20 will now be described in detail. Initially, the area 28 to be patched is preferably cleaned and otherwise primed or prepared, although the present invention may be implemented without this preliminary step.
[0041] The main portion 50 of the container 30 is then squeezed by hand or other method such that the container 30 deforms and the new texture material 22 is forced along the dispensing passageway 100 and onto the applicator surface 48 .
[0042] As shown in FIG. 2 , reference character 22 a identifies a small portion of the new texture material 22 on the applicator surface 48 . The entire container 30 is then displaced in the direction of arrow A such that the texture material 22 a comes into contact with the surface 24 at the area 28 to be patched. Surface tension will cause at least a portion of the texture material 22 a to adhere to the surface 24 . At this point, the container 30 is displaced away from the surface 24 in the direction shown by arrow B, leaving a portion 22 b of the new texture material 22 on the surface 24 at the area 28 to be patched.
[0043] The process of squeezing the container 30 to cause the texture material 22 a to accumulate on the applicator surface 48 , displacing the container assembly 30 as shown by arrow A such that the material 22 a is deposited on the surface 24 , and then withdrawing the container 30 in the direction shown by arrow B is repeated until the entire area 28 to be patched is covered with the texture material 22 b.
[0044] The compressibility of the sponge member 44 is of significance in that the sponge member 44 does not define rigid edges or surfaces that will scrape and thus flatten the particulate within the texture material 22 . In addition, the texture material 22 a is daubed onto the surface 24 such that particulate material within the texture material 22 projects from the surface 24 in a manner similar to that obtained by an application process involving spraying. The daubing action used to apply the texture material 22 is substantially straight toward the surface 24 along the arrow A and substantially straight away from the surface 24 along the arrow B. The sponge member 44 is not wiped against the surface 24 during normal use.
[0045] To the contrary, a wiping action (movement substantially perpendicular to the direction shown by arrows A and B), would orient the particulate in the texture material 22 such that the particulate 38 is pressed into and embedded within the material 22 and does not extend from the surface 24 . Again, the idea is to match the existing texture material 26 , which in the vast majority of cases will have been blown or sprayed on using an air sprayer. The blowing process allows the particulate 38 to project out from the surface 24 .
[0046] Clearly, the cap member 34 must be removed while the system 20 is used to apply the texture material 22 to the surface 24 . After the first time the system 20 is used, the cap member 34 is fixed relative to the container such that the cap member 34 protects the sponge member 44 and facilitates re-use of the system 20 at a later time.
[0047] In particular, the dispensing system 20 is preferably distributed and sold with the container opening 64 unformed or possibly with an adhesive tab covering the container opening 64 . If the container opening is unformed during distribution and sale, the opening 64 is formed by the end user immediately prior to use by piercing the surface 62 with a sharp object such as a knife, nail, screw driver or the life. If an adhesive tab is used, the user detaches the sponge assembly 32 from the container 30 , removes the removable tab, and reattaches the sponge assembly 32 to the container 30 .
[0048] Once the factory seal on the container opening 64 is broken by a method such as just described, air may infiltrate the material chamber 58 through this opening 64 and cause the material 22 therein to harden. The cap member 34 substantially seals the opening 64 and thus prolongs the life of the dispensing system 20 after it has initially been opened.
[0049] From the foregoing, it should be apparent that the present invention may be embodied in forms other than that described above without departing from the principals of the present invention. For example, the various components 30 , 34 , 42 , and 44 are generally symmetrical about the dispensing axis 66 . (e.g. cylindrical or frusta-conical or define cylindrical or frusta-conical surfaces). This configuration of parts is relatively easy to manufacture and is thus preferred. However, the present invention may be embodied with forms that are not symmetrical about an axis of rotation, and such other forms are considered within the scope of the present invention.
[0050] In addition, containers other than the exemplary container 30 described herein may be used. For example, cylindrical cartridges with a floating piston member are often used to dispense materials of this type. Such cartridges are placed into a squeeze gun that contains a ratchet mechanism that acts on the floating piston member to force the material out of the opening. This type of arrangement could also be used in conjunction with the principals of the present invention to apply more viscous texture materials such as stucco or the like to wall surfaces.
[0051] The scope of the present invention should thus not be determined with reference to the foregoing preferred embodiment. | A method of applying texture material to a destination surface defining a pre-textured portion formed by a spray system and an untextured portion, comprising the following steps. A flexible container, texture, material, a sponge base, a resilient sponge are provided. The resilient sponge is adhered to the sponge base to form a sponge assembly. The texture material is arranged within the container chamber, and the sponge member is fixed relative to the container. Texture material is forced out of the container member and onto an applicator surface. At least a portion of the texture material on the applicator surface is transferred to the untextured portion of the destination surface by displacing the container member along the dispensing axis towards the destination surface with the applicator surface substantially parallel to the destination surface. The container member is then displaced away from the destination surface along the dispensing axis with the applicator surface substantially parallel to the destination surface such that an exposed portion of the particulate material on the untextured portion of the destination surface stands out from the destination surface and is visually perceptible. | 4 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
This application claims the benefit of French National Patent Application No. 0116713, filed Dec. 21, 2001, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates in general to the fabrication of semiconductor substrates, and more particularly, to assembling a donor wafer.
BACKGROUND
Known techniques for preparing a wafer that includes a thin semiconductor layer for forming circuitry (e.g., electronic, optoelectronic, or optical circuits or components) include Smart-Cut® type processes. In general, such processes involve implantation of a gaseous species at a controlled depth in a bulk donor wafer in order to create a weakness at a desired depth in the donor wafer, and the application of stresses to cause a separation at the desired depth due to the weakness. Molecular adhesion or wafer bonding may have been used before separation to bond a receiving wafer with a layer of the bulk donor wafer to be separated. Molecular adhesion or wafer bonding may be typical techniques by which the separated layer from the donor wafer and the receiving wafer are assembled. Once separated, further processing for producing circuits or components for the circuits in the separated layer may take place.
In some circumstances (e.g., when re-use is desired), it may be desired to subject the remaining structure of the donor wafer to further processing. The remaining structure may be the subject of mechanical, chemical-mechanical, or other polishing steps to ready remaining portions of the donating material of the donor wafer for further use. Other processing activities may involve chemical cleaning steps, relatively high temperature operations (e.g., 300 to 900° C., such as for oxide deposition), or substantially high temperature operations (e.g., 1150° C., such as for thermal oxidation in cases such as a silicon carbide wafer).
In some circumstances, it may be desired to recycle the bulk donor wafer through reuse. In such circumstances, the remaining structure may be required to be subject to additional implantation of one or more gaseous species, bonding with a receiving wafer, or further separation steps (e.g., through thermal or mechanical stresses).
Such reuse may progressively decrease the thickness of the donor wafer through consecutive removal of thin layers from the donor wafer. Progressively decreasing the thickness of the donor wafer may lead to an excessively thin donor wafer, which may not be reusable for further recycling.
There are other difficulties or deficiencies that are faced in recycling a donor wafer. There may be a high risk of fracture during predominantly mechanical operations such as when stress is applied to separate a thin layer from the donor wafer or such as when bonding is performed through CMP planarization of a surface oxide, etc. A high risk of fracture also arises for example during high-temperature heat treatment. The risk may be due to non-uniform temperatures in a donor wafer.
There may also be a high risk of fracture when an operator or processing machinery is required to handle a donor wafer. Another deficiency may involve large strains that are induced in certain operating steps when a donor wafer has been thinned through reuse. Operations such as implanting gaseous species or certain deposition steps may induce strains in thinner donor wafers that may cause the wafers to sag significantly (e.g., causing a wafer to take on a convex profile). Sagging may seriously compromise operations that require suitably flat contacting surfaces. Thus, a donor wafer may not be usable for further recycling once a minimum donor wafer thickness has been reached (e.g., a thickness at which deficiencies or drawbacks mentioned above may exist).
Discontinuing recycling at a minimum donor wafer thickness may be economically detrimental and/or inefficient in material consumption because the remaining material is typically discarded as waste material. Deficiency in this process is heightened in cases where the semiconductor material of a donor wafer is relatively expensive (e.g., is a high quality semiconductor material) or relatively fragile. For example, in the case of a standard silicon carbide wafer (e.g., a silicon carbide wafer having a standard diameter of 2 inches), a wafer thinned to about 200 μm may become unusable either because of frequent fractures during the process or because of a sag caused by implantation of gases prevents the wafer from suitably bonding to a receiving wafer.
In other applications, thickness may be relatively thin from a starting donor wafer (e.g., because wafers for a particular semiconductor material are typically offered on the market at that thickness). Gallium Nitride donor wafer may be one such example. Known techniques for producing such wafers involve using a thick eptixay technique called HPVE (Hybrid Vapour Phase Epitaxy) on an epitaxially grown substrate (seed layer) that is removed after epitaxy. This technique, however, has two major drawbacks. Firstly, it only makes it possible to obtain self-supporting wafers having a thickness of at most around 200 to 300 μm. If a greater thickness is sought, imperfect lattice matching with the seed layer may generate excessive strains. Secondly, the rate of growth using the thick epitaxy technique is extremely slow (typically, 10 to 100 μm per hour). Such drawbacks may seriously handicap manufacturing costs.
Drawbacks may also be associated with conventional techniques in which ingots of some single crystal semiconductor material such as SiC are used for producing bulk donor wafers. In conventional techniques in which ingots of semiconductor material such as SiC are used for producing bulk donor wafers, the following operating steps are typically implemented: the ingot may be cut (e.g., using a saw) into slices having a thickness of around 1 mm, each of the faces of the slice may be coarsely polished to remove crystal damaged by sawing and to obtain good planarity, and the future front face (the removal face) may be successively polished to obtain appropriate surface roughness. Such techniques, which may start from relatively thick slices, may often involve substantial losses of material during the successive polishing steps. This obviously affects the manufacturing cost.
Thus, there is a need for providing such processes and structures in a more economically advantageous and efficient way. Within this context, there may also be a need to continue recycling even when extremely small thickness is reached.
BRIEF SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, a process for repeated treatment of wafers may provided that involves preparing a reusable donor wafer for donating a thin layer of semiconductor material by assembling a donor layer of semiconductor material (e.g., a monocrystalline semiconductor material) having a thickness of plural thin layers onto a support layer (e.g., a support layer of a non-monocrystalline semiconductor material). Thus, a support layer is provided in a donor wafer that is of a lower quality or less precious than the donor layer of the wafer. With respect to “less precious,” for example, monocrystalline silicon may be considered to be less precious than monocrystalline silicon carbide or another example may be that monocrystalline material of one semiconductor may be considered to be less precious than a higher quality monocrystalline material of the same semiconductor due to differences (e.g., substantial differences) in price, availability, or usability. Such processes may be for providing an electronic, opotoelectronic, or optical component.
In one aspect, a process may be provided for transferring successive thin layers from a semiconductor material of a donor wafer to a receiving wafer. A bulk slice may be assembled that includes a donor layer of a semiconductor material and a support layer. The donor layer and the support layer may form a mechanically stable assembly, which may constitute a donor wafer. A region of weakness may be created in the donor layer at a controlled depth. The donor wafer may be bonded to a receiving wafer via the free side of the donor layer of the donor wafer. A separation may be effected in the region of weakness of the donor layer to transfer a thin layer of the semiconductor material from the donor wafer to the receiving wafer. The process may be repeated to recycle the “assembled” donor wafer without breaching the support layer of the donor wafer.
If desired, assembly of the donor wafer may be carried out by wafer bonding using polished faces of the donor layer (which may be a bulk slice) and a support (which may be the support layer). High temperature welding between polished faces may also be used for preparing the assembly. If desired, a region of weakness may be created by implanting gaseous species. In some embodiments, wafer bonding may be implemented to bond the donor wafer to the receiving wafer. Separation of the thin layer may be effected by applying stresses, especially thermal and/or mechanical stresses.
With the use of a support layer, the donor wafer may be recycled a maximum number of times to separate thin layers from the donor layer. The maximum number of times may depend on the thickness of the donor layer and the depth at which a weakness is created in the donor wafer in each cycle.
If desired, the donor layer may be a single crystal semiconductor material and the support may be a single crystal of inferior quality, a single crystal material of a different semiconductor, the same semiconductor in polycrystalline form, or the same semiconductor as a different polytype. The semiconductor material of the donor layer, support layer, or both may for example be silicon, silicon carbide, or large-gap monometallic or polymetallic nitrides. In some embodiments, the donor layer may for example have a thickness of around 100 to 300 μm. In some embodiments, the support layer may for example have a thickness of around 100 to 300 μm.
The semiconductor material of the donor layer, support layer, or both may be a large-gap monometallic or polymetallic nitride such as gallium nitride.
If desired, the support layer may be a bulk layer and may be produced for example from silicon, gallium nitride, silicon carbide, aluminum nitride, or sapphire.
Another aspect is aimed at producing donor wafers with reduced losses, and therefore with more profitable use of the starting material (in this case single-crystal SiC). A process may be provided for producing a donor wafer intended to be used in a process for transferring successive thin layers of a given semiconductor material from the donor wafer to a receiving wafer. The process may involve producing a bulk slice of the semiconductor material and assembling the bulk slice and a support in order to form the donor wafer. These techniques may alleviate some of the drawbacks in conventional technology that exists when a slice from an ingot of a semiconductor material (e.g., SiC) is used as a bulk donor wafer.
If desired, the bulk slice may be produced by sawing an ingot or by thick-film epitaxy on a seed layer. If thick film epitaxy is used, the step of removing the seed layer may be implemented.
The bulk slice may be polished only on its face that is intended to come into contact with the support. In the prior art, both faces are typically coarsely polished. Polishing may be performed to a defined degree on the face of the bulk slice and the face of the support which are intended to come into contact with each other.
Assembling the bulk slice and the support may be carried out at a temperature and for a time such that wafer bonding or welding may be achieved between the bulk slice and the support. The semiconductor material of the bulk slice may be a single-crystal semiconductor and the support may be chosen from the group comprising the same semiconductor as the bulk slice but with a single crystal of inferior quality, the same semiconductor in polycrystalline form, or the same semiconductor as a different polytype. The bulk slice, the support, or both may be silicon, silicon carbide, or large-gap monometallic or polymetallic nitrides (e.g., gallium nitride). If desired, the support layer, the bulk slice, or both may be produced from silicon, gallium nitride, silicon carbide, aluminum nitride, or sapphire. If desired, other materials may be contemplated.
Further features, objects and advantages of the present invention will become more clearly apparent on reading the following detailed description of preferred embodiments of implementation of the invention, the description being given by way of non-limiting example and with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 e are block diagrams of semiconductor materials in an illustrative sequence for preparing a reusable donor wafer and forming a thin layer from the donor wafer for forming electronic, optoelectronic, and optical circuitry in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Techniques may be provided in which the cost and inefficiency in existing recycling techniques involved in Smart-Cut® type processes may be addressed. By bonding a support layer with a donor layer, an inexpensive handle wafer for the donor semiconductor material may be provided. Costs may be reduced by employing a support layer of a less-expensive semiconductor material since the primary purpose of the support layer will be to provide mechanical support for the donor layer during processing treatment that may involve, for example, implantation of gaseous species, bonding the donor side of a donor-support assembly to a receiving wafer, separating a thin layer from the donor-support assembly, polishing after separation, and/or other further processing treatments. Lesser amounts of donor semiconductor materials may be scrapped using such techniques since a portion of the minimum thickness that is required for such processing may be fulfilled using the support layer. Bonding techniques may be implemented in such processes to use a donor layer and support layer that are made different types of semiconductor material.
In some embodiments, a starting donor wafer, that is used in a process for removing successive thin layers, may be formed by assembling a donor slice and a mechanical support. The assembling operation may be implemented using for example wafer bonding, performed on the donor slice and/or on the mechanical support and using appropriate interface bonding layers when appropriate.
A mechanical support may be chosen to have characteristics that are compatible, especially in terms of temperatures, with processing operations that will be applied to the donor wafer in successive cycles of removing thin layers from the donor slice. In this respect, one important factor may be the relationship between the thermal expansion coefficient of the material of the donor slice and that of the material of the mechanical support. Firstly, “homo-assemblies” may be distinguished, that is to say those with materials for the donor layer and for the support layer that have similar chemical and mechanical properties. Examples of such assemblies may include:
single-crystal SiC (donor) on low-quality single-crystal or polycrystalline SiC (support);
single-crystal GaN (donor) on low-quality single-crystal or polycrystalline GaN (support); and
single-crystal Si (donor) on low-quality single-crystal or polycrystalline Si (support).
When “homo-assemblies” are used, there is practically no limitation with respect to a thermal budget for producing the donor wafer. In such circumstances, the two materials are thermally well matched and the donor layer will typically be undisturbed by diffusion or the like.
“Hetero-assemblies”, as opposed to “homo-assemblies” may be considered to be assemblies in which materials for the donor layer and for the support layer have different mechanical and/or chemical properties. Examples of “hetero-assemblies” may include single-crystal SiC (donner) on Si (support), indium phosphide InP on Si, and GaN on Si. Other “hetero-assemblies” may also be implemented.
In “hetero-assembly” type cases, the thermal budget or the temperature to which the assembly may be exposed may be more limited because there may exist a thermal mismatch between components of the assembly. A thermal mismatch may result in deformation or fracture. For example, in the case of a donor wafer made of SiC (donor layer) on Si (support layer), difficulties arise with temperatures of around 900 to 950° C. being exceeded.
Another factor to be considered is the thickness of the donor slice/support assembly produced, which may be selected to be compatible with the steps of the treatment that the wafer is to undergo and selected to allow as much of the donor layer to be consumed.
Once the bonding has been carried out and if necessary strengthened by suitable treatments, this assembly may be considered a full-fledged donor wafer, which may be handled during the successive process operations of removing thin layers as if it were a conventional bulk donor wafer that is homogeneous throughout its thickness. The number of thin layers removed may be chosen essentially according to the thickness of the donor layer and the depth of the region of weakness so that the final removal is effected without the support layer being reached and without any regions of defects likely to exist at the transition between the donor layer and the support layer, being reached.
If necessary, when the assembling operation has been completed, the donor wafer may be thinned at its rear face (on the support layer side) in order to adjust the thickness of the wafer and make it compatible with downstream technological steps and with possible standards. For example, when the support layer is made of silicon, this thinning step can be very easily carried out by mechanical lapping.
EXAMPLE 1
SiC case
When a donor slice consists of single-crystal SiC, it may be assembled on a support that comprises polycrystalline SiC. The assembling operation may be carried out by direct bonding or else by producing, on the faces to be assembled, intermediate layers made of silicon oxide SiO 2 for example.
Bonding may be performed by facilitating a bonding surface of the donor layer, support layer or both to suitably bond with the donor layer and support layer. For example, in cases where the donor is layer is monocrystalline and the support is polycrystalline, an amorphous layer may be formed on the support to facilitate the bonding of the two layers. Examples of such techniques are illustratively shown in Attorney Docket No. 4717-5100 entitled “Method of Fabricating Substrates and Substrates Obtained by This Method” which was filed on Dec. 16, 2002, and which is incorporated herein in its entirety.
In terms of polarity, a SiC single crystal is, for example, bonded to a support on its Si face, whereas the C face of the single crystal is the exposed face from which thin layers will subsequently be removed. The reverse situation may also be possible. The question of polarity may occur with all materials having a hexagonal crystal structure such as GaN and AlN.
An initial polishing step on this face as well as intermediate polishing steps between two successive removal operations may preferably be carried out.
Because of the fact that the single-crystal SiC of the donor slice and the polycrystalline SiC of the mechanical support both have expansion coefficients close to 4.5×10 −6 /K, the assembly thus formed may undergo, without any damage, all the recycling, chemical cleaning, deposition and heat treatment steps associated with the Smart-Cut process for transferring thin layers.
According to a variant, the mechanical support may be made of silicon. In this case, compatibility between the support and the donor slice from the thermal standpoint may prove to be inferior, but nevertheless remains satisfactory in particular if the maximum temperatures to which the assembly is subjected during the treatments are limited. For example it may be limited, by producing the oxide layers involved in bonding the thin layer using deposition and not thermal oxidation.
Advantageously, the fabrication of the donor slice/mechanical support assembly in this example may for example involve: cutting a slice from an ingot with a thickness substantially less than the usual thickness that is conventionally used for bulk single-crystal SiC donor wafers (e.g., a thickness of around 500 μm rather than around 1 mm); performing a polishing operation that is carried out on only one of the faces of the slice; positioning the polished face in intimate contact with a face of a suitably planar polycrystalline SiC support wafer to bond them together by wafer bonding; and producing the support wafer having a thickness for example of around 200 to 300 μm (before bonding with the donor layer) typically by thick-film deposition of the CVD type. It should be noted that a low-quality (and therefore inexpensive) single-crystal SiC, or a SiC of a polytype different from that of the donor layer (for example, 6H SiC for the support and 4H SiC for the donor layer), could also be used for the support.
Additional processing steps may include, exposing the assembly to a suitable thermal budget (for example 1100° C. for 2 hours) in order to obtain suitable bonding forces between the slice and the support wafer. The degree of polishing of the contacting faces should also be taken into account so that satisfactory wafer bonding may be obtained under the aforementioned conditions. A single thick single-crystal SiC (donor layer)/polycrystalline SiC (mechanical support layer) combination wafer may thus be obtained. As a variant, it may also be possible simply to lay the wafers on top of one another and bond them together by welding (typically at temperatures of 2000° C. or higher); however, this is more demanding.
The combination wafer is then polished on the free face of the single-crystal SiC, with the standard degree of polishing, in order to end up with a single-crystal SiC layer having no buried work-hardened region and having a suitable surface roughness.
This process may thus produce donor wafers with much less loss of expensive material (e.g., single-crystal SiC) than the technique mentioned in the introduction of using bulk slices. Moreover, the donor layer and the support may be assembled upstream in-the wafer fabrication line, and therefore may not effect the process of transferring layers from the donor wafer to a receiver wafer.
The potential savings that may be achieved are even greater when the particular SiC ingot of interest is more difficult and/or more expensive to produce (e.g., a semi-insulating SiC ingot of very high purity obtained by HTCVD or of an SiC ingot having a very low concentration of intrinsic crystal defects such as dislocations and micropipes).
EXAMPLE 2
The GaN case
In the case of the use of Smart-Cut® type techniques with a GaN donor wafer, various steps employed may involve temperatures that are generally very much lower than those encountered in the case of SiC. Thus, the problem of the respective thermal expansion coefficients of the support and the donor wafer is less crucial. This may give more flexibility in the choice of support material.
In the present example, a GaN slice of a thickness for example of around 100 to 200 μm may be wafer bonded to a mechanical support made of polycrystalline or single-crystal SiC for example. As in the case of SiC, the polarity of that face of the GaN wafer which will be on the support side and, consequently, the reverse polarity of that face of the wafer on the free side, that is to say on the side from which layers are removed, may be determined in advance.
The support layer/GaN donor layer assembly becomes a fully-fledged wafer used until the donor layer has been completely or almost completely consumed in the various cycles of a Smart-Cut® process.
Techniques described herein are illustratively shown in sequences shown in FIGS. 1 a to 1 e.
Slice 10 may be the semiconductor material that will form successively transferred thin layers. Wafer 20 may be a support wafer.
In FIG. 1 b , slice 10 and support wafer 20 may be assembled using techniques illustratively described herein or using other techniques to form donor wafer 30 . In FIG. 1 c , buried region of weakness 12 may be formed at a certain depth from the free surface of donor layer 10 . Region 12 may define thin layer 101 with respect to remainder 102 of the donor layer. In FIG. 1 d , wafer bonding may be carried out between the free face of donor layer 10 (if necessary, with prior oxidation or other treatment on this face) and one face of receiving wafer 40 (if necessary, also with prior oxidation or other treatment on this face).
In FIG. 1 e , a separation is performed, especially by thermal and/or mechanical stress, at the region of weakness 12 in order to obtain, on the one hand, desired assembly 40 , 101 , typically forming a substrate for applications in electronics, optoelectronics or optics, and, on the other hand, donor wafer 30 ′ whose donor layer 10 , essentially corresponding to region 102 , has been substantially thinned down by the thickness of thin layer 101 that has been transferred.
These steps may be repeated with donor wafer 30 ′ until donor layer 10 has been almost entirely consumed, without however breaching support layer 20 .
In one implementation, steps shown in FIGS. 1 a and 1 b may be carried out on the premises of the donor wafer fabricator, whereas the following steps may be part of a separate process carried out on the premises of the fabricator of composite substrates for electronics, optoelectronics and optics industries.
Of course, the invention applies to the production of wafers comprising donor layers made of other materials, such as aluminum nitride and more generally semiconductor, especially large-gap, monometallic or polymetallic nitrides, diamond, etc., or else single-crystal silicon of very high quality for the donor layer and low-quality single-crystal or polycrystalline silicon for the support.
It is to be understood that the invention is not to be limited to the exact configuration as illustrated and described herein. Accordingly, all expedient modifications readily attainable by one of ordinary skill in the art from the disclosure set forth herein, or by routine experimentation there from, are deemed to be within the spirit and scope of the invention as defined by the appended claims. | Processes that may be used in producing electronic, opotoelectronic, or optical components may be provided. The processes may involve preparing a reusable donor wafer for donating a thin layer of semiconductor material by assembling a donor layer of a semiconductor material having a thickness of plural thin layers onto a support layer of. The semiconductor material for the support layer may be selected to be less precious or to have a lower quality than the donor layer. The support layer may have sufficient mechanical characteristics for supporting the donor layer during desired semiconductor processing treatments. | 8 |
DESCRIPTION
The invention relates to a bar screen for use in separating oversize particles from a mixture, e.g. separating thick pieces of wood chips from a mixture of wood chips.
In the cellulose industry, nearly all chip screening is done on conventional holed screens which separate the chips according to their length and breadth. It is known, however, that if chips that are too thick are used in the production of sulphate pulp, the pulp yield will be lower and the shives content higher. A new type of screen has therefore begun to be installed in sulphate mills, a so-called disk screen, which screens the chips according to their most important dimension, --their thickness. See for example "Svensk Papperstidning" 65 (22): 905. This screen comprises disks mounted on rotating shafts and has a constant distance between the disks. See for example "Svensk Papperstidning" 82 (18): 534.
The disadvantage with this screen, primarily due to its low capacity per square meter of screening surface, is that it becomes large, and thus expensive, costing about five times more than a conventional screen. The low capacity is partly due to the open area of the screen being relatively small and partly due to many chips travelling a considerable distance over the screen before they are accepted by it, thus partially blocking the open area, with resulting reduced capacity. Another disadvantage of the disk screen is that it is more demanding in energy than conventional holed screens. A disk screen operated such that the chips are lifted or thrown up before they are accepted or rejected, and this lifting work results in high energy consumption.
The invention relates to a screen with a high capacity per square meter of screening surface and with low energy consumption.
FIG. 1 is a perspective view of a bar screen embodying the present invention.
FIG. 2 is a plan view of the bar screen.
FIG. 3 is a cross-sectional view taken on line A--A of FIG. 2.
FIG. 4 is a plan view of a suitable drive mechanism for the bar screen.
FIG. 5 is a plan view of a modified form of the invention shown in the preceding drawings.
FIG. 6 is a cross-sectional view of the modified embodiment shown in FIG. 5, taken along line A--A of FIG. 5.
FIG. 1 is a perspective view of the inventive bar screen, which has parallel and sloping bars. The screening plane may slope in the direction of the bars or at right angles to them. On one side the bars 1, 3, 5 and on the other side bars 2, 4 are mutually movable. The upper side of the bars is not smooth, but has projecting portions 6, e.g. triangular flights. Chips that are fed out onto a screen fall higgledy-piggledy, as is illustrated by the different positions in FIG. 1. Only a few chips fall down directly through the gaps between the bars. In most cases (8, 9) they fall across the bars, and would block them if they were not quickly reoriented in the direction of the gaps. This is accomplished in the inventive screen by the flights 6 engaging with the chips and turning them in the direction of the gaps when the bars move. Narrow chips are thus rapidly accepted, while chips thicker than the gap are conveyed away over the sloping screen surface by the action of gravity.
FIG. 2 illustrates the inventive screen in a plan view showing the screening surface, and FIG. 3 is a section along the line A--A in FIG. 2. The bars 10, 11, 12, 13 are kept together by the end walls 14 and are suspended by links 15 mounted in screen frame side members 16. The bars 17, 18, 19 are kept together by cross beams 20, suspended by links 21 mounted in members 16. The screen thus comprises two bar arrays suspended in oscillatable links. The bar arrays are given an oscillating motion such that they move in mutually opposite directions. FIG. 4 illustrates in a plan view an embodiment of an apparatus that can be used to provide the desired oscillating movement, which is predetermined in magnitude. A motor 22 drives a shaft on which are mounted two conical gears 23, 24. On each of the two output shafts, one to each gear, there are mounted two eccentrics, each of which imparts a reciprocating motion to rods connected to the bar arrays. The connecting rods 25, 26 and 27, 28 coact to give each bar array an oscillating motion in counter direction to the other and of a predetermined magnitude. Since each bar array is actuated by two rods, a stable reciprocating motion is obtained. If the bar arrays are given the same mass and the eccentrics have a mutual angular shift of 180 degrees, the acceleration and retardation forces will cancel each other. The frame side members will therefore not need to take up any notable forces, enabling the screen to be suspended in cables mounted on the side members, for example.
The screen may also be implemented such that one bar array is fixed while the other is movable. A drawback here is that the side members are subject to a larger periodical force. One way of avoiding this is to subdivide the movable array into two or more minor arrays having opposing oscillating motion.
In the inventive screen, blockage of the gaps is avoided by the bars describing an oscillating motion. A very old way of avoiding blocking the screening apertures in a screen is to allow the screen to vibrate. The vertical component of the oscillating motion gives the same effect, but there is an additional effect from the movement of the bars in the screening plane, which assists in loosening chips that have fastened.
To still further eliminate the risk of blockage it has been found advantageous to make the gaps with "relief," i.e. they diverge in the accept direction.
For a bar screen to have good efficiency, i.e. to separate over thick chips as completely as possible, it is required that the gaps have the same size over the entire screen. This can be achieved by the bars being given greater rigidity, e.g. by the selection of a suitable profile such as a T section. Another method is to provide the gaps with spacers keeping the bars at mutual, given spacing.
However, the spacers cause friction and get rapidly worn. FIGS. 5 and 6 illustrate a novel method where rollers are placed between, and engage against, pairs of bars. When the bars move, the rollers will make a reversing rotational movement. If the screen has fixed bars, the rollers can be mounted on either the fixed or the moving bars. Another method is to mount the rollers on fixed bars, so that they bear against a moving bar on either side of the fixed bar. | A bar screen for the separation by size of lump goods, such as wood chips, according to its thickness, and comprising parallel bars (1-5) provided with flights (6), where the bars are mutually movable. | 3 |
FIELD OF THE INVENTION
The present invention relates to wearable devices for hiding items, and more specifically to wearable jewelry for hiding keepsakes and other valuables.
BACKGROUND
A locket is a jewelry pendant that has been around a long time and is well-known in the art. A locket typically consists of a front face and a back face with a hinge on one side and a ring on the top to accept a necklace. The front and back faces are typically concave surfaces that, when mated, form a shallow internal compartment. This internal compartment is usually sized to hold something the thickness of a photograph or other thin item such as a lock of hair.
Some lockets are made with a clear front face (like glass) so that a person can see what is inside without opening the locket. Such lockets are generally used for items like locks of hair which could fall out and become lost if the locket were repeatedly opened. Other lockets, like a picture locket, are generally enclosed on all sides and the photographs are secured to the inside back face by an assembly to hold the photograph to the back face but allow a viewer to see the photograph when locket is opened.
One drawback with the well-known standard prior art lockets is that the front and back faces are permanently connected to the locket. So, the locket owner has no ability to change the outside look of a locket without buying a new locket.
Another drawback of well-known standard prior art lockets is that the interior space is similar to the interior of a clam shell. Such space is suitable for a pearl or small item. But such a space is not suitable for other shaped items.
SUMMARY OF THE INVENTION
The present invention is incorporated in a wearable device (the “device”) 10 for hiding keepsakes and valuables. The device 10 comprises a front face 12 , a back face 14 , and a channel-shaped retaining assembly 16 configured to create a vault 18 (i.e., an internal hidden compartment to store a keepsake (such as a recovery medallion or chip 24 , a small notepad or photo album, money, etc.) between the front face 12 and the back face 14 .
The front and back faces 12 , 14 are preferably rigid, opaque and adorned with ornamental objects 30 or other decorations. Because the front and back faces 12 , 14 are removable when the retaining assembly 16 is in the open position, the front and back faces 12 , 14 are changeable by the user.
It is an object of this invention to create a locket that can be changed out to suit one's personal style and taste without having to switch to a completely different locket. Also, the internal hidden compartment is thick enough through the entire width of the piece to hold a coin or notepad or other keepsake thicker than standard photo paper.
The structure, overall operation and technical characteristics of the present invention will become apparent with the detailed description of a preferred embodiment and the illustration of the related drawing as follows.
BRIEF DESCRIPTION OF THE DRAWINGS OR PICTURES
FIG. 1 illustrates a perspective view of an embodiment of the wearable device 10 when the retaining ring 16 is in the open position.
FIG. 2 illustrates a front view of an embodiment of the wearable device in the closed position.
FIG. 3 illustrates section view A-A from FIG. 2 , showing an embodiment of the device 10 with an empty vault 18 .
FIG. 4 illustrates section view A-A from FIG. 2 , showing an embodiment of the device 10 with a coin-filled vault 24 .
FIG. 5 illustrates section view A-A from FIG. 2 , showing an embodiment of the device 10 with an empty vault 18 and a O-ring spacer 26 between the front and back faces 12 , 14 which maintains the open void between the front and back faces 12 , 14 when the locket is empty.
FIG. 6 illustrates section view A-A from FIG. 2 , showing an embodiment of the device 10 with an empty vault 18 and a plurality of post spacers 28 secured to the outside edge of the back face 14 which maintains the open vault space 18 between the front and back faces 12 , 14 when the locket is empty.
FIG. 7 illustrates an embodiment of a partially transparent face 35 .
FIG. 8 illustrates a perspective view of an alternative embodiment of the wearable device 10 having a partially transparent face and a backer 34 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the invention is shown in FIGS. 1-4 . Two optional embodiments for adding spacers between the front and back faces are shown in FIGS. 5-6 .
As shown in FIGS. 1-4 , the preferred device 10 comprises a front face 12 , a back face 14 , and a retaining assembly 16 . The front and back faces 12 , 14 are preferably opaque. In addition, the front and back faces are the same size and are held in place by the sides (i.e., legs) 22 of the channel which is the retaining assembly 16 when hinge 20 is in the closed position (see FIG. 2 ). When hinge 20 is in the open position, the front face 12 and back face 14 (and anything stored in the hidden compartment 18 between the front and back face) can be removed (and replaced) from the retaining assembly 16 (see FIG. 1 ).
It is preferred that the interior space between the legs 22 of the channel be wider than the thickness of the front and back faces 12 , 14 to create a space (or vault) to hold items. Configuring a device in this way creates a vault 18 (or “internal hidden compartment”) to store a personal keepsake 24 (such as a recovery medallion or chip, a small notepad or photo album, money, etc.) between the front face 12 and the back face 14 .
One way to keep the perimeter of the front and back faces against the sides 22 of the channel of the retaining assembly 16 is to add a spacer to create an internal hidden vault 18 . This spacer is placed between the legs 22 of the channel. Contents placed in the vault created by the spacer will remain hidden from view. As seen in FIG. 5 , one embodiment of a spacer is an O-ring 26 . Another embodiment of a spacer is one or more posts 28 as seen in FIG. 6 . A personal keepsake 24 can be placed in the hidden vault that is created by the spacer.
The front and back faces 12 , 14 are preferably rigid and adorned with ornamental objects or other decorations. The front and back faces 12 , 14 can also been engraved, embossed, carved or any other method of adornment. Because the front and back faces 12 , 14 are removable when the retaining assembly 16 is in the open position, the front and back faces are changeable by the user. The preferred method of securing the retaining assembly 16 is with a closing device, such as a standard lobster claw clasp (not illustrated) can be used to hold the device 10 in the closed position by connecting it to the bail 32 of the retaining assembly 16 . Other methods can be used such as a split ring, knotted cord or ribbon, or simply stringing a chain thru the bail 32 without the closing device.
In another embodiment, the front (or back) face can be transparent or partially transparent. FIG. 7 illustrates an alternative embodiment of a partially transparent face 35 . If the user desires to employ a transparent or partially transparent face, but still wants to keep vault 18 hidden, the user can insert backer 34 as shown in FIG. 8 . Backer 34 is preferably made of a colored material, but most any material of the right size will suffice.
While the invention has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those ordinarily skilled in the art without departing from the scope and spirit of the invention set forth in the claims. | This invention is embodied in a wearable device for hiding keepsakes and valuables. The preferred embodiment of the device creates an internal hidden compartment formed between a first face, a second face and a channel-shaped retaining ring. | 0 |
FIELD OF THE INVENTION
This invention relates to an improved apparatus for the formation of a uniform dry laid web of non-woven fibers. More particularly, this invention relates to an apparatus for forming uniform air laid webs by depositing dry fibers on a foraminous wire moving at high speeds.
BACKGROUND OF THE INVENTION
The production of non-woven webs involves the dry forming of fibrous materials, such as dry fibers, filaments, and particulate matter onto a moving forming surface. In systems for dry-forming fibrous materials, critical process limitations have been found to exist in systems where the speed of the forming surface increases to greater than 500 feet per minute. At such high speeds, fiber lay-down on the moving forming surface tends to become uneven in the machine direction. The deposited webs exhibit an upper surface having an undulated, wave-like or ripple effect extending in the cross-machine direction and the webs exhibit corresponding variations in thickness, and basis weight. The rippling effect worsens with increasing speed of the forming surface, and eventually renders the web commercially unacceptable when a certain high range of speed of the forming surface is used.
Commonly assigned U.S. Pat. No. 4,276,248 to Widnall describes the problems associated with the formation of dry laid non-woven webs, particularly at wire speeds of greater than 500 feet per second and offers some solution to these problems. As disclosed therein, a critical fiber velocity relationship exists which can alleviate these detrimental wave characteristics in the web. This relationship, hereinafter "formation ratio", provides that the magnitude of the difference between the foraminous wire or web horizontal velocity and the fiber horizontal velocity component divided by the vertical velocity component of the fibers should be less than 3.0, preferably less than 2.5.
Attempts to alleviate the above-described problems are described in U.S. Pat. No. 4,264,290 to Dunkerly et al. (herein "Dunkerly et al.") and U.S. Pat. No. 4,285,647 to Dunkerly (herein "Dunkerly"), both commonly assigned. These patents illustrate certain means for inducing a horizontal velocity component to dry-laid fibers. Dunkerly et al. and Dunkerly show that a suction box beneath a moving foraminous wire may be offset in the machine or downstream direction to induce a horizontal velocity to the dry-laid fibers. That is, the upstream wall of the suction box lies beneath the distributor and is displaced by a finite distance from the distributor upstream wall, while the downstream suction box wall extends beyond the distributor to draw fiber-laden air in the direction of the moving wire.
Dunkerly et al. and Dunkerly also show additional means for inducing a horizontal component to dry-laid fibers to augment the effect of offset suction. Dunkerly et al. teaches use of a plurality of foils directing air horizontally into the gap between a fiber distributor and forming wire. Dunkerly illustrates various vane and deflector arrangements directing air horizontally within a fiber distributing system above the forming wire.
The present invention provides new means for accelerating fibers in the horizontal direction to alleviate the aforementioned problems to produce a uniform dry-laid web at high speeds, and may be used alone or in combination with existing systems.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide improved apparatus for depositing a uniform web of dry fibers onto a foraminous wire moving at high speeds to alleviate the problems associated with the rippling effect of forming dry-laid webs at high speeds.
Additional objects and advantages of the invention will be set forth in part in the description which follows and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention are realized and obtained by means of the apparatus, particularly pointed out in the appended claims.
To achieve the objects in accordance with the purposes of the invention, as embodied and broadly described herein, the invention is an apparatus for depositing a uniform web of dry fibers onto a foraminous wire moving at speeds greater than 500 feet per minute in a horizontal, upstream-to-downstream direction. The apparatus comprises a fiber distributor disposed above the foraminous wire, the distributor having a plurality of connected side walls, a foraminous bottom, fiber inlet means for introducing dry fibers into the distributor and an air inlet at the top of the distributor, and means to disperse fibers on the wire moving below the distributor; a suction box disposed below the wire and offset from a relative position of the fiber distributor in a downstream direction of the moving foraminous wire; and at least one air deflector means located in the distributor above the dispersing means, said air deflector means, preferably, being movable to a deflecting position and to a second position permitting passage of an increased flow of air and fibers, said air deflector means in the deflecting position extending horizontally covering between 10% to 40% of a horizontal cross section of the distributor and positioned adjacent the downstream outermost wall of the distributor for forming a zone of low pressure beneath said air deflecting means, wherein fibers introduced into the distributor acquire a horizontal velocity component in the downstream direction which is greater than the component would be in the absence of the inlet air deflector means. In a preferred embodiment of the invention, the apparatus includes a centrally positioned fiber distributor inlet and a second fiber distributor inlet proximate to the outer upstream wall of the distributor for introducing dry fibers into the distributor. In a more preferred embodiment of the invention, the average angle of incidence of the dry fibers being deposited upon the foraminous wire is less than 50° and more preferably less than 40°, wherein the difference between the horizontal velocities of the foraminous wire and the dry fibers being deposited onto the foraminous wire is less than 2.5 times the vertical velocity component of the fibers and more preferably 1.5 times the vertical velocity component of the fibers.
The invention further provides the formation of dry-laid, non-woven webs on a foraminous wire moving horizontally in an upstream-to-downstream direction substantially free of cross-machine ripples at forming speeds of greater than 500 feet per minute. The invention comprises introducing fibers into a distributor disposed above the foraminous wire for downward dispersion of the fibers onto the moving foraminous wire, the fibers being introduced proximate the upstream end of the distributor relative to the moving wire; inducing a pressure gradient in the downstream direction by means of a suction box disposed beneath the foraminous wire offset in a downstream direction relative to the distributor and drawing air through a top end of the distributor; and creating a zone of reduced pressure in the downstream end of the distributor by use of baffling to impart an increased horizontal velocity component to the fibers being dispersed upon the foraminous wire. In a preferred embodiment, the fibers are introduced into the distributor in a central portion of the distributor in addition to introduction of the fibers proximate to the upstream end of the distributor. In a more preferred embodiment of the invention, the average angle of incidence of the dry fibers being deposited upon the foraminous wire is less than 50° and more preferably less than 40°, and the difference between the horizontal velocities of the foraminous wire and the dry fibers being deposited onto the foraminous wire is less than 2.5 times the vertical velocity component of the fibers and more preferably 1.5 times the vertical velocity component of the fibers.
It is to be understood that both the foregoing general and the following detailed description are exemplary and explanatory only and are not intended to be restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, taken mostly in cross section, illustrating the device of this invention as used with a fiber distributor and a vertically offset suction box.
FIG. 2 is a cross-sectional view across section 2--2 of FIG. 1.
FIG. 3 is a vector diagram of the fiber laden air impinging on the forming wire.
FIG. 4 is a side view, taken mostly in cross-section, illustrating the baffling means of the invention in greater detail than shown in FIG. 1.
FIG. 5 provides graphical data illustrating the effect of the invention on fiber incidence angle along the length of the distributor.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Referring to FIGS. 1 and 2, in accordance with the invention the apparatus for dry forming an air laid non-woven web is designated generally by numeral 10. The apparatus 10 comprises a distributor 11, a suction box 12, and a foraminous forming wire 13. The wire is in horizontal transit from left (upstream) to right (downstream) in FIG. 1 as indicated by the arrows, and moves along guide rolls 14 and table rolls 15 between the distributor 11 and the suction box 12. The distributor 11 is disposed above the forming wire 13 and the suction box 12 is disposed below the forming wire 13.
The distributor 11 is essentially box-shaped, and has a top end 21 open to the atmosphere, and a bottom end which is provided with a screen 22. Of course, the top end may be enclosed, and provided with air intake vents in order to provide an inlet for air. A plurality of rows of impellers 23, serially arranged in the machine direction, are located within the distributor 11 proximate the screen 22 and provide means to disperse fibers through the screen and onto the wire 13 below. The impeller shafts 24 are rotatably suspended from cross beam members 25, which are positioned in the upper region of the distributor as known in the art. Typically, the distributor of the type described has from three to ten, preferably six, rows of impellers.
In prior art machines, a centrally positioned fiber inlet conduit 26, here adapted to top entry, introduces loose fibers into the distributor pneumatically, while recycle conduit 27 recycles oversized fibers back to the fiber comminution means (not shown). Dispersion of the fibers in the distributor onto and through the screen 22 is achieved by impellers 23 as is known in the art.
The suction box 12 having outlet port 31 is disposed beneath the distributor in offset relationship as described in U.S. Pat. No. 4,264,290 to Dunkerly et al. Due to the offset, an air stream drawn into the distributor and through the suction box by vacuum producing means (not shown) in communication with port 31 has imparted to it a curvilinear flow path illustrated by dashed lines 32. Hence, fibers 16 impinging on wire 13 receive a horizontal velocity component V H as depicted in the vector diagram of FIG. 3. Thus, the fibers 16, relative to the wire 13 moving at velocity V W , have a horizontal velocity difference V F equal to the difference between V W and V H , and are incident upon the wire at an angle equal to arc tan (V V /V H ). The ripple effect as defined in U.S. Pat. No. 4,276,248, to Widnall, intrinsically associated with webs obtained from the above-described apparatus at wire speeds greater than 500 fpm is alleviated as the formation ratio, in absolute values V F /V V , decreases, the limiting value of the ratio for adequate formation being less than about three. The ratio, at a fixed vertical velocity component V V , thus decreases as V H increases and the angle decreases.
The above arrangement may be further improved according to the following features of the preferred embodiments in accordance with the invention. Since fibers from inlet 26 receive a horizontal velocity in the machine direction during residence within the distributor itself, the upstream portion of the distributor proximate to wall 41 is "starved" for fibers. The impellers 23 do not provide sufficient fiber momentum to propel the fibers toward wall 41 to thereby overcome the maldistribution problem. This difficulty is rectified by placing a second fiber inlet conduit 42 proximate the wall 41, preferably between the wall and the adjacent row of impellers 23. The amount of fibers directed to inlet 42 can be regulated by diverter valve 43 therein, or other means well known in the art.
By curing the maldistribution problem, the horizontal fiber velocity component V H can be increased thereby reducing the formation ratio. To do this the fiber free air stream entering through top end 21 is provided with a horizontal velocity component by inducing a pressure gradient in the machine direction within the distributor 11. The gradient is obtained by placing one or more baffles transversely of the wire 13 and in the distributor 11, the baffles extending inwardly from the direction of downstream wall 45. To prevent fiber accumulation above the baffles 44, it is necessary that the level at which the baffles are situated be above the outlets of the fiber inlets 26 and 42. The baffles 44 are hingeably supported by cross beam members 25, the gradient being regulated by the size of the opening 46 between a free edge of the baffle and the adjacent cross member. Typically, the baffles are at an angle of 0° to 30° and preferably between 5° and 15° from the horizontal. In lieu of hinged baffles 44, louvres with adjustable dampers can be used.
FIG. 4 illustrates, with greater detail, adjustable baffle means in accordance with the invention. The adjustable baffles 44 are mounted on the cross members 25 by means of a hinge member designated generally as 53 rotating about a hinge pin 55. The baffles 44 are adjusted by any suitable mechanical means (not shown) acting upon the hinge member 53 to raise the baffle and create an opening 57 for air flow to pass through. The position of the baffle is preferably adjusted at an angle from the horizontal between a closed position =0° or an open position where =30°. The angle of the baffle 44 and size of the opening 57 is adjusted as desired to control the air flow amount and direction to meet intended purposes. Preferably, the baffles are adjusted to an angle of between 5° and 15° from the horizontal. The baffles 44 may optionally be connected to locking means 59 for locking the baffle at the desired raised angle. Choosing a suitable type of locking means employed is within the skill of one in the art. Stationary baffle means 51 may extend substantially horizontally from the cross member 25 to the downstream wall (not shown, see 45 of FIG. 3).
Generally, 10 to 40% of the distributor cross section may be baffled, preferably 20% to 30%. Pressure gradients as measured between outer walls 41 and 45, range from a lower limit of 0.5 inches of water up to a maximum of 1.5 inches water, the normal operating range being 1.0 inches water. The induced incremental horizontal velocity component can be from 0 fpm up to 300 fpm, with the optimum incremental increase being something less than 200 fpm.
FIG. 5 illustrates graphically by curve #1 and #2 the comparative advantages that accrued in tests of the baffled and conventional units. The distributor had six rows of impellers, while the suction box was off-set by about one row. In each instance, the vertical velocity V V was 300 fpm with the wire traveling anywhere from 500 fpm to 1300 fpm, but most frequently at about 900 fpm.
The abscissa parameter is the distance travelled by the web in feet from the upstream wall 41 of the distributor, while the angle of incidence is plotted on the coordinate. Curve #1 is for an unbaffled machine; curve #2 is for a machine wherein baffles were placed above the two rows of impellers adjacent the downstream wall.
The average angle of incidence of the unbaffled machine represented by curve #1 was 82.4° which is equivalent to a V H of 40 fpm. In the baffled machine represented by curve #2 the average angle of incidence was 40.8°, and the equivalent V H was 347 fpm. The peaks at measurement locations 3, 4, 9 and 10 were caused by table rolls, such as rolls 15, which prevent wire sag. It should be noted in curve #1, the shaded peaks indicate fibers travelling in the reverse machine direction (angle of incidence of greater than 90°). Fiber approach angles of greater than 90° work against good web formation. Whereas, in the baffled configuration, the fibers are shown in curve #2 to be accelerating and travelling in the machine direction along the entire length of the distributor.
The scope of the present invention is not limited by the description, examples and suggested uses herein, and modifications can be made without departing from the spirit of the invention. For example, various suction box modifications for achieving preferred air stream flow paths are known to the art, such as partitioning the lower section thereof, and can be used in combination with the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | An apparatus for depositing a uniform web of dry fibers on a foraminous wire moving at speeds greater than 500 feet per minute including offset suction and air deflecting means within a fiber distributor for imparting a horizontal velocity component to the deposited fibers in the direction of the moving wire, also a method for depositing a uniform web of dry fibers onto a moving foraminous wire including imparting a horizontal velocity component to fibers deposited onto the wire in the direction of the wire by inducing a pressure gradient and baffling the air flow within a fiber distributor. | 3 |
FIELD OF THE INVENTION
[0001] This invention relates to new and useful improvements for footwear. More particularly, the present invention relates to footwear with an audible alarm that can be activated by the person wearing the footwear wherein when the alarm is activated it emits an alarm that will sound an acoustic alarm signal, which in turn will attract the attention of others in the vicinity.
BACKGROUND OF THE INVENTION
[0002] Subconsciously everyone fears the unexpected and wants to feel secure as they go about their daily life. More than ever these days, people fear for their personal safety. Many people are constantly thinking of new ways of protecting themselves as they return home from work, are out shopping or enjoying themselves away from the safety of their homes. Emergency alarms are usually installed in automobiles or on doors. Example of such devices is a burglar alarm characteristically of a box shape (about twice as large as a pager). However, the emergency alarm device of this invention is small and compact in size and can be installed in footwear. This compact design makes it very convenient to use, since most people wear footwear all the time for in such activities as going to work, school, exercise or when they perform sports. In an emergency situation or a situation of threatening dangers occurring at night, the wearer of a footwear with an emergency alarm device of this invention can send an alarm to request help by simply pushing the safety switch on the shoe from “OFF” to “ON” to make the electrical circuit inside the footwear operate. Sound alarm products have been made that can be carried in a purse, but locating the product in an emergency can be difficult.
[0003] What is needed is an alarm device that is always ready to be used where a person can press a button and sound an alarm for help or to frighten an attacker. The ideal device would be located in something a person wears like footwear or shoes and as is always ready in case of an emergency. By just pressing the safety switch on the footwear or on a remote control will sound an acoustic alarm signal, which in turn attract the attention of others in the vicinity. Several products have been patented that try to address this need.
[0004] U.S. Pat. No. 4,352,853 issued to Ganyard on Sep. 21, 1982 discloses an alarm toe switch. This patent covers an alarm that is intended for use in a covert manner. The footwear and switch allows the person to activate the switch and alarm without being noticed. The alarm signals people that are not located near the person wearing the footwear. When the switch and alarm is activated people or authorities that are distal from the person wearing the footwear are notified, and can provide assistance. While this patent covers a footwear alarm, it does not provide an alarm that can be heard by people near the alarm to scare away attackers.
[0005] U.S. Pat. No. 5,235,761 issued to Chang on Aug. 17, 1993 discloses multi-purpose elastic footwear. The footwear provides the basic purpose of providing an alarm, but it also provides lights, and melodies. The patent allows the use to select one of the three or more functions for the footwear. The invention does not provide for a safety switch or remote control that reduces the possibility of accidental activation of the alarm, allows the person to start the alarm from a remote control.
[0006] U.S. Pat. No. 5,343,190 issued to Rodger on Aug. 30, 1994 discloses for signaling footwear. The signaling comprises a motion sensing mechanism that activates the signaling mechanism when the shoe is in motion. The signaling consists of lights and or sound that operate while the person is walking, or moving the footwear. While this patent covers making sound, the sound is intended for entertainment, and not for signaling an alarm.
[0007] What is needed is footwear that provides a simple to operate alarm that can scare away an attacker and bring help or assistance. The ideal alarm show would be waterproof, allow for easy battery replacement, have a safety mechanism that reduces accidental activation, and offer a remote switch that can activate the alarm. The proposed invention satisfies these requirements.
BRIEF SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide an alarm that is located within footwear. The footwear alarm is intended for placement within standard footwear of nearly any style. The footwear alarm may also be a device that can be a replacement heel for footwear. The footwear may also include a safety interlock that reduces the possibility of accidental activation. Another feature of the footwear alarm is a remote control that can be used to activate the alarm in the footwear from a remote location.
[0009] The basic invention inside the footwear consists of micro-electronic component with an alarm that reaches ±100 dB, at a distance of approximately 100 meter. The alarm mechanism consists of an electrical circuit in the footwear that is waterproof. The circuit consists of a power supply with a removable or replaceable battery, safety catch for activating unit, oscillation mechanism and an audible sound device or speaker.
[0010] To be use, the activation mechanism on the footwear or on the remote control is pushed “ON” in an emergency situation to request help. This will sound the alarm and notify people that can hear the alarm that a person is in need of help or can be rescued.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an isometric view of a slip on type footwear with the safety alarm installed within the footwear.
[0012] FIG. 2 is an isometric view of sandal type footwear with the safety alarm installed within the footwear.
[0013] FIG. 3 is an isometric view of high heel type footwear with the safety alarm installed within the footwear.
[0014] FIG. 4 is a top view of a dress shoe with the safety alarm installed within the footwear.
[0015] FIG. 5 is an isometric view of an athletic shoe with the safety alarm with a remote control installed within the footwear.
[0016] FIG. 6 is a view of a schematic circuit for the safety alarm.
[0017] FIG. 7 is an isometric view of the safety alarm with the remote outside of a shoe.
[0018] FIG. 8 is a box diagram of the operation of the remote control unit and the safety alarm.
DETAILED DESCRIPTION OF THE INVENTION
[0019] As shown in FIGS. 1-5 various configurations of foot covering articles of clothing or footwear are shown. In these figures integrated electronics are installed into the footwear. A more detailed description of the electronics will be covered in future figures, but from these figures the safety switch with a remote receiver 10 is shown where the user initiates the sounding of the alarm. Each of these figures shows the safety switch with the remote receiver located in the back of the footwear, but the safety switch with the remote receiver can be located on any side of the footwear. The switch is located in the back of the footwear for several reasons including reducing the possibility of activating the alarm, and ease of ability to activate the alarm in the case of an emergency.
[0020] The electronics 20 that operate the alarm 40 are shown mounted within the footwear. These electronics are sealed, coated or protected from damage from water moisture or other contaminants that may exist on the ground. The electronics may also be molded into the shoe when the footwear is fabricated or can be located within a pre-formed cavity located in the bottom of the footwear. The electronics with all the remaining alarm components can be located in a replacement footwear heel that can be placed onto existing footwear. FIG. 3 shoes footwear with the electronics located within the lower portion of high-heal footwear. This can also be performed in dress footwear, or can be configured to located in the area between the heel and the pad of footwear. The footwear alarm that is added to existing footwear can be retained on the footwear with adhesives, Velcro or laced onto footwear. In this configuration, a single alarm can be transferred onto many type of footwear.
[0021] The alarm is powered by a single power source. In the preferred embodiment the power source is a 12V (R23) battery. This type of battery is a standard camera flash battery 30 that is available from a variety of stores. The battery is installed in a battery compartment 50 that can be opened on the side of the footwear. This battery compartment is also sealed from water or other contaminants that may damage the battery or the alarm mechanism. While the figures show the battery and the battery compartment located on the side of the footwear, these components can be located on any side of the footwear. They may also be located on the same side as the safety switch with remote receiver.
[0022] The speaker or transducer 40 is shown located at the side of the footwear to provide sound out of the side of the footwear. The speaker can be a variety of types that provide sound. In the preferred embodiment the transducer is a piezoelectric element. The piezoelectric device is used because they can emit a loud sound, and does not require a high amount of power to operate. The figure shows the speaker on one side of the footwear, but the speaker can be placed on any side of the footwear. The speaker is also show oriented to send sound horizontal to the footwear, but the speaker could be oriented in a vertical orientation, so the speaker can be larger in size.
[0023] FIG. 6 shows one variation of the speaker drive electronics. This schematic utilizes a driving circuit for a self-drive type piezoelectric buzzer. From this figure the battery 100 is connected to a switch 110 . When the switch is closed, power is supplied to the remainder of the circuit. A current limiting resistor 160 limits to amount of power to the circuit. A biasing resistor 150 set the turn on voltage for the transistor 120 that switches power to the buzzer 170 . A resistor 140 limits the voltage to the gate of the transistor. A diode 130 blocks voltage to the transistor from exceeding the gate voltage. In a simpler contemplated embodiment the alarm consists of just the switch, battery and the buzzer. The emergency alarm can be activated immediately after the safety switch embedded in the footwear's heel is “ON”. The water-proof electrical circuit embedded in the footwear's sole start working after the safety switch is “ON” by drawing power from a battery embedded in the inner heel. The footwear wearer can conveniently and quickly replace this battery.
[0024] FIG. 7 shows the electronic components located outside of the footwear. From this figure, the components are easily seen. The circuit board containing the drive electronics 20 is shown in this figure with the speaker 40 , and the safety switch with a remote receiver 10 and the battery 30 inside the battery housing 50 .
[0025] In another embodiment the circuit consists of a more intelligent activation mechanism where the safety switch in the remote receiver is connected to a time delay circuit or a microprocessor that de-bounces and or requires that the switch be closed for a period of time such as a second or more before the alarm begins to sound. The circuit may further include a timer circuit that allows the alarm to sound for a period of time that could be a fixed or variable duration of several seconds to several minutes regardless of the condition of the safety switch or the remote control transmitter and receiver.
[0026] The remote control 60 shown in FIG. 1 and 7 works like a wireless switch. When the switch on the remote control unit is operated the remote control unit sends a wireless command to the receiver. The wireless command can operate in the radio or TV frequencies or other frequency bands. The wireless transmitter may also operate as an infrared or ultrasonic transmitter. In the preferred embodiment the transmitter operated in the UHF frequency. The remote control operates Instead of requiring the user to press a button on the shoe. The control sends an on/off signal from the transmitter to the receiver to control an electronic circuit 20 that generates the alarm sound. The remote control can have a one or more button that may have different function such as activating, de-activating and delayed activation. In one embodiment when the button is held down for more that one second the alarm will sound. When the button is pressed briefly the alarm will shut-off. If the button is pressed twice the alarm will sound in ten or more seconds. Other combinations are possible using one two or more buttons or a combination of buttons. It is also contemplated that the shoe alarm remote be programmed to operate with a car alarm or other remote control device.
[0027] When the circuit for the remote control sends an on or off signal, the receiver will trigger a relay and connect power from the batteries or power supply to the sound generator circuit. The sound generating circuit will then operate the speaker or sound-making device. Prototypes have been made using a normally open relay. When operated with the remote control is operated the normally open relay closes the circuit and operates the sound-making portion of the alarm. In another contemplated embodiment the alarm can consist of a pre-recorded message that can make a statement such as “HELP HELP” or if the person has a medical condition, the alarm may say “I NEED MEDICIAL HELP CALL 911”.
[0028] FIG. 8 shows a box diagram of the operation of the remote control unit and the safety alarm. From this figure the remote control switch 200 is located in the remote control unit shown as item 60 in FIGS. 1 to 7 . When a button or a combination of buttons are pressed on the remote control unit. The remote control sends a wireless command 210 the remote control receiver 10 . The remote control receiver activates a relay 230 . The relay can also be activated with the manual switch 240 . When the relay and/or the manual switch are activated the sound generator 260 will begin to generate sound. The sound generator is connected to a speaker 40 . The power source or battery 30 is connected to the mechanism to supply power to the shoe alarm components. Components 10 , 230 , 240 , 30 , 260 , and 40 are all located within the footwear.
[0029] As previously discussed the alarm or buzzer can be a variety of types. In the preferred embodiment of the alarm, samples have been made that reaches ±100 dB, at a distance of approximately 100 meter.
[0030] The safety switch can be a variety of types that reduce the possibility of accidental activation, but also allow easy activation is the case of an emergency. The switch must provide high reliability and must not be affected by contaminants such as water or dirt. In another contemplated embodiment the activation of the alarm can be made from pressing a remote activation switch that provides a wireless link to the footwear alarm. In one embodiment, the safety switch allows the operator to rotate the switch to arm the switch and then depress the switch to activate the alarm. The safety switch may also require a de-activation sequence to silence the alarm. In one contemplated de-activation sequence, the sequence may include both pulling out the switch and rotating the switch to stop the alarm from sounding.
[0031] The footwear alarm comprises of a shoe or other similar foot covering or protecting article that contains a sound producing mechanism integrated within the footwear. To activate the sound producing alarm, a switch or similar activating mechanism is depressed, turned, removed, altered to enable the sounding mechanism. The footwear can be any type of shoe such as sandals, high-heel shoes, athletic shoes. The sound producing mechanism is integrated in to the footwear and is over-molded, conformal coated, or otherwise protected from water or other elements that may cause damage or undesirable performance from the alarm mechanism. The switch that activates the alarm can consist of a momentary switch, multi-position switch, a removable activation safety mechanism or operate with a remote control transmitter and receiver. The activation mechanism may be a wireless or wired remote control that is separate from the footwear. In the preferred embodiment, power to the alarm is supplied with a sealed replaceable power source.
[0032] In another embodiment of the invention the footwear alarm is a separate unit that can be installed onto an existing article of footwear. The separate footwear alarm can be installed onto the footwear as a replacement heel, or can be attached to the underside of the footwear. The attachment location of the separate alarm can be in the location between the heel and the ball of the foot. Another potential attachment location can allow the alarm to wrap around the heel of the shoe. It is also contemplated that the separated footwear alarm is laced into the top of a shoe. The attachment of the separate footwear alarm can be from a variety of methods including but not limited to glue, adhesives, nails, screws, brads or something other than glue, adhesives, nails, screws, or brads.
[0033] Thus, specific embodiments and applications for footwear with an integrated alarm have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. | This invention discloses an emergency alarm device that can be installed in footwear of all types. This device can be activated by the wearer of the footwear who is in danger or emergency situation and is in need of help from other persons. The wearer simply pushing to “ON” a safety switch on a hand held remote control or on the back of the footwear heel or on both sides to cause a water-proof electrical circuit within the footwear to operate using power from a battery. This electrical power is converted into sound energy and then sent to an audio amplifier or a speaker, generating a loud alarm of approximately 100 decibels per 1 shoe. The sound of alarm can be immediately deactivated by reinserting the safety mechanism back in its original place. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 488,606 filed July 12, 1974 now abandoned which application in turn is a division of application Ser. No. 380,180 filed July 17, 1973 (now U.S. Pat. No. 3,842,427 ).
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to apparatus for producing electrical energy and has particular reference to a compact mechanically-powered electric generator suitable for use as an integral power source in a camera or other device.
2. Description of the Prior Art
Photographic cameras having mechanically actuated and driven generators that produce an electric current which fires a photoflash lamp or energizes other devices in the camera are well known in the art. A camera having such an electric generator wherein a voltage pulse is produced by a flat coil of wire that is attached to the camera shutter and propelled into the gap of a permanent magnet when the shutter is tripped is disclosed and claimed in U.S. Pat. No. 3,709,118 issued Jan. 9, 1973 to the present applicants. The "built-in" electric generator replaces the batteries normally employed in the camera and thus eliminates the aggravating problem of lamp misfires due to weak or dead batteries and high-resistance contacts with the terminals of the batteries.
A camera having a flap-type shutter with a permanent magnet that enters a stationary wire coil when the shutter is actuated and thus generates a voltage which "fires" a thyratron tube in an external electrical circuit that flashes a gaseous discharge lamp is described in U.S. Pat. No. 2,538,577 issued Jan. 16, 1951 To C. W. McCarty. A camera having a magnetic circuit with an oscillating core element which generates a voltage and fires a photoflash lamp when the shutter is actuated is disclosed in U.S. Pat. No. 3,480,808 issued Nov. 25, 1969 to H. F. Reith. A camera with an electric generator wherein the voltage is produced by a magnet which is rotated when the shutter is tripped is disclosed in Japanese Pat. No. 39-22075 published Oct. 7, 1964.
Various other types of electric generators per se that produce electrical energy in response to changes in the flux density or flux distribution in a magnetic circuit as disclosed in U.S. Pat. Nos. 2,426,322; 2,784,327; 2,904,707; 3,065,366; and 3,500,086.
Camera flashguns having integral electric generators comprising a permanent magnet and a pivoted armature that is actuated manually by a shutter-release cable or by a leaf spring are disclosed in U.S. Pat. Nos. re 22,433; 2,448,897 and 2,490,225.
While the prior art cameras with integral electric generators greatly simplified the picture-taking operation by eliminating the batteries and the various problems they created, further improvements which will reduce the cost and size of the generators would be highly desirable, particularly in view of the continuing trend to make cameras as compact and reliable as possible. It would also be desirable to increase the electrical out-put of such mechanically-powered generators without increasing their physical size and, preferably, to accomplish this with a generator that is more compact and can be easily and automatically cocked.
SUMMARY OF THE INVENTION
The foregoing objectives and additional advantages are achieved in accordance with the present invention by placing a small but powerful permanent magnet within the camera housing which provides a magnetic circuit that includes the pole pieces of the magnet and a movable keeper that is rapidly shifted relative to the pole pieces and thus effects a sudden change in the reluctance of the magnetic circuit. The keeper is latched in spring-loaded position when the shutter is cocked and is released in synchronism with the actuation of the shutter. The resultant change in the reluctance of the magnetic circuit causes a wire coil disposed on one of the pole pieces to generate a voltage pulse which fires a photoflash lamp mounted on the camera and thus produces the additional light necessary to properly expose the film while the camera aperture is open.
According to a preferred embodiment, the keeper is returned to its original spring-loaded position by a cam that is coupled to the film-advancing and shutter-cocking mechanism and the latter is also coupled to a socket which holds a multi-flashlamp unit and indexes a fresh flashlamp into position for the next picture.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention will be obtained by referring to the exemplary embodiments shown in the accompanying drawings, wherein:
FIG. 1 is a simplified illustration of an electric generator and circuit means according to the invention which automatically fires a flashlamp in synchronized relationship with the operation of the shutter of a camera;
FIG. 2 is a schematic representation of the magnetic and electric circuits defined by the various components of the generator shown in FIG. 1;
FIG. 3 is a simplified front elevational view of a camera which includes the electric generator, photoflash lamp and interconnecting circuit shown in FIGS. 1 and 2;
FIG. 4 is an enlarged front elevational view of the interior of a more sophisticated camera which includes a compact electric generator similar to that shown in the precedings figures and is provided with a multiflash unit (shown in dotted outline);
FIG. 5 is an enlarged plan view of the top of the camera shown in FIG. 4, portions of the camera housing being removed for illustrative purposes;
FIG. 6 is an enlarged elevational view of the opened back of the camera shown in FIGS. 4 and 5, portions of the camera housing being removed to illustrate the gear train, etc.;
FIG. 7 is a perspective view of the electric generator, the shutter mechanism and the film-advancing and socket-rotating mechanisms employed in the camera shown in FIGS. 4-6;
FIGS. 8 and 9 are elevation view of the electric generator, the shutter-tripping mechanism and the push-button linkage system during and after tripping of the generator, respectively;
FIG. 10 is an elevational view of the electric generator employed in the camera shown in FIGS. 4-6 after the keeper has been tripped and one of the photoflash lamps in the multiflash unit is about to be fired; and
FIG. 11 is a composite graph illustrating the manner in which the voltage pulse produced by the electric generator of the present invention, the light output from the fired photoflash lamp, and the opening of the camera aperture by the shutter mechanism of the camera shown in FIGS. 4-6 are synchronized.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic concepts involved in generating the desired pulse of electrical energy in accordance with the invention are depicted in FIG. 1. As illustrated, the electric generator EG includes a permanent magnet 10, spaced pole pieces 12 and 14 that extend from the magnet, a coil 16 of fine wire disposed on at least one of the pole pieces (pole piece 12 in the drawing), and a movable member or keeper 18 that is hinged to one of the pole pieces 14 and is swung by a leaf spring 20 toward the other pole piece 12. The keeper 18 is made of ferromagnetic material (preferably the same material from which the pole pieces are fabricated) and, when swung by the spring 20, is magnetically attracted into bridging relationship with the pole pieces 12 and 14--thus rapidly changing the reluctance of the magnetic circuit. The resulting rapid change in the flux distribution in the magnetic circuit causes the wire coil 16 to produce a voltage pulse that is delivered by suitable conductors 19 to an electrical device, such as a photoflash lamp P that is associated with a camera. The generator EG can thus be characterized as a "magnetic-flux" type generator.
The keeper 18 is held in raised position against the action of the spring 20 by a suitable latch means 22 that is actuated by the same mechanism in the camera that actuates the shutter. The generation of the voltage pulse by the coil 16 and the firing of the photoflash lamp P are thus synchronized with the movement of the shutter in such a manner that the light from the flashlamp illuminates the scene being photographed when the aperture of the camera is opened.
As shown schematically in FIG. 2, the magnetic circuit (indicated by arrows and connecting dotted lines) is defined by the magnet 10, the pole pieces 12 and 14 and includes the keeper 18 when the latter has been tripped and is in bridging relationship with the ends of the pole pieces. The electrical circuit consists of the wire coil 16, the conductors 19 and the resistance R L of the photoflash lamp P. The voltage pulse produced by the magnetic-flux generator EG is so correlated with respect to the resistance R L of the photoflash lamp filament that the current i which flows through the electrical circuit is sufficient to rapidly and reliably fire the flashlamp P.
The reluctance of the magnetic circuit can be changed in four different ways: (1) by pulling the keeper off the pole pieces, (2) by placing the keeper onto the pole pieces, (3) by sliding the keeper on or off of the pole pieces, and (4) by rotating or sliding the keeper past the pole pieces without actually touching them.
Experiments and a computer study demonstrated that pulling the keeper 18 off the pole pieces 12, 14 or placing it onto the latter would generate the most voltage and that the voltage magnitude increased as long as the keeper 18 was accelerating. The "closing" keeper design is preferred (and is illustrated) because the force exerted on the keeper 18 increases rapidly as the gap decreases and the force required to push the open keeper 18 off the latch 22 is in keeping with the small push-button force need to trip the shutter of a camera.
As shown in FIG. 3, the electric generator EG and latch 22 together with the conductors 19 comprise integral parts of an apparatus such as a camera 24 that has a housing 26, a lens 28 and a shutter 30 that opens an aperture (not shown) and exposes film when the shutter is tripped. The housing 26 encloses the generator EG and is provided with a rotatable socket 31 that releasably holds a flashcube 32 that contains four photoflash lamps P and is rotated through 90° each time the film-advancing mechanism of camera 24 is operated, thus indexing a fresh lamp P into firing position in the well-known manner.
The camera shutter 30 is actuated by a spring-loaded striker member 33 that is released by a pushbutton 34 located at the front and upper left-hand portion of the camera housing 26 (as viewed in FIG. 3). The required synchronization of the operation of the generator EG and resultant flashing of the lamp P with the opening of the aperture by the shutter 30 is achieved by a lever 36 that is attached to the push-button 34 and is so configured that its free end engages the elevated end of the keeper 18 when the latter is in its cocked position. When push-button 34 is pressed downwardly, lever 36 releases the striker member 33 (which actuates the shutter 30) and simultaneously pushes the keeper 18 away from the latch 22 so that the keeper rapidly drops into bridging position across the pole pieces 12 and 14 of the permanent magnet 10. The resulting voltage pulse generated by the wire coil 16 thus fires the photoflash lamp P in synchronism with the opening of the camera aperture.
The mass of the keeper 18 and the distance it travels (when tripped) are so small that there is no perceptible vibration or movement of the camera when the generator is actuated. The picture-taking operation is thus normal in all respects.
According to this embodiment, keeper 18 is returned to its original latched (cocked) position by another lever 38 that is coupled to and actuated by the film-advancing and shutter-cocking mechanism (not shown). Thus, the generator EG and shutter 30 are both returned to their cocked positions by the film-advancing lever (or knob) located at the back of the camera 24.
A more sophisticated camera and electric generator are shown in FIGS. 4-6 and will now be described. As illustrated, the camera 40 in this embodiment is similar to and of the same compact size as "Instamatic" type cameras marketed by the Eastman Kodak Company. It has a housing 42 of molded plastic that includes a front panel 44 and a hinged back panel 45 that serves as a door for loading and unloading a film cartridge 46 (see FIG. 6) into the camera. The front panel 44 houses a push-button 47 and a lens 48 that is shielded by an annular shroud 49 (shown in FIG. 5).
In FIG. 4 the front panel 44 has been removed to show the structural arrangement of the various mechanisms. As illustrated, an electric generator EG (consisting of the permanent magnet 10, pole pieces 12 and 14, wire coil 16, hinged keeper 18 and spring 20 pursuant to the invention) is disposed on the side of the camera housing 42 that is opposite the mechanism which cocks and triggers the shutter 50. The shutter-actuating and film-advancing mechanisms are of the standard type used in compact cameras of this kind and, as illustrated, generally consist of a pawl 51 on a striker member 52 which pivots about a pin 53 and is concurrently carried in a downward direction (as viewed in FIG. 4) along with a reciprocably movable carrier 54 to which it is attached. This carrier 54 rides within a channel defined by a plate 55 that is secured to internal portions of the camera housing 42 and holds the carrier 54 and rotatable shutter 50 in place.
Carrier 54 has a tongue 56 (FIG. 4) which is engaged by a slot recess (element 95 in FIGS. 8 and 9) on the internal surface of the push-button component 47 which is movably mounted on the front panel 44. Thus, when the push-button 47 is depressed, carrier 54 is also depressed along with striker 52 which is subsequently tripped and actuates the shutter 50 in the manner hereinafter described. After the picture is taken and push-button 47 is released, the carrier 54 and button are automatically returned to their original positions by the action of a spring 57 (FIG. 4) that is attached to the carrier and a cleat 58 on plate 55.
In FIGS. 4 and 5, the shutter-actuating mechanism and electric generator EG are shown in cocked position ready to be triggered when the push-button 47 is depressed. As the striker 52 is carried downwardly with carrier 54, a shoe 59 engages and slides around a curved guide 60 provided at the top of holding plate 55, thus swinging the striker 52 about the pivot 53 against the action of a spring 61 that encircles the pivot and is held in place by a tab 62 on the striker and a second tab 63 on the carrier 54. Upon further downward movement of the carrier 54 and striker 52, shoe 59 drops clear of guide 60 thus releasing the striker which is then rapidly rotated by the action of the tensioned spring 61. Just before striker 52 is rotated, pawl 51 on the end of the striker engages a tongue 64 on the shutter 50 (as indicated by the phantom showing of pawl 51 in FIG. 4), thus causing the shutter 50 to be flipped in a counterclockwise direction against the action of a coupled spring (not shown) and then be immediatedly returned to its position of rest against a protruding tap 65 on the holding plate 55. Thus, a circular hole 66 in plate 55 (which hole constitutes the aperture of the camera 40) is opened for a precisely controlled period of time sufficient to properly expose the film located in the chamber at the back of the camera.
In accordance with this particular application of the invention, the keeper 18 of the electric generator EG is cocked at the same time that the shutter-actuating mechanism is cocked and the film is advanced. This is achieved by a cam 67 (shown in FIGS. 4 and 5) that is rotatably anchored to an internal part of the camera housing 42 by suitable bushings 68 and has a gear 69 which meshes with a larger gear 70 rotatably fastened to the housing. Gear 70 carriers a socket 71 which is configured to releasably hold a multi-flash lamp unit 72 (shown in dotted outline on top of the camera 40 in FIGS. 4 and 5). Gear 70, in turn, engages a third gear 73 which is integral and rotates with the film-advancing wheel 74 that protrudes slightly beyond the back of the camera 40 (as shown in FIG. 5).
As is best seen in FIG. 7, after the picture has been taken and film 75 has been exposed, the keeper 18 is disposed in bridging contact with pole pieces 12 and 14. Rotation of film-advancing wheel 74 prior to taking of the next picture rotates gears 73, 70 and 69 and causes a cam-follower 76 (which is rotatably fastened to the end of the keeper 18 and engages the surface of cam 67) to be forced upwardly, along with the keeper 18, until the latter engages and is held in raised or cocked position by an auxiliary magnet 78 (see FIGS. 4, 5) that is secured to the camera housing 42 and thus serves as the latch means for the electric generator EG.
As will be noted in FIGS. 4 and 5, keeper 18 is held in proper alignment with the pole pieces 12 and 14 of the generator EG by a cap-like cowl 79 that is attached to the camera housing 42.
The gear ratios in the gear train coupling the rotatable socket 71 with the film-advancing wheel 74 are correlated to permit the use of a multiflash unit 72 (shown in phantom in FIG. 4) that contains twelve photoflash lamps P. The unit 72 is automatically rotated in such a manner that the lamps are sequentially indexed into firing position when wheel 74 is rotated to advance the film and simultaneously cock the shutter-actuating and generator-latch mechanisms of the camera 40. This is achieved by making the ratio of gears 70 and 73 such that the socket 71 is rotated through an angle of 30° each time the wheel 74 is rotated through one cycle required to advance the next position of the film into position for exposure. The ratio of gear 69 is such that cam 67 rotates 90° during this interval so that the cam-follower 76 on keeper 18 rides up the inclined portion of the cam 67 and raises the keeper into its latched and cocked position against magnet 78 (shown in FIG. 4). The surface of cam 67 is divided into two identically-shaped segments for this purpose.
Cocking of the shutter-actuating mechanism during the aforesaid cycle or interval is effected by a cog 80 that is integral with and disposed beneath gear 70 (as shown in FIGS. 4-7) and has twelve teeth 81. The latter are so spaced that one of them engages a tab 82 on the end of the striker 52 (see FIG. 5) and rotates the latter into its cocked position as the wheel 74 is being rotated through one cycle. Striker 52 is locked in cocked position by a spring-loaded stop mechanism 83 which is triggered (as the striker swings into cocked position) and pushes a stop (not shown) against the teeth of wheel 74.
As shown in FIGS. 6 and 7, coil 16 of the generator EG is electrically connected by wires 19 to a pair of stationary contacts 85 disposed within the socket recess 86 provided in the top wall of the camera housing 42. The multiflash unit 72 (see FIG. 4) has a base portion 87 which is suitably shaped and holds the lead wires of the individual photoflash lamps P in such a position that they engage the contacts 85 of the camera 40 as the inserted multiflash unit is sequentially indexed in 30° steps by the gear 70 and socket 71.
As will be noted in FIG. 6, camera housing 42 defines two generally cylindrical chambers 87 and 88 which accommodate a film cartridge 46 and permit a sprocket 90 on resetting wheel 74 to automatically engage the take-up reel (not shown) of the film cartridge in the usual fashion when the cartridge is inserted into the camera 40. Rotation of wheel 74 rolls the film 75 past an opening 91 in the housing 42 that is aligned with the camera aperture 66 in the holding plate 55. The film is locked in position by a pin 92 that engages an opening in the edge of the film in the usual manner when the stop-mechanism 83 is triggered.
Composition of the picture to be taken is accomplished by looking through a conventional viewer 93 located at the upper left-hand corner of the camera 40, as seen from the rear as shown in FIG. 6. After the film cartridge 46 is loaded into the camera 40, the rear panel 45 is closed and locked in place to provide a light-tight film chamber.
As shown in FIGS. 4 and 7, the compact electric generator EG is so positioned within the camera 40 that none of the generator components or the keeper-cocking and releasing mechanisms interfere with the proper exposure of the film 75 by the light passing through the lens 48 and aperture 66 in holding plate 55.
As depicted in FIG. 7, the magnetic-flux generator EG has just been actuated and keeper 18 is disposed in bridging contact with pole pieces 12 and 14 of the magnet 10 and cam-follower 76 is resting on the flat part of the surface of cam 67. The aperture 66 is closed by the shutter 50 and the tab 82 of striker 52 is positioned to be engaged by the next tooth 81 of cog 80 when the gears 69, 70, and 73 are actuated by rotation of the film-advancing wheel 74. At this point in time, the photoflash lamp P of the multiflash unit 72 that was previously indexed into electrical engagement with the socket contacts 85 has just been fired by the voltage pulse delivered from the wire coil 16 by the conductors 19.
The phantom showing of pawl 51 in FIG. 7 illustrates the manner in which it engages tongue 64 of the shutter 50 when the striker 52 is depressed by the downward pressure on the push-button 47.
The electric generator EG and the shutter 50 are actuated in a predetermined time-sequence such that the photoflash lamp P is fired in synchronism with the opening of the camera aperture 66 and properly exposes the film 75. This is accomplished by the mechanism shown in FIGS. 4, 5, 7 and more particularly in FIGS. 8 and 9. As shown, such mechanism consists of a lever 93 that is attached to and moves along with the push-button 47. As will be noted in FIG. 5, the lever 93 is movable relative to the front panel 44 of the camera housing 42 and is of such length and configuration that an offset arm 94 at its free end is positioned above the keeper 18 when the latter is in its elevated and cocked position. A slot recess 95 on the inner surface of a depending part of the push-button component 47 engages the tongue 56 (FIG. 4) on the carrier 54. Thus, button 47 actuates both the shutter-tripping and generator-tripping mechanisms in a prescribed manner and time-sequence.
In the case of a twelve-lamp flash unit 72 of type shown in FIGS. 4 and 5, the electric generator EG flashes a selected lamp P in the unit. This is illustrated in FIG. 10 which depicts the generator EG just after it has been tripped and keeper 18 is being swung down onto the pole pieces 12 and 14. Coil 16 is in the process of generating a voltage pulse which will be delivered by conductors 19 to a preselected lamp P in the flash unit 72 and ignite it.
As shown in FIG. 8, when button 47 is depressed during the taking of a picture, lever 93 is also depressed and its offset arm 94 engages the end of the keeper 18. At this point in time, the pawl 51 of the striker 52 has just engaged the tongue 64 of the shutter 50 (as indicated by the phantom outline of the pawl). Further movement of button 47 causes the lever 93 to push the keeper 18 away from the magnetic latch and concurrently causes the striker 52 to flip the shutter 50 into its aperture-open position. The latch can also be a suitable mechanical latch. As shown in FIG. 9, when the aperture 66 is completely open, the keeper 18 has already been propelled into bridging contact with the pole pieces 12 and 14 and the voltage pulse has already been generated by coil 16 and ignited photoflash lamp P.
The synchronization of the voltage pulse, the flash of light produced by the ignited photolamp P and the opening of the aperture 66 achieved by the above-described structure is depicted graphically in FIG. 11. As there shown, the generation of the voltage pulse (curve 96) is so correlated that the voltage reaches a peak of over 10 volts at approximately five milliseconds after the electric generator EG is tripped and just about at the time that the camera aperture 66 begins to open (curve 97). The camera from which the data shown in FIG. 11 was obtained had a fixed shutter speed such that the aperture began to open at approximately four milli-seconds after the electrical generator EG was actuated (at 0 milliseconds) and was completely closed 20 milliseconds later, as indicated by curve 97. The photoflash lamp P was ignited at about the same time that the voltage pulse (curve 96) reached its peak value and the light flux (curve 98) produced by the lamp reached its maximum value at about 10 milliseconds after the electrical generator was tripped and then gradually decreased to about 55% of its light output around 22 milliseconds (again, after the generator was tripped). Thus, the major portion of the light generated by the flashed lamp P was available and illuminated the scene being photographed while the camera aperture was open. Light output curve 98 is a typical zonal lumen-millisecond curve of a zirconium-fueled AG 1/2 photoflash lamp of the kind used in the well-known flashcube.
Tests have shown that by properly selecting the size and amount of wire used in coil 16, the coil impedance can be closely matched with the impedance of the flashlamps employed in the various types of multi-flashlamp units presenting being marketed. The electric generator will, accordingly, reliably and quickly ignite all flashlamps now in use.
Other tests have also shown that by properly correlating the size of the permanent magnet with the number of turns and size of wire used in the coil, voltage pulses having peak values of 800 volts and even 1250 volts can be generated which will reliably fire a "spark ignition" type photoflash lamp having a primer-filled gap between the inner ends of the lead wires instead of the usual tungsten or tungsten-alloy filament that is connected to the leads and serves as an incandescible element which ignites the lamp. | An electrical component, such as a photoflash lamp that is associated with a photographic camera, is energized by an electric current produced by a compact mechanically-driven electric generator that is located within the camera and coupled to the shutter-actuating mechanism. The generator employs a spring-driven keeper that changes the reluctance of a magnetic circuit and causes an associated wire coil to produce a voltage pulse that is synchronized relative to the opening of the camera aperture. The generator is compact enough to fit inside "Instamatic" type cameras and provides a simple, reliable and inexpensive substitute for the batteries now employed in such cameras. The small size and reliability of the generator adapt it for use in other types of devices and systems that require a passive easily-triggered electrical power source. | 7 |
FIELD OF THE INVENTION
The present invention relates to injection molding die halves within which optical disks or the like are molded, particularly by which a plurality of disks can be molded simultaneously.
BACKGROUND OF THE INVENTION
Generally injection molding halves for the molding of optical disks provide a cavity located between a movable mold half and a stationary mold half with which a sprue bushing is provided, in order to mold the optical disks by injecting molten resin into the cavity through the sprue bushing. Such apparatus also provides a punch associated with the movable mold half concentric to the sprue bushings to sever a central aperture of the molded disks by forward motion of the punch.
As such injection molding halves for molding optical disks in the prior art are composed of but a single cavity, there are limits in improvements of productivity possible. But there exists difficulty in carrying out injection molding with a plurality of cavities formed between the stationary mold half and movable mold half, that is, molten resin has to flow into plural cavities through plural sprue bushings which are provided in the stationary mold half and connected to a passage provided with the stationary mold base plate, and moreover each of central apertures of a plurality of the disks molded in the respective cavities has to be severed by forwarding of each punch provided with the movable mold half.
In such mold halves, the construction becomes overly complicated as each front portion of the sprue bushings is forwarded to a predetermined position while injecting molten resin in order to make the gate annular in the center of the each cavity and is retracted according to the forwarding motion of each punch when severing the central aperture of the disk.
SUMMARY OF THE INVENTION
An object of the invention is to provide injection molding halves for molding disks provided with more simple construction and mechanism which realizes simultaneously injection molding of a plurality of disks without the necessity of providing a complicated operating mechanism for each sprue bushing individually.
This object is accomplished by providing injection molding halves for disks which halves contain a plurality of cavities located between a stationary mold unit fixed on a stationary mold base plate and a movable mold unit fixed on a movable mold base plate, a plurality of sprue bushings fixed in the stationary mold unit and a runner with gates in order to introduce molten resin respectively into a plurality of cavities, and a plurality of punches provided with the movable mold unit located concentrically to the plurality of sprue bushings in order to sever a central aperture of the molded disks in each cavity, comprising; interval means which locates the stationary mold unit leave a predetermined interval from the stationary mold base plate, or closes it, a plurality of the sprue bushings which are forced ceaselessly to contact a plurality of hot tip nozzles provided in the stationary mold base plate by resilient means in order to connect closely a channel for molten resin provided in the stationary mold base plate to respective inner holes of the sprue bushings provided with the stationary mold unit a plurality of punches which operate correspondingly to the operation of the interval means. And it is preferable in the above interval means to open and close the interval between the stationary mold base plate and the stationary mold unit by means of reciprocating motion of each piston rod of a plurality of hydraulic cylinders provided in the stationary mold base plate.
Moreover, when the means of the hydraulic cylinder are adopted, it is preferable as interval means for alternative connecting of the stationary mold unit to the stationary mold base plate or movable mold unit that a plurality of connecting rods be supported rotatably on the stationary mold unit; and a plurality of the pinions which gear with a plurality of racks provided with a traverse bar, be provided with each of the connecting rods in order to connect an end portion of each connecting rod to the front portion of the each piston rod or other portion of each of the connecting rods to the movable mold unit alternatively and simultaneously by reciprocating of the traverse bar.
The invention provides function that an annular gate is formed in each cavity by both of the interval means to close the interval between the stationary mold base plate and the stationary mold unit and the resilient means to push the sprue bushings to the direction of the stationary mold base plate, and each aperture in the central portion of each disk is severed by forwarding of each punch which is permitted by leaving the interval between the stationary mold base plate and the stationary mold unit in order to enable the sprue bushing to retract.
According to the invention construction of the mold halves is more simple in comparison with mold halves of the prior art which are provided with complicated driving mechanism for forwarding and retracting of each sprue bushing, because the invention can sever central aperture of each disk by providing interval mean and the resilient means. Also the construction of the inventor is convenient for cleaning of faces between the stationary mold base plate and the stationary mold unit, because the stationary mold unit can separate from the stationary mold base plate and simultaneously connect the stationary mold unit to the movable mold unit to enable space between the stationary mold base plate and the stationary mold' unit to open widely in accordance with opening motion of the movable mold base plate by rotation of the connecting rods which causes the stationary mold unit to connect or release alternatively to the stationary mold unit or the movable mold unit. Moreover it is an additional advantage to connect or release easily the stationary mold unit to the stationary mold base plate or the movable mold unit easily by means of the reciprocating of the traverse bar provided with a plurality of racks which causes each of the connecting rods to rotate simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view to explain an embodiment of the injection molding halves of the invention;
FIG. 2 is II--II sectional view of FIG. 1; and
FIG. 3 is III--III sectional view of FIG. 1.
FIG. 4 is a perspective view to explain the mechanism of the rack and traverse bar in the FIG. 1.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a cross sectional view of the injection molding halves of the invention for molding disks. In FIG. 1, a stationary mold unit 12 includes two stationary mold block units 10, and a movable mold unit 18 includes two movable mold block units 16 which are fixed to a movable mold base plate 20 positioned face to face to the stationary mold block units 10. When the mold halves are brought together, two cavities 22 for disk molding are formed between the stationary mold block unit 10 and the movable mold block unit -6. There are provided a mirror plate 24 and a back up plate 26 in the concave portion of each block plate 28. An annular plate 29 has an inner periphery which defines the outer periphery of the cavity 22 at the outer edge of the convex part of the mirror plate 24. A die block 30 is provided concentrically with the center portion of each mirror plate 24. A first end portion of a sprue bushing 32 is movably put in the center hole of each dieblock 30, and a second large diameter end portion 36 of the sprue bushing 32 is movably put in a concave portion 34 provided in each block plate 28. The sprue bushing 32 can be reciprocated between a position in which a lower face of the large diameter end portion 36 touches the bottom face of the concave portion 34 and a position in which an upper face of it touches a stopper flange 40. The sprue bushing 32 provides a cooling channel and is supported resiliently by a plurality of springs 41, 42 placed in each hollow within each block plate 28. There is provided an air passage between the outer periphery of each die block 30 and the inner periphery of each mirror plate 24. Two hot tip nozzles 44 of spherical convex outer shape are provided in the stationary mold base platen 14 and the exterior of each hot tip nozzle 44 is closely received in a spherical concavity of each sprue bushing 32 due to the action of the springs 42 on the sprue bushing 32.
A divergent passage 48 for molten resin is provided in the stationary mold base plate 14. Two end portions of the divergent passage 48 are connected respectively to each hot tip nozzle 44 and the opposite end is connected to an inlet 46.
Two block plates 54 are fixed to the movable mold base plate 20 with the interposition of each intermediate block plate 56 and rear block plate 58. There are fixed a mirror plate 50 and back up plate 52 in the concave portion of each block plate 54. An inner stamper holder 60 for the inner periphery of a stamper (not shown in the drawing) is provided concentrically through a center hole of each mirror plate 50. An outer stamper holder 62 is provided concentrically with the outer periphery of each mirror plate 50. A stamper in which suitable informational indicia are embossed is held on the surface of each mirror plate 50 by the inner stamper holder 60 and the outer stamper holder 62. An ejector sleeve 64 is placed movably in the inside of each inner stamper holder 60. A punch 66 which reciprocates on the same axis as the center axis of each sprue bushing 32 is placed concentrically on the inside of each ejector sleeve 64. An ejector pin 68 is in turn concentrically movably located in the inside of the each punch 66. The rear end of each ejector sleeve 64 is fixed to each ejector sleeve plate 70 and the rear end of each ejector pin 68 is fixed to each ejector pin plate 72. Each ejector sleeve plate 70 is connected to each ejector pin plate 68 by each connecting rod 74. A plurality of springs 76 are provided between the rear block plate 58 and the ejector pin plate 72 in order to retract the front end surface of the each ejector pin 68 and each ejector sleeve 64 from the surface of each cavity 22. A plurality of guide rods 80 is fixed to the movable mold base plate 20 in its rear portion. Each spring 76 is put in the outer periphery of each guide rod 80. The rear end portion of each punch 66 is fixed to its respective punch supporting plate 82 which is connected to its respective piston rod 86. A plurality of hydraulic cylinders 84 for severing the center aperture of molded disk in which the piston rod 86 is put, is fixed to the movable mold base plate 20.
Two connecting rods 94 are rotatably supported by respective brackets 88 fixed on the block plate 28. A connecting means 90 and 92 are provided with both end portions of the respective connecting rod 94. Two hydraulic cylinders 96 in which each piston rod 100 is put respectively, are provided with the stationary mold base plate 14. There are provided connected means 104 which are fastened to the connecting means 92 with the concave portion 102 in the end portion of the each piston rod 100 as shown in FIG. 2.
A connecting bracket 98 to which the connecting means 90 of the each connecting rod 94 is fastened, is fixed on the block plate 54. Each of the connecting means 90 and 92 is fastened alternatively to either the connecting bracket 98 or the connected means 104 due to the rotating of the each connecting rod 94 at an angle of 180°. Due to above mentioned rotating, the stationary mold unit 12 is connected to the stationary mold base plate 14 or alternatively, to the movable mold unit 18. When the stationary mold unit 12 is connected to the movable mold unit 18, retracting of the movable mold unit 20 can keep sufficiently wide spacing between the stationary mold base plate 14 and the stationary mold unit 12.
As shown in FIGS. 1, 3 and 4, each pinion 106, provided with the two connecting rods 94, gears a pair of racks 108 provided in parallel. Each end of racks 108 is fixed by a traverse bar 110. The connected means 104 is rotated by rotation of the pinion 106 which in turn is caused to rotate by reciprocation of the rack 108. Operation of the traverse bar 110 causes rotating of the connecting rod 94. A ball 112 is provided in the groove on the outer periphery of the each connecting rod 94 as shown in FIG. 1. There are two concave portions 116 in the groove. The ball 112 is pushed to either of concave portions 116 by a spring 114 to keep the position for alternative fastening of the connecting rod 94 to either of connecting bracket 98 or connected means 104. A main guide bracket 118 and a sub guide bracket 120 are provided with each block plate 28 for guiding movement of the each rack 108 as shown in FIG. 1, 3 and 4. There is fixed a plurality of guide pins 122 with the block plate 28 for positioning the stationary mold unit 12 to the stationary mold base plate 14.
When a disk is molded by the mold halves of the invention, each connecting means 92 of the connecting rods 94 are connected with the each connected means 104 provided with its respective piston rod 100 of the hydraulic cylinder 96 by operation of the traverse bar 118 to fix the block plate 28 of the stationary mold unit 12 to the stationary mold base plate 14 by retracting of the piston rod 100. After the movable mold unit 18 is clamped to the stationary mold unit 12, molten resin is injected into the cavities 22 through each sprue bushing 32 and the diverged passage 48. Each sprue bushing 32 is pushed to its respective hot tip nozzle 44 against the resilient force of the spring 42 to form an annular gate between both end faces of each punch 66 and sprue bushing 32. After completion of resin filling, each punch 66 moves forwards to sever the central aperture of its respective molded disk by operation of the hydraulic cylinders 84 and 96 as soon as the stationary mold unit 12 is separated from the stationary mold base plate 14. The above-mentioned separating operation permits retracting of each sprue bushing 32 to the stationary mold base plate 14 corresponding to forwarding of the respective punch 66.
In the illustrated embodiment of the invention, there is provided an electrical sequence circuit for corresponding operation between the operation of the hydraulic cylinders 84 for forwarding of each punch 66 and the operation of the hydraulic cylinder 96 for causing the predetermining interval between the stationary mold unit 12 and the stationary mold base plate 14. When the movable mold unit 18 is retracted from the stationary mold unit 12 to take out the molded disk after severing of central aperture of the disk by the punch 66, each molded disk with an aperture and sprue are ejected respectively by an ejector sleeve 64 and an ejector pin 68.
And then the above described molding cycle is repeated. When cleaning of contact surface between the hot tip nozzles 44 and the sprue bushings 32 becomes necessary, the traverse bar 110 is operated by hand so that the surface of the stationary mold unit 12 is in contact with the surface of the movable mold unit 18. Displacement of the traverse bar 110 causes each connecting rod 94 rotate at an angle of 180° to release connecting between the connecting means 92 of the each connecting rod 94 and the connected means 104 of the each piston rod 100, and on the other hand to connect the connecting means 90 of each connecting rod 94 to its respective connecting bracket 98 on the movable mold unit 18. When the movable mold base plate 20 is retracted after above mentioned displacement of the traverse bar 110, space enough to clean is created between the stationary mold unit 12 and the stationary mold base plate 14.
As mentioned above, the injection molding halves of the invention can keep the end face of the sprue bushing 32 in the predetermined position of the each cavity 22 while injecting molten plastic without providing such complicated construction as in the prior art; a plurality of sprue bushings 32 are thus reciprocably provided with each cavity 22 and can sever the central aperture of the disk with forwarding of the punch 66 corresponding to the retracting of the sprue bushing 32. And also the injection molding halves of the invention can clean the contact face between the sprue bushing 32 and the hot tip nozzle 44 periodically or at any required time, by simple of operating the traverse bar 110 for causing of simultaneous rotating of the each connecting rod 94.
The embodiment of the invention specifically described and illustrated herein is exemplary only, and is not intended to limit the scope of the invention, which is to be interpreted in the light of the prior art and appended claims only with due consideration for the doctrine of equivalents. For example, the embodiment of the invention shows the injection molding halves for two cavities, but it is possible to provide for more than three cavities. Moreover it is possible to adopt an interval means to substitute for the hydraulic cylinder 96 as means for separating the stationary mold unit 12 from the stationary mold base plate 14.
The invention promotes productivity of injection molding for a plurality of disks with a simple construction without providing an reciprocating mechanism to respective sprue bushing. And the invention has provision for easy cleaning of resin passages in the mold for a plurality of disks by means of providing a plurality of hydraulic cylinders in which each piston rod provides connecting means, a plurality of connecting brackets which is fixed on the block plate, a plurality of connecting rods which connects the piston rod or the connecting bracket alternatively by rotating and the traverse bar which rotates the connecting rod. | Injection molding halves for forming disks having a plurality of cavities between a stationary mold unit, in which a plurality of sprue bushings and a runner with gates for introducing molten resin into said plurality of cavities are provided, and a movable mold unit in which a plurality of punches are provided concentrically to the sprue bushings for severing a central aperture of the molded disk, and an interval mechanism for providing a predetermined interval between a stationary mold unit and stationary mold base plate to ease the removal of escaped material, and connecting structure for connecting the stationary mold unit and the stationary mold base plate by alternative rotating of a connecting rod. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to the field of surfing reefs. More specifically, the preferred embodiment of the present invention involves a floating reef system adapted to float on or near the surface of an ocean to capture the energy of deep water swells and surface waves and transform the energy into preferred surfing waves.
[0003] 2. Description of the Related Art
[0004] The sport of surfing has attracted enthusiasts all over the world. Many of them travel long distances to locations where ideal surfing conditions exist. Particularly prized by expert surfers are the waves called “the chute” or “the pipeline”, that is, waves which move with sufficient velocity and height that, when they encounter an upwardly sloping bottom of certain configuration, curl forward over the advancing base of the wave to form a tunnel, inside or at the mouth of which expert surfers move laterally across the face of the wave, seeking to keep pace with the formation of the tunnel without being caught in the collapsing portion thereof.
[0005] The formation of such waves under natural conditions requires a comparatively rare combination of factors, including wind of a certain constancy of velocity and direction, and waves of a certain velocity, direction and height, approaching a shore having a certain bottom slope and configuration. There are not many places in the world with such a favorable combination of characteristics. Surfers generally must travel several hundred to several thousand miles to reach such locations where the optimum conditions can exist. Because there are few places where succeeding waves can be counted upon to be uniform for extended periods, the places that do offer such waves are often overcrowded. When crowded conditions exist, instead of focusing entirely on riding a wave, surfers must also try to avoid encountering and injuring other surfers, which can dampen the quality of the surfing experience.
[0006] Since the 1970's, wave pools have been built to combat the problem of non-ideal wave conditions that exist in many areas of the world, and hence alleviate the overcrowded locations where optimum surfing conditions exist. Typically, a wave pool is a modified pool for swimmers without detailed design for surfing, but the waves produced are meant to peel, rather than close out. However, surfers have had mixed reaction to the existing pools, and most have rejected them due to poor surfing wave quality. Generally, wave pools have been disfavored due to the inadequately designed shape of the pool, which controls wave height in the pool, and the poor bottom, shape, which acts as the reef for the wave to break on. Additionally, to make waves break for surfing, the bottom of the wave pool must be similar to ocean surfing reefs. However, the space available for the wave conditioning prior to the breaking of the waves is not available in wave pools. Therefore, although advances have been made in wave pool design, the characteristics of waves produced in wave pools have yet to match the ideal quality waves desired by surfers around the world. Thus, there still exists a demand for technology that can produce waves with ideal characteristics while simultaneously providing a realistic surfing environment that is not overcrowded.
[0007] Man-made oceanic reefs have also been used to try and solve the problem of non-ideal wave conditions at various locations. However, the production of a man-made reef can require substantial amounts of time and labor, resulting in significant costs. Similarly, the creation of a man-made reef also requires careful government monitoring and approval, which can also contribute to a delay in completion. In a like manner, obtaining the land rights to create such a reef can involve much effort as well as cost, and could face delay from court challenges by conservation and environmental groups. Lastly, even if such a man-made reef were feasible, the time, effort, and costs associated would likely limit the creation of such reefs to locations that contain the resources to build the reef. While a possibility, this solution does not present an adequate means for allowing surfing and other recreational activities in various locations worldwide.
[0008] Another problem closely associated with waves and wave action is the problem of beach erosion. In many locations throughout the world, wave action can cause beach material (sand, soil, pebbles, rocks, etc.) to wash away into the ocean at a significant rate. Various efforts have been made to combat the problem of beach and reef erosion. However, these efforts have been time consuming, costly, and not produced adequate results. Thus, a demand exists for technology that can be utilized to help prevent beach and reef erosion.
[0009] Therefore, it would be highly desirable to provide a relatively compact, mobile, and controllable free-floating apparatus that can capture and transform the energy of natural ocean swells, creating optimum wave conditions in any location for a variety of surf activities, including surfing, and can also be placed in proximity to an existing beach to help prevent erosion of the beach.
[0010] In this respect, before explaining at least one embodiment of the invention in detail it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
SUMMARY OF THE INVENTION
[0011] The principle advantage of this invention is to provide a device that can be used to capture the energy of deep water swells and surface waves and transform the energy into preferred surfing waves.
[0012] Another advantage of this invention is to provide a device for transforming ocean wave energy into preferred surfing waves that can be readily transported to various locations.
[0013] Another advantage of this invention is to provide a device for transforming ocean wave energy into preferred surfing waves that is relatively compact.
[0014] And still another advantage of this invention is to provide a device for transforming ocean wave energy into preferred surfing waves that can be self-supported in water.
[0015] And yet a further advantage of this invention is to provide a device for transforming ocean wave energy into preferred surfing waves that can be placed in proximity of an existing beach to protect against erosion of the beach by wave action.
[0016] And yet another advantage of this invention is to provide a device for transforming ocean wave energy into preferred surfing waves that, because of its mobility, does not present the problem of having to forecast the complex long-term consequences of a fixed man-made ocean reef, but rather presents the opportunity to adjust and keep focused the effects of the device's placement relative to the constantly changing patterns of multiple ocean waves.
[0017] And still a further advantage of this invention is to add a new and unique device to the field of surfing reefs.
[0018] These advantages, and other advantages of the invention, will be apparent to those of ordinary skill in the art from the disclosure of the present invention as set forth herein.
[0019] The present invention involves an apparatus, namely a reef, used to transform ocean wave energy into preferred surfing waves. The reef is comprised of a hull having a substantially flat top surface with a vertically convex shape that preferably creates about a seventy degree tangential bow angle with the ocean surface. The bottom portion is tri-hull shaped and includes two side hulls and a center hull. The preferred embodiment is connected to a master vessel by control arms. The control arms can control the depth of the reef in water, thus controlling the wave characteristics. The control arms can also provide a ducting means for ballast pumps on the master vessel. In an alternative embodiment, the reef can be self-supporting in water. The reef can be placed near a beach or natural reef to prevent erosion by wave action. Several reefs can be connected for longer-lasting waves.
[0020] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principals of this invention.
[0022] FIG. 1 depicts a perspective view of the floating oceanic surfing reef attached to a master vessel, constructed in accordance with the present invention;
[0023] FIG. 2 depicts a side view of the floating oceanic surfing reef attached to a master vessel by a control arm, situated within water, constructed in accordance with the present invention;
[0024] FIG. 3A depicts a perspective view of one end of the preferred embodiment of a control arm unattached to either floating oceanic surfing reef or a master vessel, constructed in accordance with the present invention;
[0025] FIG. 3B depicts a top view of the end portion of a control arm for connection to a master vessel, constructed in accordance with the present invention;
[0026] FIG. 4 depicts a bottom view of the floating oceanic surfing reef attached to a master vessel by three control arms, illustrating the tri-hull configuration of floating oceanic surfing reef, constructed in accordance with the present invention;
[0027] FIG. 5A depicts a perspective view of an alternate embodiment of the floating oceanic surfing reef containing four retractable wave dampening means, constructed in accordance with the present invention;
[0028] FIG. 5B depicts a perspective view of an alternate embodiment of the floating oceanic surfing reef containing two retractable wave dampening means, constructed in accordance with the present invention;
[0029] FIG. 6 depicts a side view of the preferred depth and angular positioning of the floating oceanic surfing reef in relation to the ocean surface, constructed in accordance with the present invention;
[0030] FIG. 7 depicts a perspective view of an alternate embodiment of the floating oceanic surfing reef containing means for freestanding capabilities within the ocean, constructed in accordance with the present invention;
[0031] FIG. 8 depicts a perspective view of several floating oceanic surfing reefs positioned in close proximity to or adjacent to a beach shoreline or natural reef for recreational use or the purpose of preventing erosion of the beach material or natural reef, constructed in accordance with the present invention;
[0032] FIG. 9 depicts a perspective view of an combination of several floating oceanic surfing reefs to allow for waves to break for a longer period of time and a farther distance, constructed in accordance with the present invention; and
[0033] FIG. 10 depicts a perspective view of an alternate configuration of several floating oceanic surfing reefs to allow for waves to break for a longer period of time and a farther distance, constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Referring now to the drawings, wherein similar parts are identified by like reference numerals, there is seen in FIG. 1 a perspective view of the floating oceanic surfing reef 10 attached to a master vessel 20 by control arms 30 . The optimum dimensions of floating oceanic surfing reef 10 to produce waves with desirable characteristics are 480 feet in length and 360 feet in width. At these dimensions, floating oceanic surfing reef 10 can transform free ocean wave energy into waves 11 with 20 foot faces and 15 second periods. It is to be understood that the dimensions of floating oceanic surfing reef 10 can be varied to produce waves with certain specific characteristics, such as favoring either a right or left shoulder, as would be recognized by one with ordinary skill in the art. These dimensions can range upward from 125 feet in length and 100 feet in width, as long as the length is approximately 25% larger than the size of the width. Floating oceanic surfing reef 10 is preferably constructed of a steel or aluminum, but can be comprised of other lightweight and strong materials, such as a carbon fiber epoxy composite, and other materials as recognized by one with ordinary skill in the art. Floating oceanic surfing reef 10 has a top surface 12 and a bottom portion 14 . Top surface 12 is comprised preferably flat, but can contain surface variations to focus and optimize smaller wave energy and assist in producing waves that contain specific characteristics for a variety of recreational activities including but not limited to surfing, body boarding, and swimming. Top surface 12 is preferably comprised of rubber with an elastomer coating for safety and comfort reasons.
[0035] Top surface 12 employs the phenomenon of wave defraction and refraction to focus smaller wave energy. The focusing of smaller wave energy is done by changing the substantially flat top surface 12 with incompressible water filled bladders (not shown) via a ducting manifold that can be controlled within control arms 30 . These bladders can preferably be comprised of a high tension rubber material. When filled, the bladders create a physical obstruction to the wave energy as it propagates over the top surface 12 . Refraction occurs bending the wave energy to advantage. This, coupled along with defractive lateral propagation wave energy from the edges of reef 10 can help create waves that momentarily are higher than the adjacent waves.
[0036] Master vessel 20 can be any type of floating vessel capable of towing a large object, ranging from small yachts to cruise ships. Floating oceanic surfing reef 10 is attached to master vessel 20 by control arms 30 . Control arms 30 are rigid structures that help control floating oceanic surfing reef 10 . In the preferred embodiment, floating oceanic surfing reef 10 is attached to master vessel 20 by three control arms 30 . However, it is within the scope of the present invention for floating oceanic surfing reef 10 to be attached to master vessel 20 by one or several control arms 30 . When control arms 30 are in a locked position, floating oceanic surfing reef 10 and master vessel 20 are engaged in a substantially fixed orientation. Control arms 30 can be adjusted to control the depth and positioning of floating oceanic surfing reef 10 within the ocean, thereby varying the character of the waves breaking over floating oceanic surfing reef 10 .
[0037] Control arms 30 also can provide a means of ducting for ballast pumps (not shown) on master vessel 20 , which further control the positioning and depth of floating oceanic surfing reef 10 in ocean water. Control arms 30 can also serve as a conduit for electrical or air lines that facilitate the process of controlling the positioning and depth of floating oceanic surfing reef 10 in ocean water.
[0038] As illustrated in FIG. 2 , there is seen a side view of floating oceanic surfing reef 10 attached to master vessel 20 , within water 22 . Floating oceanic surfing reef 10 is attached to master vessel 20 via control arms 30 (only one shown). Floating oceanic surfing reef 10 , while inherently possessing buoyant characteristics, can be submerged in water 22 to a desired depth. Control arms 30 preferably allow the hydraulic pivotal adjustment of floating oceanic surfing reef 10 to attain the desired depth positioning in water 22 . Bottom portion 14 is comprised of side hulls 16 (only one shown) and center hull 18 . Side hulls 16 extend in a downward and inward curvilinear fashion from top surface 12 to center hull 18 .
[0039] When floating oceanic surfing reef 10 is desired to be transported by master vessel 20 , side hulls 16 and center hull 18 are unballasted so that floating oceanic surfing reef 10 will float. Before floating oceanic surfing reef 10 can be used to generate waves 11 , side hulls 16 and center hull 18 must be ballasted to lower floating oceanic surfing reef 10 into the water to the desired depth. Although control arms 30 can aid in positioning floating oceanic surfing reef 30 to a desired depth, additional depth positioning procedures, such as ballasting are needed to provide maximum depth adjustment capabilities. Additionally, floating oceanic surfing reef 10 contains several buoys 24 attached to the perimeter of top surface 12 for the purpose of providing attachment means for protective netting against sharks, etc.
[0040] Also seen in FIG. 2 is the preferred method for controlling the depth positioning of floating oceanic surfing reef 10 . Control arm 30 is preferably comprised of a horizontal shaft 32 with master vessel end 31 and reef end 33 . At master vessel end 31 , at least two support plates 36 are welded or otherwise attached to master vessel end 31 for attachment of control arm 30 to master vessel 20 . To adjust positioning of control arm 30 , a drive shaft 38 is connected to a bevel gear 40 that turns a screw drive 42 . Drive shaft 38 can be controlled by a control motor 44 contained within master vessel 20 . Screw drive 42 is used to rotate a gear 46 that is attached to an axle 48 (see FIG. 3A ), thereby altering the positioning of floating oceanic surfing reef 10 . Reef end 33 is preferably rigidly attached to a rigid structure 49 within floating oceanic surfing reef 10 by welding or some other method to prevent movement of control arm 30 in relation to floating oceanic surfing reef 10 . In other embodiments, hydraulics or pneumatics contained within master vessel 20 or control arm 30 can be used to adjust the depth positioning of floating oceanic surfing reef 10 .
[0041] A wave dissipater 29 can also be contained within floating oceanic surfing reef 10 . Wave dissipater 29 is used to help prevent waves from crashing into the back of master vessel 20 . Wave dissipater 29 preferably is comprised of a slotted hollow cavity where water passing over floating oceanic reef 10 can enter into and be slightly or substantially dissipated, depending on the size dimensions of wave dissipater 29 , helping to lessen the wave force encountering master vessel 20 .
[0042] As illustrated in FIG. 3A there is seen a perspective view of one end 31 of the preferred embodiment of control arm 30 unattached to floating oceanic surfing reef 10 . Depicted in the figure is the portion of control arm 30 , namely master vessel end 31 , for attachment to master vessel 20 . Master vessel end 31 is preferably comprised of several rounded leaf-like portions 34 . At least two support plates 36 are welded or otherwise attached to master vessel 20 for attachment of control arm 30 to master vessel 20 . As discussed above, to adjust positioning of control arm 30 , a drive shaft 38 is connected to a bevel gear 40 that turns a screw drive 42 . Drive shaft 38 can be controlled by a control motor 44 contained within master vessel 20 . Screw drive 42 is used to rotate a gear 46 that is attached to an axle 48 , thereby altering the positioning of floating oceanic surfing reef 10 . A hydraulic ram (not shown) is preferably used to drive a stopping pin 52 through holes 54 in gear 46 to prevent the rotation of gear 46 when the proper positioning of floating oceanic surfing reef 10 has been set. Alternatively, a hydraulic ram can be used to compress at least one set of brake calipers (not shown) attached to master vessel end 31 to prevent rotation of gear 46 .
[0043] As illustrated in FIG. 3B there is shown a top view of master vessel end 31 of control arm 30 for connection to master vessel 20 . Master vessel end 31 is comprised of preferably three leaf-like portions 34 . However, it is to be recognized that master vessel end 31 can also contain two leaf-like portions 34 or more than three leaf-like portions 34 . Leaf-like portions 34 are designed so that support plates 36 can interweave within leaf-like portions 34 , thereby providing for both secure attachment and rotational ability of control arm 30 .
[0044] As illustrated in FIG. 4 , there is seen a bottom view of floating oceanic surfing reef 10 attached to master vessel 20 by control arms 30 , illustrating the tri-hull configuration of floating oceanic surfing reef 10 , particularly the location of side hulls 16 and center hull 18 . Master vessel 20 may contain one or more propellers 26 to aid in towing floating oceanic surfing reef 10 . Control arms 30 are preferably attached to master vessel 20 away from propellers 26 . Control arms 30 are preferably comprised of a strong, but flexible, corrosion-resistant material. Also depicted in the figure are the positioning of wave dampers 60 contained within an alternative embodiment of floating oceanic surfing reef 10 (see FIG. 5A ).
[0045] As illustrated in FIG. 5A , there is seen a perspective view of an alternate embodiment of floating oceanic surfing reef 10 . This embodiment of floating oceanic surfing reef 10 preferably includes at least four wave dampers 60 retractably contained within floating oceanic surfing reef 10 . When floating oceanic surfing reef 10 is being towed to sea, wave dampers 60 are retracted into floating oceanic surfing reef 10 . However, when floating oceanic surfing reef 10 is positioned within the water, wave dampers 60 can be lowered into the ocean to help provide stability. Wave dampers 60 are all preferably lowered to the same depth in the ocean. However, to produce waves that break from different directions or with different characteristics, some wave dampers 60 can be lowered to different levels by retractable members 61 , or not lowered at all. Additionally, floating oceanic surfing reef 10 can include a sea anchor 62 to prevent the floating oceanic surfing reef 10 from straying from the intended relative position within the ocean.
[0046] As illustrated in FIG. 5B , there is seen a perspective view of an alternate embodiment of floating oceanic surfing reef 10 that can be self-supported in water. This embodiment of floating oceanic surfing reef 10 preferably includes two elongated wave dampers 64 retractably contained by retractable members 65 within floating oceanic surfing reef 10 . In this embodiment, both wave dampers 64 can be lowered at different levels or not lowered at all to produce varying waves. A sea anchor 62 can also be attached to the floating oceanic surfing reef 10 containing only two wave dampers 64 .
[0047] As illustrated in FIG. 6 , there is seen a side view of the preferred depth and angular positioning of floating oceanic surfing reef 10 in relation to the ocean surface 28 . In the preferred embodiment, to produce waves with ideal characteristics top surface 12 is positioned between 3 and 20 feet below ocean surface 28 with the outer-most forward edge 15 of bottom portion 14 positioned at a depth of approximately 120 feet below ocean surface 28 . This positioning of floating oceanic surfing reef 10 creates a bow angle to tangent 38 at outer-most forward edge 15 with ocean surface 28 that is preferably about 70 degrees. Bow angle to tangent 38 can be varied to a larger or smaller angle, ranging from about 40 degrees to 80 degrees to produce waves with certain specific characteristics, as would be recognized by one with ordinary skill in the art.
[0048] As illustrated in FIG. 7 , there is seen a perspective view of an alternate embodiment of floating oceanic surfing reef 70 . Floating oceanic surfing reef 70 is freestanding and does not need the support of a towing vessel. Thus, floating oceanic surfing reef 70 can be towed to a location, positioned, and left to help create ideal surfable waves 73 or protect beaches or natural reefs from incoming waves (see FIG. 8 ). Also shown in the figure is a light 71 . Light 71 is used to help notify other crafts of the location of floating oceanic surfing reef 70 . One or more sea anchors 62 can be attached to floating oceanic surfing reef 70 for maintaining location within the ocean.
[0049] As illustrated in FIG. 8 , there is seen a perspective view of several floating oceanic surfing reefs 10 in a fixed positioned in close proximity to or adjacent to a beach shoreline 72 for recreational use or the purpose of preventing erosion of the beach material. The impact of the wave energy shown by arrows 74 coming into the beach will be partially absorbed and deflected by the floating oceanic surfing reefs 10 , thereby preventing damage to the beachfront. The positioning of several floating oceanic surfing reefs 10 into array “A” as shown in the figure allows natural current drift shown by arrows 76 to build up an accumulation of beach sand in the pattern as shown by mound 78 . The positioning of several floating oceanic surfing reefs 10 into array “A+B” as shown in the figure allows natural current drift shown by arrows 76 to build up an accumulation of beach sand in the pattern as shown by mound 79 . Thus, depending on the number of and positioning of floating oceanic surfing reefs 10 , it is possible to gradually build up sand around a particular shoreline area.
[0050] As illustrated in FIG. 9 , there is seen a perspective view of a combination of several floating oceanic surfing reefs 10 to allow for waves 81 to break for a longer period of time and a farther distance, thus allowing more surfers to surf the waves. Coupling members 80 are used to connect two floating oceanic surfing reefs 10 . Coupling members 80 are preferably comprised of high strength rubber that allow for movement of the reefs 10 . In this arrangement, the additional floating oceanic surfing reefs 10 do not need to be attached to a master vessel 20 , however it is possible that more than one master vessel 20 can be used to help support the combination. Because numerous floating oceanic surfing reefs 10 can be possible connected to the floating oceanic surfing reef 10 attached to a master vessel 20 , the additional reefs are preferably somewhat smaller in dimension than the attached floating oceanic surfing reef 10 . Transitional reefs 90 can be connected to the floating oceanic surfing reef 10 to help set other floating oceanic surfing reefs 10 off at a 45 degree angle to the floating oceanic surfing reef 10 that is attached to master vessel 20 and serves as the base reef for other floating oceanic surfing reefs 10 to attach. Transitional reefs 90 can be of varying shapes depending on the particular angle that is chosen to offset the additional reefs from the attached reef.
[0051] As illustrated in FIG. 10 , there is seen a perspective view of an alternate configuration of several connected floating oceanic surfing reefs 100 to allow for waves 91 to break for a longer period of time and a farther distance, thus allowing more surfers to surf the waves. In this configuration, transitional reefs, such as transitional reefs 92 , 94 , 96 and 98 extend outward to starboard from the stern of the master vessel 20 . Additionally, transitional reefs 102 , 104 , 106 and 108 can extend to port. Moreover, both sets of transitional reefs may extend in both directions from the center reef. Transitional reefs 92 , 94 , 96 , 98 , 102 , 104 , 106 and 108 as shown here are constructed to mount flush to each other when connected, unlike the transitional reefs shown in FIG. 9 , and previously described.
[0052] With respect to the above description it is to be realized that the optimum dimensional relationships for the parts of the invention, including variations in size, materials, shape, form, function and manner of operation, assembly, and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents fall within the scope of the present invention.
[0053] The above description, together with the objects of the invention and the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific advantages attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
[0054] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting, as to the scope of the invention in any way. | The present invention involves an apparatus, namely a reef, used to transform ocean wave energy into preferred surfing waves. The reef is comprised of a hull having a substantially flat top surface with a vertically convex shape that preferably creates about a seventy degree tangential bow angle with the ocean surface. The bottom portion is tri-hull shaped and includes two side hulls and a center hull. The preferred embodiment is connected to a master vessel by control arms. The control arms can control the depth of the reef in water, thus controlling the wave characteristics. The control arms can also provide a ducting means for ballast pumps on the master vessel. In an alternative embodiment, the reef can be self-supporting in water. A single reef or a multiple reef configuration can be placed near shore to help prevent beach erosion by wave action, and or cause beach sand to accumulate. Several reefs can be connected for longer-lasting waves. | 1 |
This application claims benefit of U.S. Provisional Application No. 60/001,349, filed Jul. 21, 1995.
FIELD OF THE INVENTION
This invention relates to microscale fluid handling systems and particularly to such systems fabricated in a microscale device.
BACKGROUND OF THE INVENTION
Recent developments in microfabrication techniques have permitted the integration of microminiature tools for biochemical analysis within a tiny device. Complete chemical processing systems, e.g., reaction chambers, separation capillaries and their associated electrode reservoirs, as well as certain types of detectors, can be consolidated on a microchip of, e.g., a glass or fused silica. Such "laboratories-on-a-chip," in principle, permit effective utilization and manipulation of minute quantities of material. After the intended procedures have been conducted, the processed compounds are available on the chip in a spatially concentrated form that is suitable for performing further analytical operations. As the sample components are in volumes on the order of nanoliters, subsequent operations should preferably be carried out on the same device. (See, e.g, Effenhauser et al., Anal. Chem. 67:2284-2287, 1995.) This constraint, however, permits less than efficient utilization of certain powerful analytical instruments, such as a mass spectrometer.
SUMMARY OF THE INVENTION
The invention is directed to a microscale fluid handling system that permits the efficient transfer of nanoliter quantities or other small quantities of a fluid sample from the spatially concentrated environment of a microscale device, such as a microfabricated chip, to "off-chip" analytical or collection devices without an increase in sample volume. The fluid handling system of the invention is fabricated in the form of one or more capillary channels in a body or substrate, which may be made of a suitable non-conductive material, such as silica or polymer plastic, or a suitable conductive material such as stainless steel, noble metal, or semi-conductive material such as silicon. The microscale device of the invention includes one or more exit ports integral with an end of one or more of the channels for consecutive or simultaneous off-chip analysis or collection of an applied sample. The exit port or ports may be configured, for example, to transfer a sample for electrospray-mass spectrometry analysis (ESI/MS), for atmospheric pressure-chemical ionization mass spectrometry analysis (APCI/MS), for matrix assisted laser desorption ionization mass spectrometry (MALDI/MS), for nuclear magnetic resonance analysis (NMR), for pneumatically or ultrasonically assisted spray sample handling, for transfer to an off-chip detection system, such as electrochemistry, conductivity or laser induced fluorescence, or for collection of specific fractions, e.g., in collection capillaries or on collection membranes. Sample transfer may be by droplet, spray or stream, as desired, or as suitable for the instrument or device receiving the transferred sample. The transferred fluid may be in the form of a liquid or a gas.
The channels of the microdevice may be arrayed in any format that allows for sequential or simultaneous processing of liquid samples. In one embodiment of the invention, the channels are arranged in spaced parallel form, each channel representing an independent microanalytical system having its own sample introduction port and exit port. In another embodiment, the channels on the microscale device are arranged in a circular pattern, like the spokes of a wheel. At the center of the circular pattern, all channels can converge into one exit port integrally formed in a face of the microscale device. The exit port is adapted to interface with an external device, such as a mass spectrometer or membrane, which receives samples via the exit port for analysis.
In any embodiment, each channel may include electrical contacts, so that an electric circuit path can be established along the channel. For example, one electrical contact can be on the entrance side of a channel and another electrical contact can be on the exit side. In an alternative arrangement, an electric circuit can be completed by an external contact, beyond the exit end of the channel. For example, if the exit port of a channel is used as an electrospray source for a mass spectrometer, the mass spectrometer sampling orifice can serve as the counter electrode. Samples can be transferred off chip for subsequent analysis by switching the electric current sequentially to each channel on the chip. At the end of the analysis, the chip may be discarded. Thus, the invention alleviates manipulations such as flushing and eliminates problems of sample carryover between runs while providing for efficient use of the mass spectrometer or other device for analysis and/or collection.
Samples can be introduced into a channel on the microscale device of the invention by a variety of methods, e.g., by pressure, electrokinetic injection, or other technique, and an electrical current and/or pressure drop can then be applied to cause the sample components to migrate along the channel. The channels may function only for fluid transfer, e.g., to a mass spectrometer, or the channels can serve as environments for various types of sample manipulations, e.g., for micropreparative or analytical operations, such as capillary electrophoresis (CE) or the polymerase chain reaction (PCR), or for carrying out any type of sample chemistry. The channels may be filled with membrane or packing material to effectuate preconcentration or enrichment of samples or for other treatment steps, such as desalting. Furthermore, other modification of sample components, e.g., by enzymes that are covalently bound to the walls of a channel or are free in a channel, are possible. Packing material may be bound to the walls of the channels or may include other components, such as magnetic particles, so that when a magnetic field is applied, the magnetic particles retain the packing material in place. The magnetic particles can also be used for efficient mixing of fluids inside the channels, using an external magnetic field. A micromachined filter or other stationary structure may also be employed to hold packing material in place. Alternatively, stationary structures can be micromachined, cast or otherwise formed in the surface of a channel to provide a high surface area which can substitute for packing material. Another method of applying samples is to attach a miniaturized multiple-sample holder as a hybrid micromachined system to the entrance ports of the channels.
A sample can be introduced into a channel in a short starting zone or can fill the whole channel completely. Filling only a small part of the channel with the sample is preferable when an on-chip separation of sample components is to be carried out, such as electrophoresis or chromatography. Filling the whole channel with the sample may be advantageous in cases when off-chip analysis requires extended sample outflow, such as sample infusion/electrospray ionization for structure analysis by mass spectrometry.
In many cases a liquid flow may be required to transport the analytes in a sample into a specific channel, or along the length of the channel, or out of the channel via an exit port. Therefore, to assist in the required fluid transfer, a pumping device may be incorporated into or associated with the microscale device of the invention. For example, a heating element can be used to cause thermal expansion, which will effectuate sample liquid movement, or a heating element can be used to generate a micro bubble, the expansion of which causes the sample to travel in the channel. Other options may include pumping by the pressure of a gas or gases generated by on-chip electrolysis. Flow can be also generated by application of a pressure drop along a channel or by electroosmosis inside a channel.
As samples move to the end of a channel, they can be subjected to detection or analysis at a site external to the microscale device of the invention by a variety of techniques, including mass spectroscopy, nuclear magnetic resonance, laser induced fluorescence, ultraviolet detection, electrochemical detection, or the like. The end of each channel may include a tip configured to facilitate transfer of the sample volume. When mass spectroscopy is the analytical method, the end of each channel may be microfabricated to form an electrospray exit port, or tip, that permits transfer of ions into the sampling orifice of the mass spectrometer by microelectrospray. Other exit port configurations can be used for, pneumatically or ultrasonically assisted spray sample transfer, among others. Furthermore, if the sample to be transferred is a dissolved gas, transported in the channel by a carrier liquid, the exit port can be configured to heat the carrier liquid, to restore the sample to the gas phase for spray transfer.
The exit end of the channel may be configured and/or sized to serve as an electrospray tip, or the tip can be formed as an extension of the channel or as an attachment to the channel. The edge surface of the substrate may be recessed between adjacent exit ports to minimize cross-contamination, or the substrate may be of a non-wetting material, or may be chemically modified to be non-wetting, so that the exiting liquid itself provides the electrospray. When necessary, the microdevice can be positioned on a translational stage so that each exit port can be precisely aligned, in turn, with the sampling orifice of the mass spectrometer or other utilization device.
The invention may be used in a fluid sheath (e.g., liquid or gas) or sheathless mode depending on the type of analysis required and the size of the sample exiting a channel. In a sheathless arrangement, the exit port is formed at the end of the channel. When a liquid sheath is required (e.g., for the addition of a liquid, a chemical and/or a standard prior to electrospray or to provide electric connection via the sheath fluid), an exit port can be created at the merge point of two channels, one supplying the sample and the other the sheath liquid. Selective analysis of analytes in both the cationic and anionic modes can be performed easily by rapid switching of the polarity of the electric field.
Different sized channels may be employed on the same microscale device. For example, larger channels may be used for cleanup operations, and smaller channels may be used for processing operations. Moreover, other operations can be performed in other regions of the device, such as chemical processing, separation, isolation or detection of a sample or a component of the sample, prior to sample loading in a channel. Thus, it is possible to carry out sample chemistries or to conduct micropreparative and analytical operations on both a starting sample and its separated components within the device of the invention, prior to transfer of the sample or its components off chip for further analysis or collection. Additionally, detection of a sample may be carried out on the microdevice itself, e.g., by a fiber optic detection system, which can provide complementary control information for off-chip analysis and detection, or by any other suitable detector such as laser induced fluorescence, conductivity and/or electrochemical detector.
Suitable processes for fabricating the microscale device of the invention are themselves well known in the art and include, as examples, photolithographic and etching techniques, laser machining, multilayer fabrication techniques such as stereolithography, and stamping, molding or casting techniques.
The channels may be cylindrical, trapezoidal or of any other cross-sectional shape. The channel pattern may be linear or curvelinear within a single plane. Furthermore, the microdevice may include multiple such layers of independent, unconnected channels. Alternatively, an individual channel may extend between two or more planes to enable transfer of a sample from a desired entrance port location to a desired exit port location. A channel also may be of any length necessary to enable such a transfer. At its most basic, a channel may be merely a straight slit connecting an inlet port and an exit port.
Buffer reservoirs, reaction chambers, sample reservoirs, and detection cells may also be fabricated along with each individual channel. More complex structures can be created by stacking or otherwise assembling two or more microfabricated devices. In addition, individual instrument blocks such as sample reservoirs, pretreatment or separation channels, and exit ports can be micromachined separately and combined into one complete system in much the same way as hybrid integrated circuits in electronics are formed. Microfabrication techniques are precise and will allow for a high degree of reproducibility of selected channel and exit port shapes and dimensions.
The microscale fluid handling system of the invention permits more efficient use of powerful analytical devices, such as the mass spectrometer, than is currently possible. In addition, the system of the invention can be manufactured as a disposable device that is suitable for cost effective automation of the analysis of a large number of samples. Using this micromachined approach, high throughput analysis by mass spectrometry would be possible. In addition, handling of small volumes and quantities of samples would be facilitated, and consumption of valuable samples and reagents would be reduced. Applications include any laboratory analysis methods, especially where high throughput and minimization of cross-contamination are desirable, such as screening and diagnostic methods, and such other analytic methods as pharmacokinetics where fresh columns are required for each run.
Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a plan view of one embodiment of the microscale fluid handling system of the invention, in which the associated channels for sample transport are in a parallel arrangement within a single plane;
FIG. 1b is a cutaway view of an embodiment of the invention showing optional well extensions;
FIG. 1c is a cutaway view of an embodiment of the invention showing an attached sample/electrode port block;
FIG. 1d is a cutaway view of an embodiment of the invention showing multiple layers of unconnected channels for sample transport;
FIG. 1e is a cutaway view of an embodiment of the invention showing a channel in multiplane configuration;
FIG. 2a is a plan view of another embodiment of the microscale fluid handling system of the invention in which the associated channels for sample transport are in a circular arrangement, merging in a common exit port;
FIGS. 2b-2d are side views of three different embodiments of the exit port depicted in FIG. 2a;
FIG. 3 shows another circular arrangement of sample transport channels in which each channel ends in a separate exit port on the rim of a hole in the center of the chip;
FIG. 4 is a plan view of an arrangement of channels in another embodiment of the invention in which the exit ports are configured as spray ports, to be used with a sheath liquid for either pneumatic spray or electrospray for off-chip sample manipulation;
FIG. 5 is a plan view of an arrangement of channels in another embodiment of the invention in which several channels merge into one exit port;
FIG. 6a is a schematic representation of the microscale device of FIG. 1a used as an electrospray interface with a mass spectrometer;
FIG. 6b is an enlargement of an indicated portion of FIG. 6a;
FIGS. 7a and 7b show electrospray mass spectra from infusing 0.01 mg/ml myoglobin (200 nl/min) from two selected channels of the microscale device of FIG. 1a, of the same width and depth;
FIGS. 8a-8d show electrospray mass spectra from infusing different samples in methanol/water/acetic acid (75/25/0.1) from different channels of the microscale device of: FIG. 8a, 0.1 mg/ml myoglobulin; FIG. 8b, 0.1 mg/ml endorphin; FIG. 8c, 0.1 mg/ml human growth hormone; and FIG. 8d, 0.1 mg/ml ubiquitin;
FIG. 9 shows an electrospray mass spectrum from ESI/MS detection of 0.001 mg/ml myoglobin in methanol/water/acetic acid (75/25/0.1);
FIG. 10 shows an electrospray mass spectrum of a mixture of 0.05 mg/ml of human growth hormone and 0.05 mg/ml of ubiquitin, in methanol/water/acetic acid (75/25/0.1), infused from the microscale device of FIG. 1a, in a study of the detection limit using the device;
FIG. 11a shows an electrospray mass spectrum from infusing 0.05 mg/ml human growth hormone from aqueous solution, with methanol/water/acetic acid (75/25/0.1) in a syringe for applying pressure, and
FIG. 11b shows an electrospray mass spectrum from infusing 0.05 mg/ml human growth hormone directly from a solution of methanol/water/acetic acid (75/25/0.1);
FIG. 12a, parts i and ii, show electrospray mass spectra of on-chip tryptic digest of melittin, at 30 μM in 20 mM Tris pH 8.2, melittin/trypsin ratio=300/1 (w/w), for two different time periods;
FIG. 12b, parts i and ii, show electrospray mass spectra of both on-chip and off-chip tryptic digests of casein, at 2 μM in 20 mM Tris pH 8.2, casein/trypsin ratio=60/1 (w/w); and
FIG. 13 shows an electrospray mass spectrum of a short DNA fragment (20mer) in 60% acetonitrile, 40% H 2 O.
DETAILED DESCRIPTION OF THE INVENTION
The microdevice of the invention permits the integration of microscale reaction and separation systems with the powerful analytical and/or collection systems that are only available off-chip. One embodiment of the invention is shown in FIGS. 1a and 1b and includes a microchip substrate or body containing a series of independent channels or grooves, fabricated in a parallel arrangement along with their associated sample inlet ports and buffer reservoirs, in one surface of a planar portion of a glass body or chip. Exit ports are fabricated at the end of their respective channels, on the edge of the chip. The grooved portion of the chip is covered with a cover plate to enclose the channels.
Referring to FIG. 1a, the chip (10), shown without its associated cover plate, contains nine parallel channels (12), all of the same width and depth (60 μm×25 μm), etched in a surface of the microchip substrate (11). The channels are of three different lengths in order to optimize the channel arrangement. Each channel (12) is connected to three wells (13, 14, 15) which allow access to the channels, e.g., for infusing samples through the channels, for manipulating different solutions that might be added to a sample in a channel, and also for use as an electrophoresis buffer reservoir. Each well has a diameter of 1 mm and a depth of 0.5 mm, with a volume of 0.4 μL. Each well (13 and 15) is coupled to its corresponding channel by a groove or channel (12a). Plastic microtubes (not shown) can be attached on top of the cover and in communication with the wells to increase their volume, for example, up to 10 μL. Referring to FIG. 1b, samples are introduced into wells (13), through optional well extensions (13a) and sample entrance holes (13b) in cover plate (13c), by any convenient means such as supply tubes or syringes at which the chip is placed during sample loading.
Referring again to FIG. 1a, exit ports (16) at the end of each channel, and at the edge of the microchip substrate, serve as electrospray exit ports through the use of a non-wetting coating, e.g., polydimethylsiloxanediol, on the external surface area (18) of the microchip substrate between two exit ports (16), to isolate a solution to be electrosprayed from an exit port. The channels are spaced from each other in the illustrated version by 6 mm. Alternatively, indentations or recesses (20) can be cut in the external surface of the microchip substrate between adjacent exit ports (16), to isolate the exit ports and avoid or minimize cross-contamination between channels.
In the embodiment of the invention shown in FIG. 1c, a sample/electrode port block is provided as a separate element which is attached to the microchip body. Referring to FIG. 1c, the body (11) has a sample/electrode port block (30) disposed along one side of the body. The block (30) contains sample inlet ports (31) which are coupled via supply channels (33) to the inlet end of respective channels (12). An electrode (32) is supported by the block (30) and has one end disposed in the supply channel (33) and the opposite end external to the block for connection to a high voltage power supply. In this embodiment, the supply channel (33) contains a packing material (34) for internal sample pretreatment. The illustrated channel (12) has a tapered end (35) forming an exit port tip from which the sample liquid is sprayed for transfer to an external collection or analytical device.
For certain applications, the microdevice substrate is fabricated to contain multiple layers of independent, unconnected channels. Referring to FIG. 1d, a cutaway view of an embodiment of the invention shows independent channels (12b), (12c) and (12d) each representing multiple channels within a single plane according to the embodiment of the invention shown in FIG. 1a. The planes containing channels (12b), (12c) and (12d) are positioned in multiple stacked layers, one above the other, in substrate block (11a), with each channel in each layer ending in its own exit port, represented by exit ports (16b), (16c) and (16d), respectively, as shown. This embodiment is particularly useful for high throughput screening of multiple samples.
In the embodiments described above, the channels lie generally within a single plane of the substrate or body. The channels may also extend between two or more planes such as shown in FIG. 1e. As illustrated, the channel (12e) extends from a first upper plane to a second lower plane and ends in exit port (16e) at the edge of the microchip substrate (11). In general, the channels can be of any configuration and follow any convenient path within the substrate or body (11) in order to permit intended packing density of the channels and associated components of the microchip device.
The distance between two given channels is chosen depending on the required density of the channels and on the associated chemistries as well as to minimize cross-contamination. If a low channel density is desired, the distance between individual channels (and between individual exit ports) can be several millimeters. In this case, the entire device can be positioned on a moving stage for precise alignment of each exit port with an off-chip (off-microdevice) analyzer. If a high channel density is desired, the channels and their associated exit ports will be closer together (separated only by several tens of microns). In this case, a moving stage may not be necessary.
The invention can also be implemented with the channels in a circular or spoke arrangement. Referring to FIG. 2a, an array of capillary channels (42) is provided in the body (40) in a circular or spoke arrangement. The inner ends of the channels (42) confront a common exit port (46). The inlet ends of the channels are coupled to a sample inlet (56) and buffer reservoirs (52) as illustrated. Electrodes, typically of thin film gold, formed on or attached to the substrate (41), each have an end disposed within a respective buffer reservoir and an opposite end accessible for connection to an external power supply. The sample inlets (56) and buffer reservoirs (52) are accessible for supply of liquids, or for associated ports and/or tubes extending to a surface of the substrate or outwardly therefrom for coupling to supply apparatus.
The exit port may be of various configurations. Referring to FIG. 2b, the exit port is shown coupled to an electrospray tip (48) extending outwardly from a cover plate (43), which encloses the channels of the substrate. The tip typically has an exit orifice of about 1 to 60 micrometers. In the embodiment of FIG. 2c, the exit port (46) is coupled to an array of field emission tips (50), each having an exit orifice of about 1 to 10 micrometers in diameter. A further alternative exit port configuration is shown in FIG. 2d in which a nozzle orifice is formed within a recess (49) in the cover plate (43) adjacent exit port (46). The nozzle orifice is of about 1 to 50 micrometers in diameter.
In a further embodiment shown in FIG. 3, the channels (62) are arranged in a regularly spaced circular array in substrate (61). The outer ends of the channels (62) join respective reservoirs (69). An electrode is provided for each reservoir (69) as in the embodiment described above. Each of the channels has an inner end tapering to an individual exit port (66), all of which are accessible through a single hole (68) in the substrate (61) in the center of the array. The channels may each contain one or more sample reservoirs and one or more buffer reservoirs to suit intended performance and operational requirements.
FIG. 4 shows an embodiment having pairs of sample separation/infusion channels (72) and sheath (reagent) liquid channels (73), each pair converging in an exit port (76). The exit ports are spray ports, to be used with a sheath liquid or gas. Either pneumatic spray or electrospray can be carried out for off-chip sample analysis or collection. For electrospray transfer of a sample in the sheath mode, a high voltage power supply (78) is connected between electrodes (79) in a sample reservoir (74) and in a sheath reservoir (75). Alternatively, the voltage can be applied between an electrode in reservoir (74) or (75) and an electrode at the entrance of a mass spectrometer adjacent to the exit ports (76). In the first arrangement, the electrospray potential at the exit ports (76) is a function of the total applied voltage and the resistances of both channels (72) and (73). In the second arrangement, the electrospray potential at the exit ports (76) is directly proportional to the voltage applied at the sample reservoir. The exit ports may also contain an electrode for active control of their potential.
The sheath liquid flow can be controlled in the same way as described earlier for flow in the sample channels. The sheath liquid composition depends on the desired application. For example, the liquid can contain a water/organic solution of a volatile acid(or base) to control the pH of the electrosprayed solution. The sheath liquid can also contain a solution of a suitable matrix (e.g., dihydrobenzoic acid, sinapinic acid) for matrix assisted laser desorption and consecutive time of flight (TOF) mass spectrometric analysis. Both electrospray and pneumatic assisted spray can be used in this case. Laser and/or matrix assisted laser desorption ionization can be performed after deposition of the solution exiting the microdevice on an external support, e.g., membrane, stainless steel, etc.
FIG. 5 shows an embodiment in which a substrate has several inlet ports (84) and channels (82) merging in one exit port (86). Two such arrays are shown in FIG. 5. Each channel (82) can be supplied with different fluids containing, for example, a calibrating standard, liquid sheath fluid or a chemical reagent to improve off-chip analysis. The flow in each channel can be pressure controlled, or a regulated electric current distributor (88) can be used for precise control of electromigration and electroosmosis in the channels.
As described above, the microchip device of the invention can be used as an electrospray interface for transfer of a sample to a mass spectrometer (ESI/MS). Referring to FIG. 6a, to increase sample injection efficiency for detection in the mass spectrometer, the microchip (10) of FIG. 1a is mounted on a three-dimensional stage (21), which allows precise alignment, as shown in FIG. 6b, of a channel exit port (16) with the sampling orifice (22) of the mass spectrometer (23). One well (14) coupled to a channel (12) is used as an electrophoresis buffer reservoir. Another well (13) is used for sample input. A third available well (15) is plugged and not used in this embodiment. When a sample infusion experiment is carried out, the wells are made airtight, e.g., through the use of plastic stoppers, so that pressure can be applied for transport of a fluid sample in a channel towards the respective channel exit port.
A low current, high voltage power supply (24) is used to apply a voltage via an electrode (25) inserted in a buffer reservoir well (14) to each channel (12) in turn, for electrospray transfer of a sample in the respective channel. The high voltage power supply (24) is grounded (26) and there is a second ground (27) on the mass spectrometer. The largest portion of the voltage potential is across the gap between the electrospray exit port (16) and the mass spectrometer sampling orifice (22), thus causing electrospray transfer of the sample to take place. The electrospray transfer of fluid samples from the nine channels of the microchip is carried out in a sequential mode. While one channel is used for injecting a sample into the mass spectrometer, another channel can be used for sample preparation. After each mass spectrometer analysis, the next channel will be moved by stage (21) to align with the sampling orifice. The alignment can be performed manually, by adjusting the position of the three-dimensional stage by hand, or automatically, by moving the stage with a stepper motor. Once an optimized voltage is reached, determined, e.g., by increasing the voltage until the best signal is obtained, it can be used for the next channel without further adjustment. The distance between the exit ports and the sampling orifice of the mass spectrometer is not critical and can be in the range of less than a millimeter to several tens of millimeters.
The following examples are presented to illustrate the advantages of the present invention. These examples are not intended in any way otherwise to limit the scope of the invention.
EXAMPLE I
Infusing the same sample from different channels
To investigate the performance of different channels, a 0.01 mg/ml myoglobin sample was infused from two selected channels of the same cross-section, using the embodiment of the microdevice of the invention shown in FIG. 1a. As shown in FIGS. 7a and 7b, the sensitivity of the recorded electrospray mass spectra was very similar for these two channels, implying that the microfabrication process used to prepare the microdevice of the invention can generate reproducible channels. The experimentally determined molecular weight of myoglobin was 16,953, which, when compared to the actual molecular weight of 16,950, represents an accuracy limit of 0.02%. The subtle differences in the spectra are typical for analyzing proteins.
EXAMPLE II
Infusing different samples from different channels for conducting high-throughput analysis
To demonstrate that the microchip of the invention can be used as an electrospray interface with a mass spectrometer for sequential analysis, four different sample were processed in sequence, with each sample (in methanol/water/acetic acid; 75/25/0.1) being sprayed from a different channel on the microdevice shown in FIG. 1a. Spectra corresponding to the four analyzed examples are presented in FIGS. 8a-8d. The experimentally determined molecular weight, the actual molecular weight and the accuracy limit for each sample were as follows: FIG. 8a, 0.1 mg/ml myoglobulin, MW exp =16,953, MW act =16,950, accuracy limit=0.02%; FIG. 8b, 0.1 mg/ml endorphin, MW exp =3438.3, MW act =3438, accuracy limit=0.01%; FIG. 8c, 0.1 mg/ml human growth hormone, MW exp =22,120, MW act =22124, accuracy limit=0.02%; and FIG. 8d, 0.1 mg/ml ubiquitin, MW exp =8565, MW act =8557, accuracy limit=0.09%. Each analysis can be carried out in a few minutes when the system is operated in a sequential analysis mode, a very high throughput for analyzing biological samples. This operational approach implies that sample preparation can be conducted in one channel while another channel is being used simultaneously to analyze a sample. In this mode, the utilization efficiency of the mass spectrometer will be higher than has been possible before. With a similar design to that shown in FIG. 1a, a microdevice of the invention with as many as 20 channels can be fabricated for increasing the analysis throughput of a mass spectrometer. Furthermore, a microdevice having a three-dimensional array of channels, such as is shown in FIG. 1d, would make even a substantially higher sample throughput possible.
EXAMPLE III
Study of detection limit
FIG. 9 shows an electrospray mass spectrum of myoglobin obtained by spraying a 0.001 mg/ml myoglobin solution at 200 nl/min in methanol/water/acetic (75/25/0.1) directly from the exit port of the microdevice to the sampling orifice of the mass spectrometer. The signal to noise ratio in this example is better than 10:1, indicating that the limit of detection is better than 10 -8 M. The electrospray voltage was 4.4 kV.
EXAMPLE IV
Electrospray of a mixture of samples
FIG. 10 shows a mass spectrum of a mixture of 0.05 mg/ml of human growth hormone and 0.05 mg/ml of ubiquitin in methanol/water/acetic acid (75/25/0.1) sprayed from micromachined chip channels of width 60 μm and depth 25 μm at a flow rate of 200 nl/min. The electrospray voltage (4.3 kV) was applied from the injection side of the chip. Two separate envelopes of multiply charged ions corresponding to individual sample components are visible in the spectrum. Exact molecular weight calculation of each sample component is possible from these data, and the experimentally determined MW values were the same as in Example II, when each sample was analyzed from a separate channel. This experiment illustrates that a complex mixture can be analyzed with only partial or even no separation of the sample components within the microdevice. The mass spectrometer serves as the separation tool. In separate experiments, MS/MS operation can be used to deduce the structure of individual ions.
EXAMPLE V
Analysis of a sample in aqueous solution
FIG. 11a shows an electrospray mass spectrum from infusing 0.05 mg/ml human growth hormone from aqueous solution, with methanol/water/acetic acid (75/25/0.1) in the syringe for applying pressure, and FIG. 11b shows an electrospray mass spectrum from infusing 0.05 mg/ml human growth hormone directly from a solution of methanol/water/acetic acid (75/25/0.1). This example shows that direct off-chip (off-microdevice) electrospraying of an aqueous sample without any prior addition of an organic solvent provides a high quality spectrum (FIG. 11a), comparable to the one obtained with a methanol supplemented sample (FIG. 11b), and that the same experimentally determined molecular weight value of 22,120 is obtained whether the sample is in an entirely aqueous or a methanol supplemented environment. In current practice with standard electrospray interfaces, samples are typically supplemented with organic additives; however, for biological samples which do not tolerate organic additives, direct spraying of an aqueous solution is the best approach to performing the analysis.
EXAMPLE VI
On-chip digestion of peptides and proteins
Referring to FIG. 12a, on-chip digestion of melittin was conducted in 20 mM Tris buffer of pH 8.2, melittin/trypsin ratio=300/1 (w/w). The concentration of melittin was 40 μM. Electrospray mass spectrum (i) is of a 10 min digestion, and spectrum (ii) is for a 1 hr digestion. The same sample fragments were detected, but at different levels, after the two digestion time periods. For example, peak no. 5, representing a molecular ion, is reduced after the longer digestion time period whereas peak no. 2, representing a product ion of the digestion, increases over time.
FIG. 12b presents a comparison of on- and off-chip digestion of 2 μM casein. The reaction conditions were similar to those used in the experiment of FIG. 12a, except that the ratio of casein/trypsin was 60. The two spectra show substantially identical patterns. These results demonstrate that the microscale fluid handling system of the invention can be used to study the digestion kinetics of peptides and proteins and also show that on- and off-chip digestion generate very similar fragments. The success of on-chip digestion also indicates that incorporating sample preparation for electrospray mass spectrometry onto a chip is practical and will simplify the sample handling process and increase analysis throughput.
EXAMPLE VII
Analysis of a model DNA sample
To exploit the potential of the invention in analyzing varieties of samples, a short DNA fragment (20mer) was analyzed by electrospray mass spectroscopy without any prior treatment, and the resulting spectrum is presented in FIG. 13. Compared to the calculated molecular weight of 6155, the experimentally measured molecular weight of the sample is 6164.3, an accuracy of within 0.015%. The DNA sample was sprayed from 60% acetonitrile, 40% H 2 O solution to facilitate the percentage of sample vaporization. With such a high accuracy in determining DNA molecular weight, it is contemplated that the invention can be analyzed to screen DNA mutations.
While the present invention has been described in conjunction with a preferred embodiment, one of ordinary skill, after reading the foregoing specification, will be able to effect various changes, substitutions of equivalents, and other alterations to the compositions and methods set forth herein. It is therefore intended that the protection granted by Letters Patent hereon be limited only by the appended claims and equivalents thereof. | A microscale fluid handling system that permits the efficient transfer of nanoliter to picoliter quantities of a fluid sample from the spatially concentrated environment of a microfabricated chip to "off-chip" analytical or collection devices for further off-chip sample manipulation and analysis is disclosed. The fluid handling system is fabricated in the form of one or more channels, in any suitable format, provided in a microchip body or substrate of silica, polymer or other suitable non-conductive material, or of stainless steel, noble metal, silicon or other suitable conductive or semi-conductive material. The microchip fluid handling system includes one or more exit ports integral with the end of one or more of the channels for consecutive or simultaneous off-chip analysis or collection of the sample. The exit port or ports may be configured, for example, as an electrospray interface for transfer of a fluid sample to a mass spectrometer. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK
[0003] N/A
BACKGROUND OF THE INVENTION
[0004] The field of this invention is that of liner hangers for the isolation of the well bore of oil and gas wells from the earth formations through which the oil or gas well is being drilled.
[0005] As different producing formations which the drilled well will pass through must be isolated from each other, a casing string must be cemented in place to isolate each zone. An oil or gas well is typically drilled by first deciding the minimum bore of the production string of casing, or the last pipe to be cemented in place, and which will be continuous from the surface all the way down to the oil or gas producing formations. This production string of casing must be large enough to allow the production tubing landed inside it to flow enough oil or gas at sufficient volumes to make the well economic.
[0006] Each casing set point requires that an additional concentric casing string be set. A typical set of casing strings in a subsea environment from the inside out would be 7″, 9.625″, 11.750″, 13.375″, and 16″ set within an 18.750″ bore blowout preventer stack, 20 and 30″ casing strings set before the 18.750″ bore blowout preventer stack is installed. Each casing string occupies a certain amount of radial space, requiring that the next string of pipe be progressively smaller. That program provides a maximum of 5 casing set points with blowout preventer protection during drilling.
[0007] Typically, a casing string, i.e. 11.75″ outer diameter, is installed in a drill well bore suspended from the surface to a depth such as 10,000 foot depth. After cementing the 11.750″ casing in place, a hole is drilled with a bit through the 11.750″ casing, i.e. 10.50″ diameter hole to 12,000 feet deep. Into this hole a 9.625″ outside diameter casing can be landed and cemented in place. If the 9.625″ casing string is suspended from the surface and is therefore 12,000 feet long, it is called a casing string. If, however, the 9.625″ casing is only 2000′ long and is suspended by a hanger from the lower end of the 11.750″ casing string, it is called a liner. The use of a liner can save substantially on the cost of casing and cement, e.g. 10,000 feet of casing not purchased. The well program would be followed with a 7.000″ casing string continuous from the surface to the bottom of the well as the production casing string.
[0008] The 9.625″ liner in the example above would have saved the operator the 10,000 feet of casing not purchased, with the cost of a conventional liner hanger being generally offset by the cost of the surface casing hanger. The liner still “costs” the drilling company the “radial space”, forcing the next string to be progressively larger.
[0009] In this conventional scenario, if an unexpected pressured formation is encountered and requires that an extra casing string be set, it would probably be 5.500″ in outside diameter. With the 5.500″ size, the tubing string landed inside would be reduced from 3″ to 2″, substantially restricting the flow of production from the well. Flow from wells is especially important offshore where the high cost of drilling and producing wells demands a high flow rate to be economic. Cases have been seen of abandonment of wells when an extra pressurized reservoir zone was encountered and the driller realized that his final well bore size would be too small to be economic.
[0010] Other methods, such as described in U.S. Pat. No. 6,435,281 provide for the ability to utilize liners which offer characteristics such as are listed in liners above, with the additional feature that they expand below the casing string they attach to. This means that the well bore will not be reduced a stage, making either the ultimate hole larger, or allowing one to start with a smaller string at the top. This style provides a feature that a substantial length of the liner could be rolled up on a reel and simply unrolled into the well bore for inflation. A disadvantage of this style was that during the unrolling and running operation, it was of a shape which could not be sealed on by blowout preventers to maintain well control. It depended upon having a “dead” well, or one in which the pressure head of the liquid mud column in the well bore exceeded the formation pressures. This can be of particular advantage when an actual application of the liner is to seal off an unexpected pressure zone in the formations.
SUMMARY OF THE INVENTION
[0011] The object of this invention is to provide a liner which does not occupy “radial space” in the well bore and therefore does not force each previously set casing hanger to be a step larger in diameter.
[0012] A second object of the present invention is to provide the capability of installing multiple liners in a drilling program to compensate for unforeseen well control situations.
[0013] A third object of the present invention is to provide a liner that can be rolled up for compact storage and shipment.
[0014] Another object of the present invention is to provide a liner assembly that is compact enough to be airlifted out to an offshore drilling vessel.
[0015] Another object of the present invention is to provide an expandable liner that is metallic in construction and impervious to fluid flow.
[0016] Another object of the present invention is to provide an expandable liner which can be sealed upon with a blowout preventer to provide well control during the running operations.
[0017] Another object of the present invention is to provide an expandable liner which can be supported by smooth face wedge slips which eliminate the need for marking the liner with sharp slip teeth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a section through the oil or gas well with a liner of the present invention unrolled into the well.
[0019] [0019]FIG. 2 is a section through the oil or gas well which eliminates the blowout preventer equipment of FIG. 1 to allow for easier viewing.
[0020] [0020]FIG. 3 is a section through the oil or gas well showing the liner inflated.
[0021] [0021]FIG. 4 is a section through the oil or gas well showing the expander in the running tool expanded.
[0022] [0022]FIG. 5 is a section through the oil or gas well showing that the running tool has been removed and a rolling expander approaching the top of the liner.
[0023] [0023]FIG. 6 is a section through the oil or gas well showing the rolling expander has expanded the liner and the lower section of the casing.
[0024] [0024]FIG. 7 is a section through the lower end of the expandable liner.
[0025] [0025]FIG. 8 is a section through the oil or gas well along lines “ 8 - 8 ” of FIG. 2
[0026] [0026]FIG. 9 is a section through a blowout preventer as shown in FIG. 1 showing the rams sealing on the liner as it is being run.
[0027] [0027]FIG. 10 is a section through a portion of reeled liner showing the stacking method.
[0028] [0028]FIG. 11 is a section through the support slip assembly taken along lines “ 11 - 11 ” of FIG. 14.
[0029] [0029]FIG. 12 is an end view of a reel holding the liner of this invention.
[0030] [0030]FIG. 13 is a side view of a reel holding the liner of this invention and sitting on a skid to assist in the deployment of the liner into a well bore.
[0031] [0031]FIG. 14 is a side view of a reel holding the liner of this invention with the liner being deployed thru a slip assembly and into the well bore.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Referring now to FIG. 1, the collapsed liner 2 is shown in a bore 4 in the formations 6 and is supported by a running tool 8 . The running tool 8 is supported by a running string 10 which is inside a casing string 12 , which is supported by a casing hanger 14 inside a housing 16 . A connector 18 is attached to housing 16 and supports two ram type blowout preventers 20 and 22 , an annular type blowout preventer 24 , and a flex joint 26 . Riser 28 extends to the surface on a subsea well, but would not exist on a land well.
[0033] Referring now to FIG. 2, an enlarged view is shown of a portion of FIG. 1 for clarity.
[0034] Referring now to FIG. 3, area 50 shows that pressure has been pumped down running string to inflate the liner and to push the central portion 52 of the shoe 54 to shear a pin. After inflation, spring 56 pushes the central portion 52 up to allow an opening through the shoe 54 . This allows cement to be circulated down to cement the lower portion of the liner in place.
[0035] Referring now to FIG. 4, a sealing dart 60 is dropped into the running tool 8 and the running string 10 is pressured to inflate the rubber element 62 to expand the portion of the liner 64 . As the liner is of a relatively soft metal, it will be yielded into the casing string and will retain contact with the casing string when the pressure is removed.
[0036] Referring now to FIG. 5, the running tool 8 (from FIG. 4) is removed by right hand rotation and a rolling expander 70 is approaching the top of the liner. As the eccentric rolls 72 , 74 , 76 , and 78 on the rolling expander 70 move into the top of the liner with a rotary motion, the non-expanded portions of the liner are expanded to the I.D. of the casing string.
[0037] Referring now to FIG. 6, a fully opened well bore is shown ready to be drilled out. The casing shoe 54 will be drilled up as drilling proceeds.
[0038] Referring now to FIG. 7, a section of the casing shoe is shown, with the collapsed liner 2 at the top going into a transition section 80 . Central portion 52 is supported by shear pin 82 and is sealed by seal 84 . During the initial pressure cycle of inflating the liner, the shear pin 82 is sheared and the central portion 52 moves down to land on shoulder 86 . After the pressure of inflation is removed, the spring 56 pushes the central portion out and allows cement to be passed through the shoe to the annular area outside of the now inflated liner.
[0039] Referring now to FIG. 8, a cross section of the collapsed liner 2 of this invention is shown with various bends to make the rolling of the liner on a reel practical. Circle 90 shows the internal diameter of the casing being run through and circle 92 shows the external diameter of the casing. Circle 94 shows the internal diameter of the liner after it is expanded and circle 96 shows the external diameter of the liner after it is expanded.
[0040] Referring now to FIG. 9, the liner of this invention is shown going through the bore 100 of a ram type blowout preventer with blowout preventer ram 102 having front personality 104 to engage one side of the liner and blowout preventer ram 106 having a front personality 108 to engage the opposite side of the liner. It should be noted that the entire external surface of the liner 2 is engaged by seals on the relative faces of the blowout preventer rams to allow for full well protection during the running operations except for a couple of feet at each end. The interface 110 between the blowout preventer rams shows the parts of the rams which separate to allow full passage of components.
[0041] Referring now to FIG. 10, several sections of the liner are engaged as they would be when rolled layer on layer on a reel, as will be discussed in later figures.
[0042] Referring now to FIG. 11, a section through a support slip assembly as will be seen in FIG. 14 is shown. Slip segment 120 engages the collapsed liner 2 with personality 122 which matches the collapsed liner on one side. The back 124 of slip segment 120 engages surface 126 of bowl half 128 . Likewise, slip segment 130 engages the collapsed liner 2 with personality 132 which matches the collapsed liner on one side. The back 134 of slip segment 130 engages surface 136 of bowl half 138 . As the bowl surfaces 126 and 136 of conventional slip assemblies are normally tapered at angles from 8 degrees to 15 degrees with respect to vertical, the contact between the front personalities 122 and 132 require sharp teeth to effectively increase the coefficient of friction and ensure support of the pipe being supported. In this case, the angles of the personality 122 and 132 of the front of the slip segments 120 and 130 tend to wedge or amplify the force in comparison to the forces on the backs of the slip segments. Due to this amplification, a smooth surface can be utilized on the personalities 122 and 132 to eliminate cutting and stress concentrations on the collapsed liner.
[0043] Referring now to FIG. 12, a roll 150 of the liner 2 is shown. Shoe 54 is shown on the free end of the roll and running tool 8 is shown on the first end of the liner which was wrapped on the reel, and is offset to make the reeling practical. Motor 152 is provided to drive chain 154 and the reel of liner through appropriate sprockets. Frame 156 supports the liner for transportation.
[0044] Referring now to FIG. 13, a side view of the roll of liner 150 is shown within frame 156 . Subframe 160 is shown with cylinder 162 which can move the frame 156 . Subframe 160 is setting on the drilling rig floor 164 in the area of the rotary table 166 .
[0045] Referring now to FIG. 14, liner 2 is shown being lowered into the well bore through slip assembly 170 . As liner 2 is reeled off the roll of liner 150 and the radius of the liner on the reel is reduced, cylinder 162 is used to keep the liner 2 centralized in the well bore. As running tool 8 is in the final rotation and moves to the vertical position, the slip assembly 170 is set to support the liner. Frame 156 and subframe 160 are removed and a running string is added to the top of the liner 2 . At this time the liner 2 is run as shown in FIGS. 2 through 6.
[0046] Other applications of this expandable pipe concept exist, such as sending a liner into a leaking water pipe to reestablish the pressure competence of the pipe or to seal a bare hole which has no other pipe associated with the hole.
[0047] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.
SEQUENCE LISTING
[0048] N/A | A method of providing a liner which can be rolled up on a reel for convenient transport and which can be unrolled into the bore of an oil or gas well and expanded to the approximate bore size of the casing size which the liner was run through and is collapsed in a way which allows sealing and stripping with a blowout preventer for well control protection during running and providing smooth surface support wedging without the need for marking the pipe with slip teeth. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to an actuator comprising an electric motor and a motor controller. Specifically, the present invention relates to an actuator comprising an electric motor and a motor controller whereby the actuator is used to work cooperatively, i.e. in piggyback configuration, with another actuator which is coupled mechanically to the actuator for driving a common load.
BACKGROUND OF THE INVENTION
[0002] It is common practice to couple mechanically two or more actuators for driving a common load, i.e. to use two or more actuators in piggyback configuration or simply “piggybacked”. For example, the actuators are mechanically coupled directly through attachment to a common drive shaft or indirectly through connecting rods, levers, bars, other linkage assemblies, or parts of the load to be driven, e.g. a damper or a valve. Typically, and depending on the type and way of the mechanical coupling of the actuators to each other and/or the common load, the materials used for the mechanical coupling, and the distances between the individual actuators, etc., the load is not equally distributed among the piggybacked actuators, the force provided by their electrical motors is not optimally used and combined, and, worst of all, as a result, gear and transmission mechanisms of the actuators are damaged in the process.
SUMMARY OF THE INVENTION
[0003] It is an object of this invention to provide an actuator which is suitable to work cooperatively with one or more other actuators which are coupled in piggyback configuration, for driving a common load, which actuator does not have at least some of the disadvantages of the prior art.
[0004] According to the present invention, these objects are achieved through the features of the independent claims. In addition, further advantageous embodiments follow from the dependent claims and the description.
[0005] According to the present invention, the above-mentioned objects are particularly achieved in that an actuator, comprising an electric motor and a motor controller, is configurable to operate as a master or a slave to another actuator which is coupled mechanically to the actuator for driving a common load. The motor controller is configured, for the case where the actuator is set as the master, to receive on an input terminal an external position control signal, to generate based on the position control signal (and the load) a motor control signal, e.g. a speed control signal or a torque control signal, to control the motor by supplying the motor control signal to the motor, and to control a slave by supplying the motor control signal to an output terminal. The motor controller is further configured, for the case where the actuator is set as the slave, to receive on the input terminal the motor control signal supplied by the master, and to control the motor by supplying the motor control signal from the master to the motor. Accordingly, two or more actuators which are coupled mechanically to drive a shared load follow the control signal of one common controller which is implemented on the actuator which is set up as the master and perceives a force feedback from the slave actuators through the mechanical coupling. Thus, inherent in the speed control signal provided by the master actuator to the slave actuator(s) is not only the speed at which the actuators are controlled to run, but also the momentum, or vice versa. Thereby, counter-productive work is avoided, the work load is balanced more equally among the piggybacked actuators, and more cooperative and efficient work load sharing is achieved and energy can be conserved, without damage to gear and transmission mechanics of the actuators, because the actuators drive their common load in the same direction and do not work against each other.
[0006] In a preferred embodiment, the motor controller is further configured to measure, at start-up time, voltage levels at the input terminal, and to set the actuator as a slave depending on the voltage levels measured at the input terminal. Automatic detection of a slave mode, based on voltage levels at an input terminal, makes it possible to set up an actuator as a slave simply through corresponding wiring of the slave actuator, provided the defined voltage levels are supplied by the master actuator or another external control system, for example.
[0007] In another preferred embodiment, the motor controller is further configured to reduce the impedance of the input terminal, for the case where the actuator is set as a slave. Furthermore, the motor controller is configured to detect at the output terminal a voltage reduction caused by a lowered impedance of another actuator connected to the output terminal, and to set the actuator as the master upon detecting the voltage reduction at the output terminal. Automatic detection of a master mode, based on an interrupt which is indicated by an abrupt voltage reduction caused by a lowered impedance level of a unit connected to the output terminal, makes it possible to set up an actuator as a master simply through corresponding wiring of the master actuator, provided the impedance level is lowered accordingly by one or more slave actuators or another external unit, for example.
[0008] In a preferred embodiment, the motor controller is further configured to set, at start-up time, a defined first voltage level at the output terminal, and to set a defined second voltage level at the output terminal, upon having been set as the master, the defined second voltage level being different from the first voltage level. Providing a different, e.g. reduced or increased, voltage level by the master actuator at the output terminal makes it possible for an actuator, which has its input terminal as a slave connected to the output terminal of the master actuator, to detect more reliably that it is indeed set up as a slave actuator connected to the master actuator.
[0009] In an embodiment, the motor controller is further configured, for the case where the actuator is set as a slave, to provide on the output terminal a position signal indicating a current actuator position. The position signal makes it possible to indicate to an external control system the actual and current positions of the actuator(s).
[0010] In an embodiment, the actuator further comprises one or more stored actuator parameters, e.g. a speed parameter and/or a torque parameter, and the motor controller is configured to generate the motor control signal based on the actuator parameters and the position control signal (and the load). Accordingly, one external position control signal can be supplied to different types of actuators or motors respectively, which have different actuator parameters stored for mapping the external position control signal internally to the appropriate motor control signal.
[0011] In an embodiment, the actuator is further configurable to operate as a stand-alone actuator, and the motor controller is further configured, for the case where the actuator is set as a stand-alone actuator, to receive on the input terminal the external position control signal, to generate based on the position control signal (and the load) the motor control signal, to control the motor by supplying the motor control signal to the motor, and to provide on the output terminal a position signal indicating a current actuator position. Thus, the same type of actuator can be used in master mode, in slave mode, or in stand-alone mode, simply by corresponding configuration, e.g. by corresponding wiring.
[0012] In another embodiment, the actuator further comprises a terminal box, the terminal box houses the electrical terminals of the actuator and has breakthrough areas for feeding electrical wires through the terminal box to the electrical terminals.
[0013] In another embodiment, the actuator further comprises manual control elements which are enclosed by the terminal box.
[0014] Preferably, the terminal box has a removable lid, whereby in a closed position, the removable lid is configured to protect the electrical terminals from splash liquid, and, in an open position, enabled is access to the electrical terminals and/or to the manual control elements.
[0015] In an embodiment, the actuator further comprises a mechanical interface with two openings on opposite sides for receiving a drive shaft. The mechanical interface has arranged at one of the openings a fastener for coupling the drive shaft to the electric motor, and one or more support rings inserted into the opposite one of the openings and configured to receive the drive shaft and to reduce lateral movement of the drive shaft with respect to a drive axis running through the two openings.
[0016] In yet another embodiment, the actuator further comprises an anti-rotation member arranged on a face of the actuator, and the support rings are inserted in the one of the openings that is arranged on the face of the actuator having the anti-rotation member arranged thereon. The supporting insert rings prevent or at least reduce lateral movement of the drive shaft that would otherwise result from the momentum or torque about the actuator's longitudinal axis resulting from the force of the electrical motor, particularly when the anti-rotation member and the fastener are arranged on opposite sides of the actuator.
[0017] In addition to an actuator, the present invention also relates to a method of operating the actuator and a computer program product comprising computer program code for controlling one or more processors of an actuator, preferably a computer program product comprising a tangible, non-transitory computer-readable medium having stored therein the computer program code. Specifically, the computer program code is configured to direct the one or more processors of the actuator to control the actuator to operate as a master or a slave to another actuator which is coupled mechanically to the actuator for driving a common load, whereby, for the case where the actuator is set as the master, the processor receives on an input terminal of the actuator an external position control signal, generates based on the position control signal (and the load) a motor control signal, e.g. a speed control signal or a torque control signal, controls a motor of the actuator by supplying the motor control signal to the motor, and controls the slave by supplying the motor control signal to an output terminal of the actuator; and whereby, for the case where the actuator is set as the slave, the processor receives on the input terminal the motor control signal supplied by the master, and controls the motor by supplying the motor control signal from the master to the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention will be explained in more detail, by way of example, with reference to the drawings in which:
[0019] FIG. 1 shows a block diagram illustrating schematically two actuators which are coupled mechanically to drive a common load and set up in a master/slave configuration.
[0020] FIG. 2 shows a block diagram illustrating schematically three actuators which are wired and set up in a master/slave configuration to drive a common load.
[0021] FIG. 3 shows different examples of piggybacking two or more actuators to drive a common mechanical load.
[0022] FIG. 4 shows a partial view of an actuator having a terminal box which houses the electrical terminals of the actuator and has a closed lid.
[0023] FIG. 5 shows the partial view of the actuator in a state where the lid of the terminal box is open.
[0024] FIG. 6 shows a view of the actuator with a cut-out section illustrating a mechanical interface for receiving and coupling a drive shaft to the motor of the actuator.
[0025] FIG. 7 shows a longitudinal cross section of the actuator illustrating the mechanical interface for receiving and coupling the drive shaft with the motor.
[0026] FIG. 8 shows a state diagram illustrating an exemplary sequence of transitions for detecting in an actuator that it is set up as a master.
[0027] FIG. 9 shows a state diagram illustrating an exemplary sequence of transitions for detecting in an actuator that it is set up as a slave.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] In FIGS. 3 , 4 , 5 , 6 , and 7 , reference numeral 1 refers to an actuator. In FIGS. 1 and 2 , corresponding actuators 1 are designated with reference numerals 1 M, 1 S or 1 S′, respectively, the reference numeral 1 M referring to an actuator 1 configured as a master, and reference numerals 1 S, 1 S′ referring to actuators 1 configured as slaves. As will be described later in more detail, preferably, configuration of an actuator 1 is determined dynamically and automatically; however, one skilled in the art will understand, that, alternatively, a slave or master mode can be set manually for an actuator 1 , e.g. by setting jumpers or entering a mode parameter through operating elements, etc. For example, parameterization and setting of master or slave modes, respectively, can be set via a communication interface, e.g. a communication bus of the actuators 1 , 1 M, 1 S, 1 S′, or via an electrical terminal, e.g. output terminal U 5 which will be described later prior to the wiring of the actuators 1 , 1 M, 1 S, 1 S′, for example.
[0029] As illustrated schematically in FIG. 1 , the actuators 1 M, 1 S comprise a housing 10 and, arranged in the housing, an electric motor 12 and a motor controller 11 . For example, the electric motor 12 is a DC motor, particularly, a brushless DC (BLDC) motor. The motor controller 11 includes a control module 14 , an optional motor task module 15 and a data store 13 having stored therein one or more actuator parameters, e.g. an optional speed parameter and/or a torque parameter. The control module 14 includes a proportional-integral controller (PI controller) or another controller for generating a motor control signal sC, e.g. a speed control signal or a torque control signal (for controlling the motor current), in response to a position control signal pC received from an external control system via an electrical input terminal Y 3 and depending on the load. In an embodiment, the control module 14 or PI controller is configured to generate the motor control signal sC from the external position control signal pC and depending on the load based on the stored actuator parameters, e.g. based on the speed parameter 13 which defines for the specific actuator 1 , 1 M, 1 S, 1 S′ or its motor 12 , respectively, a position-to-speed calculation factor, and/or based on a torque parameter which defines for the specific actuator 1 , 1 M, 1 S, 1 S′ or its motor 12 , respectively, a position-to-torque calculation factor. In different embodiments, the motor control signal sC generated by the control module 14 or PI controller, respectively, is provided directly to the motor 12 or through the optional motor task module 15 which is implemented as a (motor) ASIC, for example, and periodically receives, e.g. every 10 ms, from the control module 14 or PI controller, respectively, the motor control signal sC. Moreover, the control module 14 includes a mode detector configured to detect whether the actuator 1 , 1 M, 1 S, 1 S′ is arranged in a non-piggybacked setting (i.e. in conventional stand-alone mode), or whether it is set up as a master (i.e. in master mode) or a slave (i.e. in slave mode) in a piggyback configuration with one or more additional actuators 1 , 1 M, 1 S, 1 S′, as will be explained later in more detail.
[0030] In an embodiment, the actuator 1 , 1 M, 1 S, 1 S′ includes two separable units with separate housings which can be coupled electrically for exchanging control signals; one unit comprises the motor 12 and the motor task module 15 , whereas the other unit comprises the mode detector. Depending on the embodiment, the PI controller or other controller for generating the motor control signal sC and the data store 13 with the actuator parameters are implemented in the first unit, together with the motor 12 , or in the other unit, together with the mode detector.
[0031] The functional modules of the motor controller 11 , including the control module 14 , PI controller, mode detector and the optional motor task module 15 , are implemented as programmed software modules which direct one or more processors, as another programmed logic unit, e.g. an application-specific integrated circuit (ASIC), or fully or partly by way of discrete hardware components.
[0032] As illustrated in FIGS. 6 and 7 , the actuators 1 comprise a mechanical interface 4 , with an annular opening or bore running concentrically to drive axis z through the actuator 1 , for receiving a drive shaft 3 , e.g. a cylindrical drive axle of a mechanical load L such as a valve or a damper. The mechanical interface 4 comprises mechanical fastening means 40 , i.e. a fastener such as a clamp, pin or bolt connector, for fastening and mechanically coupling the drive shaft 3 to the electrical motor 12 . Furthermore, the actuator 1 is provided with one or more tubular or ring-shaped support elements, essentially in the form of a hollow cylinder, hereafter referred to as support rings 2 , 2 ′ for short, which are inserted into the opening of the mechanical interface 4 , opposite to the opening where the fastening means 40 are arranged. These support rings 2 , 2 ′ fill in the gap between the drive shaft 3 and the wall of the mechanical interface 4 and reduce slackness and lateral movement of the drive shaft 3 with respect to the drive axis z. The support rings 2 , 2 ′ are removable and come in different and/or variable diameters and thicknesses depending on the diameter of the drive shaft 3 . In an embodiment, the surface of the support rings 2 , 2 ′ are ripped or teethed, for example. As shown in FIGS. 6 and 7 , the actuator 1 is also provided with an anti-rotation member 5 arranged on a face 100 of the actuator 1 or its housing 10 , respectively. The anti-rotation member 5 is attached to the actuator 1 and extends beyond the width of the actuator 1 . It has one or more bores for fixing the actuator 1 to a support structure, such as a wall, a beam, a post or a pipe, for example. In installation scenarios where the anti-rotation member 5 and the fastening means 40 are arranged on opposite faces or sides of the actuator 1 or its housing 10 , respectively, the support rings 2 , 2 ′ prevent or at least reduce lateral movement of the drive shaft 3 that would otherwise result from the momentum M or torque about the actuator's longitudinal axis resulting from the force of the electrical motor 12 . In alternative embodiments, the anti-rotation member 5 is implemented in form of one or more pins or screws, for example.
[0033] As illustrated in FIGS. 4 and 5 , the actuators 1 further comprise a terminal box 6 which houses the electrical terminals 7 a, 7 b of the actuator 1 . The terminal box 6 has a four-sided wall that encloses the electrical terminals 7 a, 7 b and is either attached to the remaining housing 10 of the actuator 1 or formed as an integral part of the housing 10 . The electrical terminals 7 a are fixed to the actuator 1 and receive the connection wires 7 directly or by way of connection terminals 7 b. Accordingly, terminals 7 a are configured as receptacles whereas terminals 7 b are configured as connectors which can be plugged into the receptacle. The terminal box 6 further comprises a lid 60 for opening the terminal box 6 to get access to the electrical terminals 7 a, 7 b and optional operating elements 8 which are also arranged in the terminal box 6 . Depending on the embodiment, for opening the terminal box 6 , the lid 60 is removed entirely from the terminal box 6 or it is rotated about an axle of a hinge by which the lid 60 is attached to the terminal box 6 . In its closed state, the lid 60 is fastened and secured to the wall of the terminal box 6 by way of screws, clamps or other fastening means. In an embodiment, a surrounding sealing ring is arranged on the lid 60 and/or on the wall of the terminal box 6 for sealing the gap between the wall of the terminal box 6 and lid 60 . The terminal box 6 further comprises a plurality of breakthrough areas 61 for feeding electrical wires 7 through the wall of the terminal box 6 for connecting the wires 7 to the electrical terminals 7 a, 7 b. The wires 7 are run through a breakthrough 61 directly or by way of a sealing cable connector that further prevents splash water from entering the terminal box 6 . Preferably, to increase flexibility in arranging, installing and electrically wiring the actuator 1 , one or more breakthrough areas 61 are provided on all side walls of the terminal box 6 so that an opening can be broken through the wall or lid 60 of the terminal box 6 wherever it is needed or convenient in the particular set up.
[0034] As shown in FIG. 2 , the electrical terminals include at least two power supply terminals V 1 , V 2 , an input terminal Y 3 for receiving control signals, and an output terminal U 5 for providing an output or a feedback signal.
[0035] FIG. 3 illustrates different examples of two or more actuators 1 which are arranged in a piggyback configuration for driving a common load L. Specifically, the piggybacked actuators 1 are coupled mechanically to drive the common load L cooperatively. Reference numeral PB 1 refers to a piggyback scenario where two actuators 1 are stacked on top of each other with equal orientation and coaxial alignment of their mechanical interfaces 4 such that the drive shaft 3 of the mechanical load L, here a damper, runs through the mechanical interfaces 4 of both actuators 1 . In piggyback scenario PB 2 , the two actuators 1 are arranged with a 180° opposite orientation, overlapping only with their coaxially arranged mechanical interfaces 4 such that the drive shaft 3 runs through both mechanical interfaces 4 . In piggyback scenario PB 3 , three actuators 1 are involved; two of the three actuators 1 are arranged as in scenario PB 1 and drive a first lever 81 attached to a drive shaft running through their mechanical interfaces 4 ; the third actuator 1 is arranged separate from the other two actuators and drives a second lever 82 . The three actuators 1 of piggyback scenario PB 3 are coupled mechanically in that the two levers 81 , 82 are linked by a bar to drive the common load L. In piggyback scenario PB 4 , two actuators 1 are arranged on opposite sides of their common load L, here a damper, and have a drift shaft 3 , which is coupled to the mechanical load L, run through their mechanical interfaces 4 . One skilled in the art will understand that there are numerous other ways of mechanically coupling two or more actuators 1 for driving a common load L cooperatively, i.e. in piggyback configuration.
[0036] FIGS. 1 and 2 show actuators 1 M, 1 S, 1 S′ which are mechanically coupled in a piggyback scenario whereby in each case one of the actuators 1 M is set up as a master (actuator) of the other actuators 1 S, 1 S′ which are set up in each case as a slave (actuator). Specifically, the master actuator 1 M has its input terminal Y 3 connected to an external control system for receiving a position control signal pC. Furthermore, the output terminal U 5 of the master actuator 1 M is connected to the input terminal(s) Y 3 of the slave actuator(s) 1 S, 1 S′ for transferring to the slave actuators 1 S, 1 S′ a motor control signal sC. The output terminal U 5 of the slave actuators 1 S, 1 S′ are connected, for example, to the external control system for providing a position indicator (feedback) signal pN. In FIGS. 1 and 2 , arrow F represents schematically the mechanic coupling or force feedback of the piggybacked slave actuators 1 S, 1 S′ to the master actuator 1 M. The power supply terminals V 1 , V 2 of the actuators 1 M, 1 S, 1 S′ are wired in parallel to an external power source.
[0037] In the following paragraphs, described with reference to FIGS. 8 and 9 are possible sequences of steps and state transitions performed by the functional modules of the actuators 1 , 1 M, 1 S, 1 S′ for detecting whether the actuator 1 , 1 M, 1 S, 1 S′ is set up in stand-alone mode (no piggyback), or in a piggyback configuration in either master mode or slave mode.
[0038] FIG. 8 illustrates a sequence of steps and transitions T 1 , T 2 , T 3 , T 4 , T 5 , T 6 , T 7 , T 8 (T 1 -T 8 ) between different phases P 0 , P 1 , P 2 , and P 4 (P 0 -P 4 ) for detecting in an actuator 1 , 1 M that it is configured and set up as a master.
[0039] FIG. 9 illustrates a sequence of steps and transitions T 1 , T 9 , T 10 , T 4 , T 11 , T 12 , T 13 , T 8 between the different phases P 0 -P 4 for detecting in an actuator 1 , 1 S, 1 S′ that it is configured and set up as a slave.
[0040] In the initial start-up phase P 0 , when the actuator 1 , 1 M, 1 S, 1 S′ is powered up, a defined initial control voltage, e.g. 9V, is provided at the output terminal U 5 of the actuator 1 , 1 M, 1 S, 1 S′, e.g. by the motor controller 11 or control module 14 , respectively. After a defined initialization time, e.g. 200 ms, the control module 14 or mode detector, respectively, sets a phase timer to a defined duration of time for phase P 1 , e.g. 800 ms, and moves the actuator 1 , 1 M, 1 S, 1 S′, in transition T 1 , from phase P 0 to phase P 1 .
[0041] In phase P 1 , the control module 14 or mode detector of the actuator 1 , 1 M, 1 S, 1 S′, respectively, checks periodically the voltage level at its input terminal Y 3 . If the actuator 1 , 1 S, 1 S′ is wired as a slave, the defined initial control voltage, e.g. 9V, will be measured at its input terminal Y 3 , and, as illustrated in FIG. 9 , in transition T 9 , the control module 14 or mode detector, respectively, sets a slave indicator to true and reduces the phase timer to a reduced duration of time for phase P 1 , e.g. 400 ms. Subsequently, if the defined initial control voltage, e.g. 9V, is measured again at the input terminal Y 3 when the slave indicator is already set to true, in transition T 10 , the phase timer for the remaining duration of the time for phase P 1 is set to zero.
[0042] Once the defined duration of time for phase P 1 has expired, in transition T 4 , the actuator 1 , 1 M, 1 S, 1 S′ is moved from phase P 1 to phase P 2 by its control module 14 or mode detector, respectively.
[0043] In phase P 2 , if the slave indicator is set to true, in transition T 11 , the control module 14 or mode detector, respectively, reduces the impedance of the actuator's input terminal Y 3 to a reduced level, e.g. from an initial 100 kΩ down to 1 kΩ. The impedance level is reduced for a brief duration of time, e.g. for 100 ms. Reducing the impedance level of the actuator's input terminal Y 3 will cause the voltage level at the output terminal U 5 of the master actuator 1 M wired to the slave actuator 1 S, 1 S′ to drop abruptly. Subsequently, e.g. after a defined duration of time, in transition T 12 , the actuator 1 , 1 S, 1 S′ is moved to phase P 3 by its control module 14 or mode detector, respectively, and the phase timer is set to a defined duration of time for phase P 3 , e.g. 600 ms.
[0044] In phase P 1 , if the actuator 1 M is wired as a master, it remains in phase P 1 and provides the defined control voltage at its output terminal U 5 , as indicated in FIG. 8 by transition T 2 , as long as there is no interrupt and the phase timer has not yet expired for phase P 1 . However, its control module 14 or mode detector will detect the abrupt drop of the voltage level at its output terminal U 5 as an interrupt signalled by one or more slave actuators 1 S, 1 S′. Consequently, as illustrated in FIG. 8 , in transition T 3 , the control module 14 or mode detector of the actuator 1 M sets a mode indicator to “master mode” and sets the phase timer for the remaining duration of the time for phase P 1 to zero. Consequently, in transition T 4 , the master actuator 1 M is moved from phase P 1 to phase P 2 by its control module 14 or mode detector, respectively.
[0045] In phase P 2 , if the mode indicator is set to “master mode”, in transition T 5 , the control module 14 or mode detector of the master actuator 1 M, respectively, reduces the voltage level at its output terminal U 5 to a reduced control voltage level, e.g. 7V. Subsequently, e.g. after a defined duration of time, in transition T 6 , the actuator 1 M is moved to phase P 3 by its control module 14 or mode detector, respectively, and the phase timer is set to a defined duration of time for phase P 3 , e.g. 600 ms. While in phase P 3 , the reduced control voltage level, e.g. 7V, is maintained at the output terminal U 5 of the actuator 1 M, if its mode indicator is set to “master mode”.
[0046] In phase P 3 , if the slave indicator is set to true, the control module 14 or mode detector of the actuator 1 , 1 S, 1 S′, respectively, checks periodically the voltage level at its input terminal Y 3 . If the actuator 1 , 1 S, 1 S′ is wired as a slave, the reduced control voltage, e.g. 7V, will be measured at its input terminal Y 3 , and, as illustrated in FIG. 9 , in transition T 13 , the control module 14 or mode detector, respectively, sets the mode indicator to “slave mode”.
[0047] It should be mentioned that the example presented herein describes merely the detection or indication of a slave based on a reduction of the control voltage level; however, one skilled in the art will understand that different patterns are possible which include one or more reductions and/or increases of the control voltage level.
[0048] Once the defined duration of time for phase P 3 has expired, in transition T 8 , the actuator 1 , 1 M, 1 S, 1 S′ is moved from phase P 3 to phase P 4 by its control module 14 or mode detector, respectively.
[0049] In phase P 4 , the actuator 1 , 1 M, 1 S, 1 S′ starts operating as a master or slave, if its mode indicator is set to “slave mode” or master mode”, respectively; otherwise, it operates as a conventional stand-alone actuator that is not configured in piggyback configuration. In an embodiment with an additional possibility for manual and/or communication-based parameterization of an actuator as master or slave, the decision about the respective mode is taken in phase P 4 , after completion of the mode detection algorithm through phases P 1 , P 2 , P 3 to P 4 .
[0050] In “master mode”, the control module 14 of the master actuator 1 M activates its PI controller. The PI controller receives or measures at the actuator's input terminal Y 3 the position control signal pC provided by the external control system and generates a motor control signal sC, e.g. a speed control signal or a torque control signal, based on the received position control signal pC and the load. For example, the motor control signal is generated as a pulse width modulation (PWM) signal. The control module 14 provides the generated motor control signal sC to its internal motor 12 , directly or via the motor task module 15 , and to its output terminal U 5 .
[0051] In “slave mode”, the control module 14 of the slave actuator 1 S, 1 S′ deactivates its PI controller. The control module 14 receives or measures at the actuator's input terminal Y 3 the motor control signal sC provided by the master actuator 1 M and provides the received motor control signal sC to its internal motor 12 , directly or via the motor task module 15 . Furthermore, in “slave mode”, the control module 14 of the slave actuator 1 S, 1 S′ provides to its output terminal U 5 a position indicator (feedback) signal pN.
[0052] In “stand-alone mode”, the control module 14 of the actuator 1 activates its PI controller to generate the motor control signal sC based on the position control signal pC received at its input terminal Y 3 from the external control system and depending on the load. The control module 14 provides the generated motor control signal sC to its internal motor 12 , and provides to its output terminal U 5 the position indicator (feedback) signal pN.
[0053] It should be noted that, in the description, the computer program code has been associated with specific functional modules and the sequence of the steps or transitions has been presented in a specific order, one skilled in the art will understand, however, that the computer program code may be structured differently and that the order of at least some of the steps or transitions could be altered, without deviating from the scope of the invention. | An actuator ( 1 M, 1 S) with a motor ( 12 ) and a motor controller ( 11 ) is configurable to operate as a master or a slave to another actuator which is coupled mechanically for driving a common load. For the case where the actuator ( 1 M) is set as the master, the motor controller ( 11 ) receives on an input terminal (Y 3 ) an external position control signal (pC), generates a motor control signal (sC) for controlling the motor ( 12 ) based on the position control signal (pC), and supplies the motor control signal (sC) to an output terminal (U 5 ) for controlling a slave. For the case where the actuator ( 1 S) is set as the slave, the motor controller ( 11 ) controls the motor ( 12 ) by supplying to the motor ( 12 ) the motor control signal (sC) received from the master. Controlling the actuators with a master improves workload balancing and reduces damages to transmission mechanics of the actuators. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to decorative roof fences and more specifically to a novel roof fence unit which includes features that allow it to be pivoted fore or aft to provide clearance for maintenance of the roof or equipment installed nearby.
2. Description of the Prior Art
Many large buildings, particularly business and apartment buildings, have flat roofs upon which are mounted air conditioning equipment and associated elements that due to their size would be visible from the ground. Many communities have passed ordinances requiring that such exposed equipment be enclosed from view either by extension of the walls of the buildings or by the erection of decorative roof top fences. Since the objectives of the ordinances requiring such fences or wall extensions are primarily aesthetic, permanently constructed wood slats, panels and other wood-surfaced fencing materials are the most commonly used and accepted roof top decorative materials.
A problem encountered in the use of ordinary fencing construction is that it provides a substantial obstacle to subsequent roof resurfacing operations and in many cases must be removed prior to such operations. This requires dismantling of a rather expensive structure and an even more expensive reconstruction thereof.
A further difficulty with fence constructions of the ordinary type is that they cannot be built too close to mechanical equipment located on the roof or else it becomes impossible to work effectively on the equipment. Avoiding this difficulty thus requires that the equipment be installed at least a working distance away from the fence.
SUMMARY OF THE PRESENT INVENTION
It is therefore an object of the present invention to provide a sturdy, decorative roof fence which may be pivoted in either of two directions so as to make working around it convenient.
Briefly, the present invention relates to a pivotal roof fence unit of predetermined length which includes at least a pair of base members which are intended to be secured to the roof top in parallel disposition to each other and an upper portion which includes a triangular arrangement of a fence member which is continuous over the entire length of the unit and a plurality of buttresses and cross members. The upper portion is secured to the base members by hinges which are attached so that by disconnecting the pivot pins of the hinges on one side of the unit the upper portion can be pivoted away from the bases and out of the way.
Each base member is provided with a pitch pocket or a flashing box which is typically made of aluminum or galvanized metal and fits around the respective base members so that pitch or other sealing material may be poured around the base member to provide a seal against leakage.
An advantage of the present invention is that it provides a sturdy, decorative roof fence which may be pivoted out of the way or removed completely without destruction to allow work on the roof or equipment located closed to the fence.
These and other objects and advantages of the present invention will no doubt become apparent after reading the following detailed description of the preferred embodiments which are illustrated in the several figures of the drawings.
IN THE DRAWING
FIG. 1 is a broken perspective view showing a building roof top having a number of fence units in accordance with the present inventions installed to form a fence;
FIG. 2 is a partially broken perspective view showing a roof unit in accordance with the present invention;
FIG. 3 is an elevational view showing an end of the unit illustrating pivoting action of the upper portion thereof;
FIG. 4 is a perspective view illustrating a corner fence unit in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 of the drawing there is shown a perspective view of a building having several roof fence units 10 in accordance with the present invention installed upon a roof 12 to create a fence. Corner fence units 13 are also shown which may be either permanently affixed to the roof or pivotally affixed thereto in a manner similar to the fence units to be described below.
In FIG. 2, a partially broken perspective view of a roof unit 10 is shown as installed upon a roof. As illustrated, each unit 10 includes a plurality of elongated base members 14 which are adapted to be affixed to a roof surface by lag bolts, screws or other suitable means 15, and an upper portion 16 which will be described below. In a typical case, the interior base members 11 might take the form of 4×6 inch treated wood beams, while the end base members might be constructed of 4×12 inch beams to accommodate adjacently installed upper portions. Alternatively, individual 4×6 inch end base members are separate pitch boxes could be used if the fence members 20 are extended to have an overhang at each end.
In order to waterproof the interface between base beam and roof, a pitch box or flashing box 17 may be used. In either case, pitch or other suitable sealing material 18 is deposited within the containers formed around the bases by the boxes 17 so as to insure that moisture does not collect under the beams or allow water to leak into the roof around the bolts 15.
The upper portion of the unit 10 is generally made up of three parts; a fence member 20, cross members 22, and buttress members 24. The fence member 20 typically includes a rectangular frame 26 and a plywood sheet 27 or other means for supporting cedar shakes, tiles etc., for forming a decorative front surface The fence member 20 extends continuously along the length of the unit but may have an end treatment which interlocks with an adjacent unit to provide a joint continuity.
The second component parts of the upper portion are a plurality of cross members 22 which are similar in number and length to the base members 14.
The third component parts of the upper portion are the butresses 24 which extend from the top edge of the fence member 20 to the back ends of the cross members 22 and are affixed thereto to support member 28. In the preferred embodiment, for added stability, a back member 28 is also rigidly connected between the rearmost ends of the cross members 22.
The upper portion 16 is connected to the base members 14 by hinges 30 which are attached along both the front and back sides of the unit as illustrated. The hinges 30 are of conventional construction and of the type which includes a pivot pin that may be knocked out so that the hinge plates 29 and 31 may be separated.
Referring now to FIG, 3, a right end elevation of the embodiment shown in FIG. 2 is illustrated to demonstrate how it may be pivoted either fore or aft as required to provide access to the underlying roof surface or adjacent equipment. As can be seen, base members 14, which are rigidly attached to roof surface 12, remain in a horizontal position at all times. However, when the hinges on either the front or the back side of the fence unit 16 are disconnected by removing the appropriate pivot pins, the entire upper portion may be pivoted on the hinges that remain connected and may be flipped back out of the way of anyone trying to work upon the roof or on items near to where the fence unit would normally sit when in its upright position. Illustrated is the pivoting of the upper portion over the back hinges; shown in phantom is the unit pivoting on the front hinges as well.
In FIG. 4 a corner fence unit is shown at 40. The construction is substantially the same as that of the units described above except that it is of course adapted to accommodate intersecting fence surfaces 42 and 44, and it includes either pivoting or non-pivoting tie-down fixtures 46 at the rear. The base members 41, 43 and 45 are of course not disposed parallel to each other but are laid out as illustrated. It will also be appreciated that where hinge type fasteners are used at 46, 48 and 50 the unit will be pivotable about any of three different axes by merely removing the hinge pins from the hinges of the other two sides.
The dimensions of fence units of the type describe above may be varied to suit the needs of the user. In the preferred embodiment, the length of the unit is approximately 8 feet with one interior set of base and support frame members located at the center of the unit. The height of the triangle formed by the upper portion is approximately 4 feet.
Although the present invention has been described above in terms of the presently preferred embodiments, it is to be understood that such disclosure is by way of example only and is not intended to be considered as limiting. Accordingly, it is intended that the appended claims are to be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention. | A pivotal roof fence unit comprising elongated base members for attachment to a roof surface member extending the entire length of the unit and, at least at both ends of the unit, cross members and buttresses used to support the fence member, and pivotal connecting means for connecting the upper portion to the base members such that the upper portion may be pivoted either forward or backward relative to the long axis of the base members. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to excavation apparatus of the type which employs high velocity air to loosen soil and a pneumatic vacuum to remove the loosened soil, and in particular to excavation apparatus having an improved air lance nozzle with a blade-shaped orifice, an improved air lance adapted to be rotated during excavation, and an improved pneumatic vacuum system including a multistage venturi ejector adapted to be fitted on a material collection container.
2. Discussion of Related Art
The concept of vacuum excavation has been discussed in a number of prior patents. U.S. Pat. Nos. 4,776,781, 4,936,031, 5,140,759, and 5,361,855 all disclose pneumatic soil excavation systems in which a jet of air is directed against a mass of soil by a hand-held nozzle to cause the mass to break up, and in which the loosened soil is collected by entraining it in an air flow carried by a pipe or conduit, and depositing the entrained soil at a site away from the excavation.
The theory underlying the concept of vacuum excavation is well-known. Essentially, application of supersonic jets of air causes local fracturing of the soil and rapid release of expanding high pressure air trapped within the soil at the local fracture sites. The fracturing and gas-release properties of the soil are not shared by man-made structures buried within the soil, such as natural gas lines, water pipes, sewer lines, and the like, and thus these structures are unaffected by the supersonic air jets.
Loosening of the soil by local fracturing and rapid expansion of gases trapped in the soil rather than by direct impact means that the air delivery device generates relatively low reaction forces and can be manipulated by a single person. Vacuum excavation therefore increases productivity relative to hand-excavation methods, i.e., shovels, without sacrificing precision, significantly reducing visible alteration of local landscaping or paving. In addition, the use of a high vacuum for material collection causes an effective evacuation of solid material from difficult to reach areas such as beneath or behind pipes, where shovels cannot fit or are difficult to maneuver.
Despite these advantages, however, the conventional vacuum excavation systems have a number of disadvantages that have prevented their widespread use. On the air lance side of the apparatus used in the conventional systems, the disadvantages include difficulties in handling the air lance, which conventionally must be “bounced” up and down to loosen layers of soil across an area of the excavation, and the need for a larger air supply than is available from the type of air compressor commonly used by contractors to operate pneumatic equipment. On the material collection side of the conventional vacuum excavation apparatus, the disadvantages include both the high initial cost of the vacuum generating equipment, and high maintenance costs.
One of the reasons for the large air consumption on the air lance side of the apparatus is the low resistance provided by the conventional cylindrical nozzle or pipe nipple. Because of this problem, nearly all companies currently performing vacuum excavation are forced to use high volume (100 cubic feet per minute (cfm) or greater) high pressure compressed air for soil breakup.
In order for an air lance to be an effective digging tool, the air must exit the lance at supersonic velocity which creates a shock wave in the air, and in order to create a shock wave at the tip of a ¼ inch pipe nipple, a high volume of high pressure air is needed. The typical air lance consists of ¾ or 1 inch internal diameter pipe with a reducer and a ¼ inch internal diameter pipe nipple at the digging end, and is supplied by a vehicle-mounted engine driven air compressor having an airflow rating of 180 cfm or greater. Since the most commonly available compressor has a rating of 185 cfm, the conventional cylindrical air lance requires the full power of the compressor, leaving the compressor unavailable for use as an air supply for a vacuum system, or to power other equipment, thus necessitating a separate engine driven vacuum pump.
On the vacuum collection side of the conventional vacuum excavation apparatus, most vacuum excavation systems employ vacuum pump and engine systems that require use of positive displacement blowers and various stages of filtration or cyclonic separation between the collection container and the positive displacement blowers, as the blowers are very susceptible to internal damage from particulates passing into the motive sections. Motors to drive the positive displacement blowers in the conventional vacuum pump and engine systems vary but generally range between 15 and 50 hp, with some systems making use of power take off linkage from the vehicle on which the unit is mounted.
In addition to being expensive and difficult to maintain, such systems are difficult to transport, and generally can only effectively access locations less than 25 feet from the vacuum source. The V-belts, filters, and internal combustion engines associated with vacuum pump/engine systems require complicated maintenance, which is compounded by the typically dirty and dusty work environments in which they are used, with those systems utilizing truck mounted hoppers being especially difficult to clean. In addition, conventional excavation systems of this type have poor water handling capabilities, since water can contaminate the vacuum generating equipment and especially the filters. Such systems can obviously not be taken indoors or up to work zones in high rise buildings.
While systems have also been proposed which use venturi-type ejectors to generate the vacuum and thereby reduce maintenance costs by eliminating the need for complex filtration or cyclonic separation systems, the conventional venturi systems require high air volumes (450 CFM or more) to generate an effective suction, and therefore require the use of large high cost air compressors and high volume connection hoses, which negates the advantage of simplicity offered in theory by the venturi engine concept.
The ultimate effect of these disadvantages is that, in order to begin using a conventional vacuum excavation system, an initial investment of greater than $100,000.00 is required, with significantly increased operating costs to be expected during the life of the system. This puts the cost of vacuum excavation apparatus out of reach of virtually all private contractors, not to mention others who might benefit from an inexpensive air lance and material removal system. On the other hand, the apparatus of the invention, as described below, currently has a cost of approximately one fourth the minimum cost of the conventional systems, and far lower transportation and maintenance costs.
SUMMARY OF THE INVENTION
It is accordingly an objective of the invention to provide an improved vacuum excavation system having greater versatility, lower maintenance, and lower initial costs than conventional vacuum excavation systems.
It is a second objective of the invention to provide a vacuum excavation system which uses a single portable air compressor of the type commonly used to operate tools at construction sites, as opposed to a dedicated positive displacement blower, or unusually large air compressor.
It is a third objective of the invention to provide a vacuum excavation system which can be maintained by daily cleanup of the vacuum engine, pickup pipe or hose, and collection drum, and in which the portable air compressor can be remotely located. The system has no need for filters or cyclonic separators between the vacuum source and the collection stream.
It is a fourth objective of the invention to provide a vacuum excavation system with improved water handling capabilities, and which can therefore be used for utility vault drainage, eliminating the need for a trash pump, and which can provide dewatering apparatus capable of 200 gpm transfer at 15 foot lift.
It is a fifth objective of the invention to provide a vacuum excavation system which occupies a reduced footprint and is modular.
These objectives are achieved by making three principal improvements to the conventional systems:
The first principal improvement involves an improved air lance nozzle which provides reduced air consumption by replacing the ¼ inch cylindrical pipe nipple of conventional systems with an elongated blade-like structure that achieves supersonic airflow through the use of a slit having a gap of only 0.01 or 0.02 inches and a width of approximately 1.5 inch.
The second principal improvement is to combine the blade style orifice of the improved nozzle with an air lance made of thin wall tempered pipe and a T-shape handle to enable rotation of the lance, a swivel adapter on the air supply hose, and a lever style valve placed at the fingertips of the operator, to enable spinning of the air lance, in place of the conventional technique of bouncing the nozzle up and down on the soil. This provides improved control for digging of larger holes, and enables digging of pilot holes by rotation of the lance without the need for vacuum removal of the soil.
The third principal improvement is to combine the improved nozzle and air lance structure with the use of a separate vacuum structure featuring a highly efficient multistage venturi ejector which generates the vacuum at the spoil container near the excavation site, permitting the use of a remote compressor and eliminating the need for separate engines and extensive filtering between the vacuum pump and the excavation.
The invention thus provides a vacuum excavation system which incorporates a low air consumption lance, a highly efficient multi-stage vacuum generation system in which the compressor is isolated from the waste stream, and a highly portable material collection system. The system can be powered entirely by one 185 cfm portable air compressor, available from local tool rental firms if one is not owned, so that nearly any contractor, utility company, or design firm can easily outfit themselves for vacuum excavation, at a cost for the excavation system less the air compressor of less than one tenth that of a conventional system, and the compressor can easily be carried by a ½ ton pickup truck and located at distances greater than 200′ from the excavation site using standard 1″ compressed air hose to connect the compressor to the vacuum engine which drives the collection system, rather than being limited to a location 25′ from the vacuum equipment.
A benefit of the preferred nozzle is that it can be used to bore a small “pilot hole” quickly and with little effort even in the hardest soils. This is accomplished by placing the nozzle on the ground, providing 90 psi compressed air, and rotating the nozzle 180 degrees back and forth. Because the blade style orifice of the nozzle is wider than the pipe connecting it to the tee handle, the spoil and compressed air can escape upward through the resulting annulus between the sides of the hole and the pipe, clearing the way for further progress of the lance assembly. The device has been found to easily bore 1″ pilot holes to depths of over twenty feet. When performing vacuum excavation to locate utilities, it is very advantageous to perform 1″ pilot holes to search for the utility instead of digging full size 12″ holes with the lance and vacuum combination.
The curved face of the nozzle reduces contact wear on the orifice and helps to guide the lance straight downward through the soil. The blade effect of the nozzle also permits it to move rocks out of the way by simply spinning the air lance with the tee-shaped handle. Without the tee-shaped handle the nozzle loses much of its effectiveness because it becomes very difficult to spin the lance assembly. Other air lance designs require the operator to bounce the nozzle up and down on the soil, whereas the preferred design uses rotation, which requires much less effort, especially when the excavation is over six feet deep and the air lance is heavy due to the long pipe needed between the tee-shaped handle and the nozzle. At 90 psi, the nozzle of the invention consumes about 45 SCFM of compressed air. To perform the same amount of excavation work, a round orifice design would have to consume 90 to 150 SCFM.
The three stage vacuum engine of the preferred embodiment of the invention thus has several advantages related to practicality, the first of which is that conventional ejectors do not produce sufficient flow through a 4″ hose to be effective, and a 4″ hose is the minimum size of hose necessary to clear spoil from an excavation. In addition, the invention provides spoil containment in accordance with local regulations, and can operate effectively with a minimal 167 CFM air source. A single stage venturi of the type used in prior vacuum (excavation) systems would not produce enough flow through a 4″ pick-up hose to be effective, whereas the multi-stage venturi engine of the invention generates over 800 cfm of flow through the same 4″ hose.
Finally, the use of an air lance separate from the vacuum pick up allow both to be easily lengthened for use on deep excavations, in addition to permitting the digging of pilot holes which do not require use of a vacuum pick-up.
The potential applications for the system are widespread, including underground utility exploration, roadwork cleanup, valve box maintenance, water and gas leak detection and repair, pipeline corrosion prevention system installation and repair, gutter cleaning, residential and commercial chimney cleaning, smokestack cleaning, hazardous waste recovery, directional drilling mud removal, leaf collection, aggregate transfer, general high volume wet and dry vacuuming, and numerous others which will occur to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing the overall excavation system of the preferred embodiment.
FIG. 2 is a plan view of an air lance constructed according to the principles of the preferred embodiment of the invention.
FIG. 3 is a plan view of a nozzle for the air lance of FIG. 2 .
FIG. 4 is a side view of the nozzle illustrated in FIG. 3 .
FIG. 5 is an end view of the nozzle illustrated in FIGS. 3 and 4 .
FIG. 6 is an isometric view of a drum head adapter for use in the excavation system of the preferred embodiment of the invention.
FIG. 7 is a cut-away view of a vacuum engine constructed according to the principles of the preferred embodiment of the invention.
FIG. 8 is a plan view of a foot controlled valve for use with the excavation system of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , the vacuum excavation system of the invention includes an air lance 1 arranged to direct air at supersonic speeds at a material to be excavated, and a material pickup hose 2 arranged to remove the loosened dirt from the excavation. The material pick-up hose 2 can be an ordinary hose, PVC pipe, or combinations of hoses and pipes, preferably having at least a 4″ diameter for soil excavation applications, although hose 2 is illustrated in FIG. 1 as being fitted with a PVC extension pipe or wand 3 , pipe 3 being replaceable with longer or shorter extension pipes depending on the depth of the excavation.
The pickup hose is connected to a vacuum engine 4 , described in greater detail below, which in turn is attached to an airtight material collection drum 5 via a drum head adapter 6 , also described in more detail below. The air supply for the vacuum engine and the air supply for the air lance are both supplied by ¾″ standard compressed air hoses 7 and 8 from a single portable air compressor 9 , with the vacuum engine 4 being operated by a foot operated air valve 10 . Although illustrated as being just a few feet away, compressor 9 can easily be located more than 200′ away from the vacuum engine 4 and air lance 1 , the only limitation being the ability of the standard hoses to carry a sufficient flow of compressed air from the compressor to the lance and vacuum engine.
As illustrated in more detail in FIG. 2 , the air lance includes a pipe 11 having a flat taper nozzle 12 at the digging end, and a transversely extending pipe 13 at the opposite end, pipe 11 and pipe 13 being in communication to provide an airflow path between the air supply hose 8 and the nozzle 12 . Pipe 13 serves as at least part of the handle 15 for the air lance, with handle 15 and pipe 11 forming a “T” or tee shape. Of course, since a portion of the handle 15 is not directly in the air path, it does not need to be formed of pipe, although the use of a t-fitting 16 is used to connect pipe 13 to pipe 11 easily enables a capped portion of pipe 17 to be coupled to the fitting to complete the handle.
Preferably, one end of pipe 13 is provided with a swivel fitting 14 to connect the air lance with the compressed air supply hose 8 while permitting rotation of the air lance without kinking of the air supply hose. Fitting 14 may be in the form of a “Chicago”-type female fitting, with the connection being provided with a lever style valve 14 ′ to permit operator control of the air supply.
As illustrated in FIGS. 3-5 , the improved nozzle includes a cylindrical extension 18 arranged to be coupled to the end of pipe 11 by any convenient means such as an annular weld, and a flattened end 19 which forms an elongated structure having a blade type orifice 20 with a gap width of significantly less than the ¼ inch diameter of the conventional cylindrical nozzle, and preferably on the order of approximately 0.01 to 0.02 inches and a length approaching 1.5 inches. As a result, the air in the pipe 11 , which has an internal diameter of ¾ inches and a cross-sectional area of 0.44 in 2 , is forced through an area tat the gap of 0.015 to 0.03 in 2 to create a sheet of jetted air focused directly in front of the nozzle, and thereby accelerated to supersonic velocity, creating a shock wave which fractures and causes loosening of the soil as described above.
Preferably, the nozzle lip 21 is given a concavity as seen looking down on the flattened surface in FIG. 3 . The concavity is not believed to have an effect on the airflow, but serves to reduce contact wear on the orifice and helps to guide the air lance straight downward through the soil.
In operation, the air lance is set on the ground in a vertical orientation and the handle 11 twisted back and forth to dig a small diameter probe hole to a depth limited only by the length of the air lance with very little operator exertion. This is useful in exploration efforts to locate buried utilities and avoids the digging of large holes. Once the underground utility 9 is encountered, the larger hole can be dug by combining the air lance and the pneumatic vacuum system described below. Any size hole can be created, allowing for simple inspection for size and condition or a very complicated repair, and the blade effect of the nozzle also permits it to move rocks out of the way by simply spinning the air lance with the tee handle.
As indicated above and shown in FIG. 1 , the vacuum system comprises a tube or wand 3 , a flexible conduit 2 , a container 5 in the form of an airtight drum, and a pressure or flow responsive engine or injector device 4 that pulls air and loosened soil from the excavation hole successively through the wand 3 , the flexible conduit 2 , and into the drum 5 . In this arrangement, the excavated soil separates from the air stream during passage of the air through the drum to the intake of the vacuum engine, thereby at least partially isolating the vacuum engine from the source of contamination, while the one-way nature of the air supply completely isolates the compressor.
As illustrated in FIGS. 1 and 6 , the vacuum engine 4 is attached to the drum 5 via an adapter 6 which is made up of a lid 22 adapted to fit over the drum and form an airtight seal to ensure maximum airflow through the drum. The evacuation hose 2 enters the drum through an intake conduit 23 , hose 2 having in the preferred embodiment an outer diameter of approximately 4.0″ and being attachable to intake conduit 23 by any suitable hose attachment means. Intake conduit 23 is angled relative to the plane of the lid and located off the axis of the drum. A second opening 24 in adapter 6 is shaped to conform to the base of the vacuum engine 4 to provide an air outlet and is provided with a mounting flange and gasket arrangement 25 , including fastening means 26 , which receives and secures the base of the engine and seals opening 24 . Fastening means 26 are preferably arranged so as to permit easy removal and installation of the engine to facilitate cleaning and maintenance, while the adapter as a whole preferably includes means, including seals and attachment fittings (not shown) as well as, for example, carrying handles 27 (only one of which is shown), to facilitate both attachment to and removal from the collection drum so that drums can be replaced as they become full. The design of the system is such that very little debris passes through the drum into the engine itself. Nevertheless, the engine can easily be removed from the adapter for cleaning with brushes or high power spray washing with a radial spray nozzle.
The vacuum engine 4 , as shown in FIG. 7 , is made up of a housing 30 containing at a front end a nozzle 31 that converts high pressure air entering from hose 7 into a jet. The jet of air draws air from the drum via opening 24 and through the open base 32 of the engine as it passes sequentially through a series of venturi tubes 33 , 34 , and 35 with pressure equalizing check valves 36 and 37 to provide a three stage suction arrangement pulling the soil collection stream through conduit 2 and into the drum.
As the high pressure air jet from nozzle 31 passes through a first chamber 38 into the opening 39 of venturi tube 33 and then into reduced diameter section 40 , it draws air at a relatively high pressure from the drum through chamber 38 , as indicated by arrow A. This air is injected into the opening 41 of second venturi tube 34 , enters reduced diameter section 43 and draws air from the drum via second chamber 44 through check valve 36 , as indicated by arrow B, and the output of venturi tube 34 enters the opening 45 and reduced diameter section 46 of venturi tube 35 to draw air from the drum through chamber 47 via check valve 37 , as indicated by arrow C. Finally, the combined airstream, which by this stage is relatively low in pressure, is exhausted through opening 47 of venturi tube 35 and through a low impedance filter 48 as necessary for filtering any particulates still present in the airstream. For typical soil excavation applications, filter 48 may, for example, take the form of a 250 micron filter bag.
As is apparent from FIG. 7 , venturi tubes 33 - 35 increase in length and diameter from the first stage at the front of the engine to the third stage at the exhaust end of the engine, while the shapes of the chambers 38 , 44 , and 47 are such that the openings at the bottoms of the chambers become progressively larger as the main airstream loses velocity due to the increasing size of the venturi tubes, and the upper portions of the chambers are extended to accommodate the lengths of the venturi tubes. The relative volumes and exact shapes of the chambers are actually a matter of convenience given the constraints resulting from the lengths of the venturi tubes and the size of the opening at the bottom of the engine, but it is possible that the shapes of the chambers could have some effect on the airflow and be adjusted accordingly.
Check valves 36 and 37 are in the form of pressure sensitive check valves associated with each chamber to control air passage from the drum to the last chamber by moving in response to pressure differences in the chamber and the pressure in the container.
More specifically, the check valves remain open when the system is operating with low resistance, as is the case during most vacuum pickup functions of loose debris, the flow of air from the intake nozzle 31 taking along with it air from the chamber surrounding the venturi tube it passes through, so that the initial quantity of pressurized air together with the air brought with it will flow out from the first chamber through the first venturi tube into the second chamber. The quantity of flowing air through the nozzles will increase from chamber to chamber and thus the sub-pressure in the chambers will become greater.
When greater impedance develops in the material handling hose, however, air pressure levels within the three chambers changes until the pressure differential increases sufficiently to cause the third stage check valve 37 to close. Under this condition, only the first two stages are supplying vacuum to the collection drum, so that the overall airflow is reduced while the vacuum level at this point is much higher than in the free flow situation due to the higher pressure in the first two stages. As greater impedance develops, such as occurs during liquid pick-up, air pressure levels within the three stages again changes and reaches a point where the check valve governing airflow into the second stage shuts off so that stage one is the sole supplier of vacuum to the collection drum. The air pumping pressure and volume of the injector will thus automatically match the system requirement at each instant.
By way of example, a suitable engine of the type described above may have a length of 65″ from front to back, a width of 8″, and a height from the open base to the top of the engine of 9.5″, with the adapter being arranged to fit on a 55 gallon open top drum. A suitable material for the housing is aluminum, which will result in an engine with the above dimensions having a weight of 18 pounds. This relatively small and light engine, which has no moving parts except for the check valves, provides an air consumption of 167 cfm @ 110 psi input, a static lift of 23 in Hg @ 110 psi input, and a no load vacuum airflow of 850 cfm. The operating characteristics of the three stages are as follows: 0-23 in. Hg. lift, 167 to 358 cfm throughput for the first stage consisting of chamber 38 and venturi tube 33 ; 0-8 in. Hg. lift, 167 to 566 cfm throughput for the second stage consisting of chamber 44 and venturi tube 43 ; and 0 to 23 in. Hg lift, 167 to 850 cfm throughput for the third stage consisting of chamber 47 and venturi tube 46 , which is conveniently formed by the housing 30 .
It will of course be appreciated by those skilled in the art that the size, operating characteristics, and construction of the engine are given by way of example only and that details such as the size, weight, and materials of the engine may be freely varied to meet the requirements of applications other than soil excavation, such as roadwork cleanup, gutter cleaning, chimney and smoke cleaning, hazardous waste recovery, directional drilling mud removal, leaf collection, aggregate transfer, and other applications which may occur to those skilled in the art, without departing from the scope of the invention.
To reduce overall compressed air consumption, foot operated valve, as shown in FIG. 8 , controls the compressed air supply to the vacuum engine in an essentially on/off mode of operation, allowing more efficient use of the compressed air by permitting the operator to instantly turn the vacuum on and off. The valve includes a pedal 50 , valve 51 with air hose fittings 52 , and a protective cage 53 , and also serves as a safety mechanism by allowing air to pass when foot pressure is applied. Optionally, to prevent operators from bypassing this safety feature, the air connection at the back of the vacuum engine can be provided with a JIC threaded fitting, instead of the Chicago type quick connections used for the other air connections throughout the system.
Having thus described various preferred embodiments of the invention, those skilled in the art will appreciate that variations and modifications of the preferred embodiment may be made without departing from the scope of the invention. It is accordingly intended that the invention not be limited by the above description or accompanying drawings, but that it be defined solely in accordance with the appended claims. | A vacuum excavation system which incorporates a low consumption air lance, a highly efficient multi-stage vacuum generation system effectively isolated from the waste stream and the air source, and a highly portable material collection system. The air lance includes a cylindrical main body which narrows to a flat taper nozzle at the digging end, and a tee-shaped handle with a swivel type air fitting at one end, while the vacuum generation system is a multi-stage ejector fitted onto a collection drum and consisting of successive venturi tubes with pressure equalizing check valves on the second and higher stages, the material collection system consisting of the drum and hoses or pipes connected to the drum through a separate opening. The system can be powered entirely by one 185 cfm portable air compressor, available from local tool rental firms if one is not owned, so than nearly any contractor, utility company, or design firm can easily outfit themselves for vacuum excavation, at a cost for the excavation system less the air compressor of less than one tenth that of a conventional system. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application claims benefit to U.S. Provisional Patent Application Ser. No. 62/310,159, filed Mar. 18, 2016, and entitled “Square Pin to RF Adaptor For Probing Applications,” which is incorporated herein by reference as if reproduced in its entirety.
FIELD OF THE INVENTION
This disclosure is directed to a mechanism for signal probing, and, more particularly, to an adaptor for interfacing from square or round pins/leads into a coaxial Radio Frequency (RF) connector for testing by a test and measurement system.
BACKGROUND
Various systems have been developed to measure differential signals from a device under test (DUT). There are a variety of ways to connect the test system to the DUT. These may include a soldered connection, RF connector, pressure contacts, wires/leads, pins, adapters, interposers, clip-ons etc. A common interface to connect the test system to the DUT is accomplished by using a pair of pins/short wires that are soldered to the differential test points, which are then connected to the test system. The problem with such systems is that ambient electric fields may interact with the exposed leads/pins, which lack shielding, injecting interference into the signals being measured. Interference injected into both leads/pins is referred to as common mode interference. The exposed leads/pins may experience both common mode interference and interference affecting the individual leads/pins. There is no mechanism to isolate the differential signal from these interferences at the exposed leads/pins, resulting in added signal noise that is measured by the testing system but is not present in the actual DUT's differential signal. Further, maintaining a uniform controlled impedance of these differential leads/pins supports repeatable measurements without degradation in the frequency response. However, real exposed leads/pins may bend and change position significantly during the testing process. Bending the exposed leads changes the corresponding impedances of the differential pair. Such uncontrolled impedances alter the frequency response of the signal at the testing system, leading to bandwidth loss and ripple currents. As such, the exposed leads reduce the accuracy of test measurements taken by a testing system, particularly when measuring a differential signal with higher frequency content.
Embodiments of the invention address these and other issues in the prior art.
SUMMARY OF THE DISCLOSURE
Embodiments of the disclosed subject matter include a differential pin to RF adaptor. The adaptor contains a central contact with an RF connector on one end and a signal contact on the other end. An insulating sleeve surrounds the central contact. A reference contact surrounds the insulating sleeve. Securing elements, such as leaf springs, are employed to engage the reference pin of a differential pair to the reference/shield contact. The signal pin of the differential pair interfaces with the central contact. A protective layer surrounds the securing elements and the reference contact. The adaptor is structured to slide down over the differential pair so that the outer reference/shield contact abuts a circuit board attached to the pins. In this way, the differential pins (e.g. leads) are completely shielded all the way down to the circuit board's surface, which shields/isolates the pins from common mode and other types of interference. Further, the adaptor's contact spacing is selected to match the pin spacing. As such, the adaptor maintains the shape of the signal pin and the reference pin during testing. Accordingly, the adaptor maintains a fixed/controlled impedance of the differential pair, which reduces or eliminates impedance variations and hence preserves system frequency response and reduces/eliminates erroneous ripple currents. The RF connector may be any type of RF connector desired to connect to a corresponding probe. In some embodiments, an attenuator is positioned between the RF connector and the signal contact. The attenuator reduces the gain associated with the differential signal to increase the input signal range of the test system. The attenuator in the adaptor allows for a broader range of RF connectors to be employed (e.g. RF connectors without pre-conditioning circuits).
Accordingly, in at least some embodiments a differential pin to RF adaptor includes a central contact with a proximate end and a distal end, the proximate end including an RF connector and the distal end including a signal contact structured to interface with a signal pin of a differential pair. The adaptor also includes an insulating sleeve surrounding the central contact. Further, the adaptor includes a reference/shield contact separated from the central contact by the insulating sleeve and structured to interface with a reference pin of the differential pair.
In another aspect, in at least some embodiments a differential pin to RF adaptor includes a central contact structured to communicate a signal portion of a differential signal from a distal end to a RF connector at a proximate end. The adaptor also includes a reference contact structured to communicate a reference portion of the differential signal from the distal end to the RF connector at a proximate end. Further, the adaptor includes an insulating sleeve structured to isolate the reference portion of the differential signal from the signal portion of the differential signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an embodiment of a test and measurement system.
FIG. 2 is a cross sectional view of an embodiment of a differential pin to RF adaptor.
FIG. 3 is a cross sectional view of an embodiment of a differential pin to RF adaptor with a resistor network.
DETAILED DESCRIPTION
As described herein, the embodiments of the disclosure are directed to a differential pin to RF adaptor. The adaptor may be configured to attach to square or round pins, or short wire leads and interface from this differential pair to a testing system via a probe. The adaptor employs a center conductor contact structured to communicate a signal from a distal end to a RF connector at a proximate end. The adaptor also employs a reference contact structured to communicate a reference signal corresponding to the signal. Accordingly, the center conductor contact and the reference contact communicate the differential signal to the RF connector. The adaptor also employs an insulating sleeve structured to isolate the reference signal from the signal traversing the center conductor contact. The reference/shield contact is structured to shield the signal from common mode interference or other interference received between a circuit board of a DUT and the RF connector. The adaptor is also structured to maintain a constant coaxial connection between the RF connector, the reference connection, and the center contact pin to maintain a controlled impedance between the pins. In some embodiments the central contact further includes an attenuator structured to reduce a gain of the differential signal prior to communicating the differential signal to the RF connector at the proximate end in order to match the gain of the differential signal to an expected gain across an RF probe and/or electrically isolate the DUT from the test system. Securing elements are employed to maintain connection with the pins and a protective layer protects the adaptor, and the interfaced pins, from damage during use.
FIG. 1 is a schematic diagram of an embodiment of a test and measurement system 100 . System 100 includes a DUT 110 with a pair of differential pins 111 . Differential signals 161 from the differential pins 111 are sent to the host 150 for testing. The differential signals 161 encode information as the difference between a signal traversing the signal pin 111 a and a reference signal traversing the reference pin 111 b . The host 150 is configured to receive differential signals 161 , so an adaptor 120 conducts signals traversing the two pins/leads into a coaxial connection to be sent to the host 150 . The differential signals 161 are sent to the host 150 via a probe 130 and, in some embodiments, an accessory 140 that acts a controller and/or pre-processor for the host 150 .
A DUT 110 is any device structured to generate differential signals 161 for testing. For example, a DUT 110 may include a circuit board with any differential signals. These differential signals may be for transmission of data, controlling or biasing power supplies, high voltage signaling, or employed in other transmission systems etc. One of ordinary skill in the art will appreciate that a DUT 110 employing differential signaling encompasses a wide range for devices and the examples provided herein are included for purposes of explanation and should not be considered limiting. The DUT 110 includes differential pair 111 which are a pair of output pins that can be used to tap into the differential signal in the DUT 110 for testing purposes. The differential pair 111 include a signal pin 111 a and a reference pin 111 b . The differential signal 161 is a signal encoded as the difference between the signal traversing the signal pin 111 a and the reference signal traversing the reference pin 111 b.
Adaptor 120 is a differential pin to RF adaptor and is hence a device structured to interface between the pins/leads from the DUT's test points and a controlled impedance coaxial connection. Adaptor 120 is structured to interface with the pins/leads of differential pair 111 and transmit the differential signal 161 to probe 130 . Specifically, adaptor 120 includes a pair of contacts that connect to an RF connector. The RF connector is selected to interface with the probe 130 . The central contact of the adapter 120 , which connects to the signal pin 111 a , is connected to the center pin contact of the RF connector. Further, the adaptor 120 includes a reference contact, which connects to the reference pin 111 b , and is connected to the outer shield contact of the RF connector. The adaptor 120 is further structured to abut the DUT 110 when interfacing with the differential pair 111 in order to shield/isolate the differential signals 161 from common mode or other ambient electrical interference occurring between the DUT 110 and the RF connector. The adaptor 120 is further structured to provide physical support for the differential pair 111 . Specifically, the adaptor 120 maintains the differential pair 111 in a controlled position relative to each other and relative to RF connector and a corresponding coaxial connection, causing the entire connection to maintain a controlled impedance. The adaptor 120 may also include securing elements structured to secure reference pin 111 b to the reference contact and/or to secure the signal pin 111 a to the central contact. The adaptor 120 also includes a protective layer structured to protect the adaptor 120 and the coupled differential pair 111 during use. The adaptor 120 may or may not be soldered to the differential pair 111 . The differential pair 111 may employ round or square pins or short wire leads, and the adaptor 120 is structured accordingly to engage with the pins/leads as needed. In some embodiments, the adaptor 120 includes an attenuator between the central and/or reference contacts and the RF connector to adjust the gain of the differential signals 161 to increase the acceptable input signal range and to better electrically isolate the DUT 110 system from the host 150 .
Probe 130 is device structured to couple to adaptor 120 at the RF connector and communicate the differential signals 161 toward accessory 140 . Probe 130 includes a coaxial cable with a probe RF connector to mate with the adaptor's RF connector. Specifically, probe 130 contains a coaxial cable with a center conductor and an outer shield. Probe 130 may also be constructed using a twisted pair and may be shielded. In some embodiments, the probe 130 includes an attenuator (e.g. if adaptor does not employ an attenuator). Further, the probe 130 includes a plurality of magnetic elements (e.g. ferrites) surrounding the coaxial cable and spaced along the length of the cable. The ferrites reject common mode interference. The magnetic elements are separated by gaps, which are filled with elastomeric elements. The elastomeric elements are compressible, which allows the probe to bend and prevent adjacent magnetic elements from pressing together (e.g. reducing wear and preventing stress fractures). The probe 130 is structured to couple to, and propagate the differential signals 161 to accessory 140 . In some embodiments, the probe 130 also includes an Electrically Erasable Programmable Read Only Memory (EEPROM) containing probe 130 specifications, for example the resistance in the probe tip, tip attenuation, frequency response, and/or other parameters specific to probe 130 .
Accessory 140 is any device structured to sense and/or precondition the differential signals 161 for host 150 . The accessory 140 may include a sensor head for sensing the differential signals 161 , a controller for preconditioning the differential signals 161 , or combinations thereof. For example, the accessory 140 may obtain information from the EEPROM to adjust the gain of the signals 161 to compensate for power loss naturally occurring when the differential signals 161 traverse the probe 130 . Accessory 140 is designed to deliver the differential signals 161 to the host 150 while maintaining substantially the same electrical properties as the differential signals 161 . Specifically, the accessory 140 is designed to minimize noise injected into the signals 161 while traversing the differential pair 111 , adaptor 120 , and probe 130 .
Host 150 is structured to couple to accessory 140 and receive the signals 161 for testing and/or measurement. For example, host 150 is an oscilloscope or other test system. Host 150 receives the differential signals 161 from the accessory 140 and may display them on a graticule for a user. Host 150 may also capture characteristics from the differential signals 161 in memory for further calculation and use by the user. Accordingly, the adaptor 120 , probe 130 , and accessory 140 are employed to allow the user to measure differential signals 161 that are substantially identical to the differential signals 161 obtained from the DUT 110 .
FIG. 2 is a cross sectional view of an embodiment of a differential pin to RF adaptor 200 , which is substantially similar to adaptor 120 . Adaptor 200 includes a center conductor contact 209 with an RF center contact 209 a and a signal contact 209 b . For clarity of discussion, the portion of the adaptor 200 depicted at the top of FIG. 2 is referred to herein as the proximate end 220 , while the portion of the adaptor 200 depicted at the bottom of FIG. 2 is referred to as the distal end 222 . It should be noted that the terms proximate and distal are relative labels employed for the purpose of discussing component position and should not be considered limiting. Accordingly, the proximate end 220 of the center conductor contact 209 includes the RF center contact 209 a and the distal end 222 of the center conductor contact 209 includes the pin/lead signal contact 209 b . The RF connector on end 220 may be any type of RF connector desired to couple to a corresponding RF probe, such as probe 130 . For example, the RF connector on the end of 220 may be a Sub-Miniature Push-On (SMP) connector, a Sub-Miniature version A (SMA) connector, an Micro-Miniature Coaxial (MMCX) connector, or any other coaxial connector. The signal contact 209 b is structured to receive and interface with a signal pin, such as signal pin 111 a . Specifically, the signal contact 209 b includes an opening 212 that receives and engages the signal pin/lead. The center conductor contact 209 may be made of any material capable of conducting electrical signals from the distal end 222 to the proximate end 220 and vice versa, for example copper, copper plated steel, brass, gold, gold plated brass, etc. The center conductor contact 209 is therefore a device that is structured to communicate a signal portion of a differential signal from the signal pin engaged at signal contact 209 b at the distal end 222 to the RF center contact 209 a at a proximate end 220 .
The center conductor contact 209 is surrounded by an insulating sleeve 207 . The insulating sleeve 207 is as an insulator/dielectric that keeps the center conductor contact 209 from shorting to the outer conductive shield acting as the reference contact 205 . The insulating sleeve 207 may be made of any insulating material that provides the sufficient electrical insulation for the desired task, such as polyethylene, Polytetrafluoroethylene (PTFE) (e.g. Teflon), etc.
The center conductor contact 209 and the insulating sleeve 207 are surrounded by a layer of conductor acting as the reference contact 205 . The reference contact 205 may be made of any conductive material, such as copper, copper plated steel, brass, gold, gold plated brass, etc. The reference contact 205 is separated and electrically isolated from the center conductor contact 209 by the insulating sleeve 207 and is structured to interface with the reference pin of the pins lead, such as reference pin 111 b , at the distal end 222 . Specifically, the adaptor 200 includes at least one opening 214 at the distal end to receive the reference pin in a manner that abuts the reference contact 205 . While only one opening 214 is required to interface with the reference pin, multiple openings may be employed for ease of use. In a particular embodiment, four openings 214 are evenly spaced around the circumference of the adaptor 200 , allowing the signal pin to engage with the signal contact 209 b and the reference pin to be inserted into any of the openings 214 . The spacing between openings 214 and 212 is selected based on the spacing of the differential pins the adaptor 200 is designed to interface with. The reference contact 205 is structured to abut the DUT at the distal end 222 of the adaptor 200 . When abutting the DUT, the reference contact 205 physically contacts the DUT along an edge. By abutting the DUT, the reference contact 205 can shield the signal pin and the signal contact 209 b , and hence the signal portion of the differential signal, from common mode or other interference received between the DUT and the RF connector 209 a.
The adaptor 200 further includes one or more securing elements 203 structured to secure the reference pin of the differential pair to the reference contact 205 when the reference pin is inserted in the opening 214 . For example, one securing element 203 is employed per opening 214 . The securing element 203 may be any device that can releasably secure the reference pin in place. In the embodiment shown, a leaf spring is employed as the securing element 203 . At the proximate end 220 , the reference contact 205 forms an opening 216 that receives a probe RF connector that mates with RF center contact 209 a . The opening 216 acts as part of the RF center contact 209 a , allowing the signal portion of the differential signal to pass to a center of the probe RF connector from the center conductor contact 209 and the reference portion to pass to an outer portion of the probe RF connector. Accordingly, the reference contact 205 is a device that is structured to receive a reference pin and communicate the reference portion of the differential signal from the distal end 222 to the RF connector at the proximate end 220 . Further, as discussed above, the insulating sleeve 207 can abut the DUT. By abutting the DUT with the insulating sleeve 207 , and by securing the reference pin in opening 214 at a predetermine spacing relative to the signal pin, the adaptor 200 can maintain the signal pin in a parallel position relative to the reference pin to maintain a fixed impedance between the differential pair.
The adaptor 200 may further include a protective layer 201 surrounding the securing elements 203 and the reference contact 205 , and hence also surrounding the insulating sleeve 207 and the center conductor contact 209 . The protective layer 201 is an insulating jacket that protects the reference contact 205 from shorting to adjacent contacts or components on the DUT's surface. The protective layer 201 may be made of many materials suitable for such a purpose, for example polyvinyl chloride (PVC) or other plastics, rubber, etc.
FIG. 3 is a cross sectional view of an embodiment of a differential pin to RF adaptor 300 with an attenuator 320 . Adaptor 300 is substantially similar to adaptor 200 , and hence only components interacting directly with the attenuator 320 are labeled in FIG. 3 . Compared to adaptor 200 , the central contact 309 is extended to insert the attenuator 320 between the signal contact 309 b and the RF center contact 309 a . The attenuator 320 is any resistive network structured to reduce a gain of a signal and/or match an impedance of a signal source to minimize power transfer between the source from the test network that is unrelated to the differential signal (e.g. minimize signal reflection from the test network, etc.) By employing an attenuator 320 in the central contact 309 , a probe RF connector inserted into opening 316 need not include an attenuator for attenuation/isolation, allowing the probe to be constructed more cheaply and employ a wide variety of probe RF connectors. Functionally, the signal pin from the DUT is inserted into the signal contact 309 b via opening 312 and the probe RF connector is inserted into RF center contact 309 a via opening 316 . The signal portion of the differential signal is communicated from the signal contact 309 b to the RF center contact 309 a via the attenuator 320 . The attenuator employs a network of resistors that electrically reduce the gain of the differential signal received from the distal end of the adaptor 300 prior to communicating the differential signal to the RF center contact 309 a at the proximate end in order to match the gain of the differential signal to an expected gain at the RF probe and electrically prevent erroneous power transfers between the DUT from the testing system (e.g. host 150 ) as discussed above.
The previously described versions of the disclosed subject matter have many advantages that were either described or would be apparent to a person of ordinary skill. Even so, all of these advantages or features are not required in all versions of the disclosed apparatus, systems, or methods.
Additionally, this written description makes reference to particular features. It is to be understood that the disclosure in this specification includes all possible combinations of those particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment, that feature can also be used, to the extent possible, in the context of other aspects and embodiments.
Also, when reference is made in this application to a method having two or more defined steps or operations, the defined steps or operations can be carried out in any order or simultaneously, unless the context excludes those possibilities.
Although specific embodiments of the invention have been illustrated and described for purposes of illustration, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention should not be limited except as by the appended claims. | A differential pin to RF adaptor includes a center conductor contact with an RF connector on one end and a signal contact on the other end. An insulating sleeve surrounds the central contact. A reference contact surrounds the insulating sleeve. The signal pin of the differential pair interfaces with the center conductor contact of the RF connector. The adaptor is structured to slide down over a pair of pins/leads so that the reference contact abuts a circuit board attached to the pins. The pins/leads are shielded all the way to the circuit board, which shields/isolates the pins from common mode and other types of interference. The adaptor maintains the shape of the signal pin and the reference pin during testing. The adaptor maintains a fixed impedance of the pins, which reduces or eliminates uncontrolled impedance and hence preserves system frequency response and reduces/eliminates erroneous ripple currents. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to the field of cotton processing and represents a further improvement on the lint cleaners of U.S. Pat. No. 6,088,881 and U.S. Pat. No. 7,779,514 B2. U.S. Pat. No. 7,779,514B2 describes apparatus that reduces fiber damage by eliminating the formation of the cotton tufts into a batt, but rather, individually applies the tufts of cotton as they come from the gin stand in an airstream directly onto the teeth of the lint cleaner cleaning cylinder teeth without mechanically restraining the tufts. Such a device is for use with lint cleaners that have short, densely spaced teeth on a solid cylinder which currently are universally used in saw gins on upland cotton.
[0002] Other prior methods and apparatus include those such as illustrated in U.S. Pat. No. 6,088,881, incorporated herein by reference, wherein a revolving perforated drum is used to allow air flow through the drum such that a cleaning cylinder may remove cotton fiber from the perforated drum and carry it past a plurality of cleaning grid bars, thereby separating the airstream, and removing foreign matter from the fibers, before the fiber is doffed from the cleaning cylinder for subsequent air flow to downstream processing.
[0003] As mentioned above, U.S. Pat. No. 6,088,881 and U.S. Pat. No. 7,779,514 B2 have shown that they preserve the spinning quality of the lint, and countries that use scientific lint quality evaluation systems such as H.V.I. (High Volume Instrumentation) generally reward the lint produced on these lint cleaners. However, many countries and merchants value the well combed, “smooth” appearance above the H.V.I. evaluations, and thus the use of lint cleaners using the features of these patents has been somewhat limited.
SUMMARY OF THE PRESENT INVENTION
[0004] The Objects of This Invention are:
To increase the combed, smooth appearance of the lint produced. To increase the color grade of the lint produced. To reduce the trash content of the lint produced. To accomplish the above objects without substantially increasing lint fiber breakage and nepping. To make the degree of combing variable in response to manual or automatic control means.
[0010] These and other objects and advantages of the invention will become apparent from the following detailed description of the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] An apparatus for cleaning lint is depicted in the accompanying drawings which form a portion of this disclosure and wherein:
[0012] FIG. 1 , is a sectional view of the apparatus of prior art U.S. Pat. No. 7,779,514 B2;
[0013] FIG. 2 , is a sectional view of a Preferred Embodiment of present invention;
[0014] FIG. 3 , is an end view of a Preferred Combing Cylinder;
[0015] FIG. 4A , is a partial side elevational view substantially tangent to the surface of the Air Separator Cylinder showing the Preferred Toothed Axial Channels spaced around Air Separator Cylinder;
[0016] FIG. 4B is an end view of a Preferred Toothed Axial Channel shown in FIG. 4A ;
[0017] FIG. 5 , is a partial sectional view of a second embodiment used as a retrofit to an existing lint cleaner;
[0018] FIG. 6 is a rear view of the housing of the lint cleaner showing the variable drive for the combing roller; and,
[0019] FIG. 7 is a schematic view of a drive control system for the apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] In the prior art shown in FIG. 1 , the bulk of the tufts carried by an airstream flow directly across the top surface of streamer plate 14 and are abruptly whipped over the tip of the plate by the aggressive teeth 13 of cleaning cylinder 12 . This action produces a minimum amount of “opening” of the lint tufts. The smaller number of entering lint tufts that are drawn into the separator cylinder 22 between the brushes move to the perforated screen surrounding cylinder 22 and are swept by the brushes around to plate 14 to also receive a minimum amount of opening.
[0021] FIG. 2 is a cross section drawing of a preferred embodiment of the present invention. As the lint tufts enter the machine at duct 11 at the upper right the bulk of them are thrown against the upper surface of a slowly counter-clockwise rotating combing cylinder 101 . Air duct 11 terminates adjacent an outer surface of revolving combing cylinder 101 and a stationary separator housing and delivers the majority of the tufts to the combing cylinder 101 whose surface is covered with fine, closely spaced teeth 105 that impale some of the fibers against the leftward moving air stream flowing into the large air separator 102 .
[0022] An air separator 102 includes an air separator creel 104 circumscribed by a cylindrical housing formed by a perforated surface or section 16 , and non-porous segment 15 and 15 a such that the cylindrical housing is open to duct 11 opposite combing cylinder 101 . Perforated section 16 is a stationary separator that is porous to airflow there through but impervious to desirable fiber flow there through. Rotating within the cylindrical housing is revolving air separator creel 104 which is pervious to both fiber and foreign matter. The described air separator creel 104 and cylindrical housing are similar in construction to the air separator taught in commonly owned U.S. Pat. No. 7,779,514 B2 and incorporated herein by reference, however, instead of brushes the air separator of the present invention utilizes a series of axially aligned channels 17 bearing substantially radially extending teeth 18 which pass near the cylindrical housing and combing cylinder 101 . The surface of the high speed air separator creel 104 may be described as having peripherally equally spaced apart, substantially axial rows of sharp teeth completely surrounding it. The details of these teeth should further be described as axial channel saws whose legs project substantially radially outward or slightly forward leaning in the direction of rotation as shown in FIGS. 4A and 4B .
[0023] Cleaning cylinder 103 generally rotates in a clockwise direction such that the surface of cleaning cylinder 103 and combing cylinder 101 travel in the same direction at their closest point of approach. All of the fiber passing through the machine must pass between cylinders 101 and 103 in this region. Referring to FIG. 3 , note that the size of the teeth 105 are exaggerated to show their profile. The fine teeth 105 on the combing cylinder are aggressive when converging towards the cleaning cylinder 103 but are not aggressive when diverging therefrom. That is to say, the narrow, sharp pointed, closely or densely spaced, uniquely shaped teeth on the combing cylinder 101 comb against the aggressive teeth of the cleaning cylinder 103 as their surfaces converge, but yield substantially all the fibers to the aggressive cleaning cylinder 103 as their surfaces diverge. In normal combing operation the slowly turning combing cylinder 101 only holds a small percentage of the incoming tufts, letting the bulk of the tufts to be impaled on the outward facing fine teeth 18 on the axial channel 17 on the air separator cylinder 102 or pass between the channel strips and accumulate on the perforated section 16 surrounding the air separator cylinder 102 where the channel teeth 18 impale the tufts and sweep them back across the aggressive facing, slow turning combing cylinder 101 for the first combing action. Some of the fibers are impaled on the channel teeth 18 where they are carried around to the cleaning cylinder 103 surface where they receive a combing action against the cleaning cylinder, but the very aggressive cleaning cylinder 103 saw handily carries them around to join the fibers that were impaled on the combing cylinder for the major combing action between the combing cylinder 101 and cleaning cylinder 103 . The teeth on the combing cylinder 101 , as stated earlier, are aggressive against converging to tangential greater surface movement, but the combing cylinder tooth faces are near radial to become non aggressive as they pass tangential with another aggressive faster rotating surface. Thus, as the combed fibers pass the tangent point between the combing cylinder 101 and the cleaning cylinder 103 , the combing cylinder teeth become non-aggressive and the very aggressive teeth on the cleaning cylinder 103 pull the fibers away from the combing cylinder. As with prior art lint cleaners, adjustable “lint savers” are furnished to reapply the looser fibers to the cleaner cylinder teeth before each grid bar 109 .
[0024] An object of this invention is to make the degree of combing variable in response to manual or automatic control means. The degree of combing is a function of the surface speed of the combing cylinder 101 and that of the cleaning cylinder 103 and air separator cylinder 102 , both of which may have fixed speeds. The surface of the combing cylinder 101 moves in the same direction as both the air separator cylinder 102 and cleaning cylinder 103 at convergence, thus the slower the combing cylinder surface moves relative to the other cylinders, the greater the degree of combing. Conversely, the relatively faster the combing cylinder surface moves, the less the degree of combing until, at the same surface speeds, the combing cylinder becomes only a transfer cylinder. This condition is an option that may be desirable under some conditions.
[0025] This variable combing cylinder surface speed can be accomplished by the use of various well known mechanical or electrical drives. As shown in FIG. 7 , the automatic function can be accomplished by combining an electric motor 111 employing a variable speed drive input with the output signal from any of various well known electrical, in process, lint cotton condition sensors 112 on the market such as moisture sensors or sample color, trash or grade sensors located inside or outside the gin plant sensing these and other parameters affecting the optimum level of combing. This is also accomplished by driving the combing cylinder 101 by other means that vary the comber cylinder speed without changing the speeds of the other cylinders. This can be as simple as a separate V-belt drive to the combing cylinder incorporating a mechanical variable pitch diameter sheave. It should also be understood that the effectiveness of the combing action is not only determined by the relative surface speeds of the combing cylinder and the adjacent toothed cylinder, but also the density of the fibers passing between the adjacent cylinders. Therefore, the major combing action takes place between the combing cylinder and the cleaning cylinder where all the fibers simultaneously must pass. Furthermore, this major combing action is influenced by the processing rate; the faster the processing rate at a given combing cylinder speed, the more effective the combing. There are various conditions causing the ginning rate to change, but a catch all rate detector, such as a gin feeder feed roll speed detector 113 used to modulate the speed of the combing cylinder 101 is another combing cylinder speed control option that can be employed. These features open the way for an important development in the cotton ginning industry—variable combing of the raw cotton without delaying the ginning process.
[0026] Another embodiment of the invention, shown in FIG. 5 , provides the benefits of a variable speed combing cylinder to a different style lint cleaner, wherein the lint and commingled trash are delivered in an air stream to slow turning perforated condenser drum 118 . The relatively slowly turning condenser drum 118 causes the cotton lint and commingled trash to build up on the surface of the drum sufficiently thick to form a cohesive batt that is pressed together and doffed from the drum by a pair of doffing rollers 119 . The batt is then fed down to the low speed combing cylinder 101 ′ with its negative draft teeth which comb the lint batt as it is carried forward by the cleaning cylinder and releases the lint to the aggressive teeth of the cleaning cylinder 103 ′ as the cylinders diverge. The lint fibers are impaled on the surface of the toothed cleaning cylinder which carries fibers and trash over a series of grid bars 120 that have acute angle leading edges over which the lint is whipped, thus causing much of the trash and entangled fiber to be slung off by centrifugal force where it drops down into trash conveyor system 130 , as is well known. As cleaning cylinder 103 continues to turn past the grid bars 120 , it moves in close proximity to doffing brush 104 ′ whose surface at the point of close proximity moves faster than the surface of the cleaning cylinder. It should be understood that the combing action in this embodiment is a function of the surface speed of the combing cylinder 101 ′ and that of the cleaning cylinder 103 ′, thus the above described control of the speed of the combing cylinder 101 is applicable to combing cylinder 101 ′.
[0027] It is to be understood that the forms of the invention shown are preferred embodiments thereof and that various changes and modifications may be made therein without departing from the spirit of the invention or scope as defined in the following claims. | An apparatus for cleaning trash from cotton lint utilizes a combing cylinder having a plurality of teeth covering its surface and extending therefrom in a manner to release the cotton lint to a cleaning cylinder. The combing cylinder surface moves slower than the cleaning cylinder to comb the lint as it is delivered to the cleaning cylinder. Means are provided to vary the speed of the combing cylinder to match the lint processing parameters, including negating lint combing all together. | 3 |
The present invention relates to improvements to or in connection with reinforcements for use in stabilized or framed earth masses.
PRIOR ART
The technique of stabilizing earth masses by incorporation of flexible reinforcements in the mass itself is in general use throughout the world, and at the present time the basic theoretical principles of its operation are known fairly accurately, these principles having been originally established in British Patent No 1069361 of Henri Vidal, which is now in the public domain, and being briefly summarized below in order to provide a complete statement of the invention.
A mass of natural, unstabilized ground has a potential sliding or fracturing surface, which was initially established by Coulomb as a plane and which, usually passing through the foot of the outer surface of the mass, forms an angle dependent on the internal angle of friction of the ground, with a value of approximately 63° in relation to the horizontal for ground habitually used for this type of construction. Other forms of sliding surface, of circular and generally curvilinear development, are closer to reality. In all cases ground situated on this surface is called an "active wedge".
The fixing of this "active wedge" by means of a resistant front face is what concerns the construction of traditional walls. Fastening it by joining to the ground at the rear, from a front face of lower resistance, is what constitutes the anchored wall technique.
The inclusion of reinforcements distributed in the ground of the mass modifies the characteristics of the latter, so that the boundary of the "active wedge" is situated substantially nearer the outer boundary surface of the mass, with an inclined plane development at the base, which becomes vertical from a certain height onwards, to a separation close to 0.3 H from said outer surface, H being the mechanical height of the mass. Numerous trials and actual measurements made in the last 20 years for the different reinforcement methods employed confirm that the boundary of the "active zone" practically coincides with the position of the maximum tensions in the reinforcement elements. This means that the inclusion of reinforcements distributed in the ground modifies and improves the behaviour of the ground by giving it a certain anisotropy.
These principles have given rise to numerous methods of reinforcement consisting of a more or less light, deformable face, from which reinforcement elements extend towards the ground to be stabilized, in such a manner as to pass across the boundary of the "active zone" and extend over a sufficient length--the "resistant zone"--for the frictional forces of the reinforcement elements relative to the ground to exceed the maximum tension values developed in them (see FIG. 1). It is found that these frictional forces do not develop in a useful manner beyond a distance of 0.8 H of the face, even with low values of H, with the exception of special cases in respect of load and/or configuration of the slope on the mass.
The friction capacity of each reinforcement element is obviously dependent on the useful length behind the "active zone", on the pressure which the ground exerts on its surface, on the area of contact and on the nature of the surface material of the element, which is translated into the coefficient of friction between said material and the ground.
The reinforcements are generally incorporated in the earthwork in successive layers, over which extends a certain thickness of ground, which is compacted and over which is laid the following layer of reinforcements, this pattern being repeated until the total height of the mass is reached. The whole arrangement must be sufficiently stable to support the thrust of the ground at the rear and the thrust of the loads acting on it, with the safety coefficients required.
With these methods, and in a general way, in order to ensure sufficient frictional interaction of the reinforcement elements, it is convenient for a minimum of some 2%, and preferably some 5%, of the area of the stratum of earth on which each layer of reinforcements is laid to be covered with the material of which the latter are made, and for at least four reinforcement levels to be provided.
The tensile strength of the reinforcements must thus on the one hand be sufficient to withstand the horizontal forces caused by the thrust of the ground and the loads acting on the latter, a certain flexibility of said reinforcements being convenient in order to permit adaptation to the movements of the reinforced mass, while their properties are retained. This requirement is dependent on the tensile strength of the material of which the reinforcements are made and on the area of the latter, and is a determinant factor in the neighbourhood of the line of maximum tensions.
On the other hand, the reinforcements must provide for the ground a sufficient area of contact to mobilize frictional forces capable of balancing the maximum tension over a reasonable length. The requirement in the "resistant zone" is therefore the total area in contact and therefore the perimeter of the section of the reinforcements and length, the area of said zone not being a determinant factor.
It is in the achievement of this compromise that the improvements and perfections of the reinforcement elements have been developed, because the reduction of the length of the reinforcements, without increasing their number, reduces the required volume of the fill selected and therefore the cost of the construction work.
The frameworks or reinforcements were originally in the form of bands, in which the perimeter:area ratio reaches the highest values, this step forward corresponding to British Patent No 1069361, in which use was made of thin metal bands of a length greater than 0.7 H, with uniform characteristics over their entire length.
A first improvement in the initial process is evidently the use of bands having a different width in the "resistant zone", which is difficult to apply in practice.
One way of reducing the resistant length while maintaining the area presented would be to increase the value of the coefficient of friction between the ground and the material of the bands, by means of corrugations, fluting or ribbing of slight height in the horizontal surfaces of the bands, this process being within the scope of British Patent No 1563317.
In Patent Application PCT WO-95/11351 a distinction is made between the two functions of the bands, concentrating requirements in respect of section by means of concentrated cores of resistant material, to which are integrally added either other, lighter, less expensive material in order to obtain the required surface of the band with an improved finish, or plane lateral extensions of the same material.
In Patent No 2014562 a shortening of the length of the mass to less than 0.65 H is achieved, while the same number of reinforcement bands is retained, by bifurcation of the bands in the last third of the latter, that is to say doubling the surface presented to the ground in part of the "resistant zone".
To sum up, all the processes consist of an increase of the resistance to extraction of the bands by means of improvements of the coefficient of friction or enlargement of the surface presented by the bands to the ground fill, at least in the "resistant zone", in order thus to stabilize the frontal "active zone".
In any case, as the patents themselves show: "The area of reinforcement in contact with the earthwork is calculated so as to ensure that the reinforcements cannot be extracted by pulling".
The difference and the advantage of the present invention is clear. With the same increase of material, the application of the patent ES 452262, by means of the formation of ribs on the bands, does not achieve any increase of frictional surface but solely and exclusively an improvement of the coefficient of friction between the bands and the ground. Patent Application WO-95/11351 also does not create any frictional surface additional to that of the side wings, but on the contrary considerably increases the cost of material additional to the core.
DESCRIPTION OF THE INVENTION
In the present invention flexible reinforcements are presented for ground stabilization, which, as is natural for this purpose, are equipped with a front end for anchoring by conventional methods to the elements constituting the outside skin or face, and whose functioning in respect of resistance and friction is distinguished as follows:
A) Its resistant section (FIG. 2, 1) is not determined by perimeter requirements, so that compact, non-plane shapes can be used with a low perimeter:area ratio, including hollow configurations in which said ratio relates to the external perimeter.
B) Requirements in respect of friction are met by providing the compact resistant section with retaining modules (FIG. 2, 2), which surround it and which are so spaced that the surface in frictional contact with the ground is formed by a cylinder or prism, having a straight generatrix, of the ground itself (FIG. 2, 3) and confined between the retaining elements, in such a manner that the perimeter is the exterior of the retaining elements (FIG. 3, D) and the coefficient of friction is that corresponding to ground-to-ground, that is to say the maximum attainable.
The materials of which these reinforcements can be made are preferably metallic, preferably based on iron or steel. A variant contemplated in the present invention is that the material of the reinforcement is composed, entirely (core plus retaining modules) or partially (core or retaining modules), on the basis of polymeric material. Another preferred embodiment of the invention is for the core and/or retaining elements to be formed from cement material, for example concrete. For these purposes the material of which the core of the reinforcement is made and that of the retaining modules need not be the same. That is to say, the scope of protection of the present invention includes combinations: metallic core-retaining modules of polymeric material, or vice versa. The same type of combinations would apply in the case of concrete.
The results of the trials carried out in the laboratory indicate that, if the height of the retaining elements is greater than 3 mm and provided that their spacing does not exceed 60 times their height, the extraction responds to the ground breaking point values on the surface of the assembly comprising the reinforcement-ground cylinder, the residual value responding to the ground-ground coefficient of friction, thus achieving the qualification of the reinforcements as "high adhesion" in the general technique of Reinforced or Framed Grounds (FIG. 4). According to these tests the reinforcements forming the subject of the present invention comply with all the requirements for high adhesion reinforcements, with pairs of values all above the line (2).
The advantage in comparison with the prior art is undoubted, because it becomes possible to comply with requirements for reinforcements in respect of friction, without any preconditions whatsoever with regard to their tension-resistant section, through the addition of a small amount of material, which may be the same as or different from that of the resistant section, thus making it possible to take advantage of the shear resistance characteristics of the ground itself.
Thus, as particular examples of embodiment of the invention and more concretely for circular cylindrical configurations, we can cite by way of illustration, and without any limitative character, the details shown in the following table.
TABLE I______________________________________ D. Retaining .increment. Material: .increment. FrictionalD. Core elements Cost areamm mm % %______________________________________ 8 14 7 7512 22 10 8316 26 8 62______________________________________
in each case with an improved coefficient of friction.
Although there are no great differences in the tensional stress on the reinforcements in comparison with other reinforcements described in the prior art, since this depends solely on the nature of the material and the resistant area, the gain in friction is clearly advantageous in comparison with high-adhesion reinforcement bands having the same area, as is shown in the illustrative examples, which do not have a limitative character, shown in the following table.
TABLE II______________________________________ D. Retaining .increment. Frictional surface:D. Core elements material ratiomm mm %______________________________________8 14 1158 18 14216 26 43______________________________________
In view of the fact that the different standards which exist for the dimensioning of Reinforced or Framed Grounds require over-thickness representing a sacrifice to corrosion, the advantage of the reinforcements of the invention is impressive in providing compact sections having a low perimeter:area ratio, which will always entail a higher useful area:total area ratio than with plane reinforcements or bands, and this in turn permits the use of greater thicknesses which are economically prohibitive for the latter.
As will be appreciated, with this type of reinforcements the latter can be shorter than the usual uniform reinforcements which have the same resistant section and of which the same number are used, and it will be possible to use a smaller number of them or to use a smaller section for one and the same length. In addition, because of the advantages indicated above there is nothing to prevent the manufacture of reinforcements having a low unit weight, so that requirements in respect of resistance can be met gradually and accurately. In any case, the result will be a considerable saving, either in the volume of fill required or in the actual cost of the reinforcement material.
Comparative calculations made for one and the same mass, with an overload of 1 t/m 2 and an internal angle of friction of 30°, equipped with plain bands, ribbed bands and reinforcements according to the invention, produce the following results:
TABLE III______________________________________ Reinforcement H.L. Plain Ribbed according toMechanical Reinforcement band band the inventionm m kg/m.sup.2 kg/m.sup.2 kg/m.sup.2______________________________________ 6 4.5 18 13.25 912 9 32 25 19______________________________________
The invention is applicable to masses of all heights, since it is possible to adapt the section to requirements in respect of resistance and to adapt the dimensions of the retaining elements to requirements in respect of friction.
None of the general indications of present processes, in respect of the need for a certain ratio between the area of the ground bed on which each layer of reinforcements to be covered is laid and the material of the reinforcements, applies to the process of the invention.
EXPLANATION OF THE DRAWINGS
FIG. 1: Resistance diagram in which 1 represents the core of the reinforcement, 2 the retaining module and 3 the mobilized ground. D and d are respectively the width (diameter in the case of circular structures) of the mobilized volume of earth and of the core+the mobilized volume of the reinforcement. A represents the so-called "resistant zone" and B the so-called "active zone", while L is the distance between retaining modules (2).
FIG. 2: Three-dimensional representation of a reinforcement composed of the core (1) having a non-plane section and the retaining module or retaining element (2). In the representation it is possible to see the mobilized volume of earth (3) between retaining modules.
FIG. 3: Section of a retaining module in which d is the diameter of the core and D the diameter of the core+the mobilized volume.
FIG. 4: Representation of the coefficient of friction (Y) plotted against vertical pressure in KN/m 2 (X). The line 1 corresponds to plain tie rods and the line 2 to high-adhesion tie rods. At point 3 are shown those pairs of values which are outside the scale represented (>3).
FIG. 5: Reinforcement of solid, square section with retaining elements surrounding the core and having a square contour coinciding with the section, with bevelled edges.
FIG. 6: Reinforcement of solid, triangular section with retaining elements surrounding the core and having a triangular contour coinciding with the section.
FIG. 7: Reinforcement of solid, irregularly curved section with retaining elements surrounding the core and having an irregularly curved contour coinciding with the section.
FIG. 8: Reinforcement of solid, hexagonal section with retaining elements surrounding the core and having a hexagonal contour coinciding with the section.
FIG. 9: Reinforcement of hollow, rectangular section with retaining elements surrounding the core and having a rectangular contour coinciding with the section.
FIG. 10: Reinforcement of solid, square section with offset retaining elements half surrounding the core and having a U-shaped contour forming half-grooves.
FIG. 11: Reinforcement of solid, square section with tooth-shaped retaining elements.
FIG. 12: Reinforcement of solid, square section with retaining elements surrounding the core and in the form of a helicoidal groove.
FIG. 13: Reinforcement of solid, square section with retaining elements surrounding the core and in the form of spaced spike-like grooves.
FIG. 14: Reinforcement of solid, circular section with retaining elements in the form of half-rings.
FIG. 15: Reinforcement of solid, circular section with retaining elements in the form of teeth.
FIG. 16: Reinforcement of solid, circular section with retaining elements surrounding the core and forming a helicoidal ring.
FIG. 17: Reinforcement of solid, circular section with retaining elements surrounding the core and having circular spike-like contours.
The drawings show illustrative but not limitative embodiments of the present invention. Both the section of the core of the reinforcement and the contour of the retaining elements may be regular (parallelepiped, triangle, circle, ellipse, hexagon, etc.) or irregular. The retaining elements may or may not be arranged to surround the core of the reinforcement, or be spaced, helical, offset subdivided into 2 complementary parts, inclined relative to the perpendicular to the axis of the core, thickened, spike-like, etc. They may also have contours provided with bevelled or rounded edges, and these contours may or may not coincide with the section of the core of the reinforcement, that is to say the perimeter of the retaining elements need not be parallel or homothetic to the core (for example: circular core and rectangular or irregular retaining elements, or vice versa).
Their system of fastening to the reinforcement core may consist of any of those described in the known art: adhesive bonding, filler metal or pressure welding, additional casting, production by co-extrusion, simultaneous casting, etc. | New armatures and system using them, applicable to reinforced or armored masses of earth, which present a non planar section, with surrounding retainers having improved technical characteristics of traction resistance and friction surfaces. | 4 |
FIELD OF THE INVENTION
The invention relates to a snow chain having a running net held by an inner and an outer mounting, each arranged in the region of the tire flanks, in which the circumference of the inner mounting can be shortened by a tensioning strand guided over the tread of the tire.
STATE OF THE ART
A snow chain of the above type is known from EP 0 263 778 B1, whose inner mounting is expediently formed by a sprung steel hoop whose ends are connected to each other via a tensioning strand which is guided over the tread of the tire to the outer mounting in order to be secured there. The length of the end of the tensioning strand to be secured depends on the distance between the ends of the inner mounting bridged by the tensioning strand and the guiding of the tensioning strand at the bridging point; it may assume substantial values and result in problems with the accommodation of the end of the tensioning strand on the outside of the tire. Problems must be expected, in particular, when fitting snow chains on so-called fat tires, the more so since these, in modern vehicles, are increasingly accommodated in narrow wheel arches. In cases of the latter type, even a single threading eye for a tensioning strand arranged in the region of the tire flank may result in bodywork damage.
As is known from DE 42 25 802 A1, attempts have been made to counter the difficulties described by moving the tensioning strand, passed through a threading eye integrated into the outer mounting formed by a side chain, and guide eyes serving for its additional guidance and fixed to the side chain, into the wheel rim region, in other words towards the axle. This solution, however, makes it necessary to use a rim protector, formed by a disc which is provided with hoop-shaped connecting members into which the side forming the outer mounting must be suspended. Although the rim protector arranged between the side chain and the tensioning strand on one side and the tire flank and the rim on the other side prevents damage to the vehicle rims caused by the tensioning strand secured outside the region of the tire flanks, at the same time it too takes up more space than is desirable, not least because of the connecting members enclosing the side chain.
DESCRIPTION OF THE INVENTION
The object of the invention is to provide a snow chain of the type under consideration which eliminates the problems indicated above by virtue of a new design of the outer mounting and of the tensioning strand guide. This object is achieved, according to the invention, in that the outer mounting is designed as a flat disc, at least in the region of the tire flank, and in that it possesses means outside the region of the tire flank for securing the end of the tensioning strand.
The space taken up by the chain according to the invention between the tire flank and the wheel arch inner wall is exceptionally small. In addition to the advantage of the low space requirement of the snow chain according to the invention, a beneficial effect also results from the fact that the chain net is pre-configured by the outer mounting in a way which facilitates the assembly. Finally, it proves expedient that a special rim protector can also be dispensed with.
Further details and features are apparent from the subclaims and the description which follows of two embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing:
FIG. 1 shows the rear view of a snow chain having an inner mounting formed from a sprung steel together with a partial view of the running net of the chain,
FIG. 2 shows the front view of the snow chain according to FIG. 1 with an inner mounting formed by an annular disc and a crosspiece to secure a tensioning strand,
FIG. 3 shows a section along the line III—III in FIG. 2,
FIG. 4 shows a modification of the region indicated by IV in FIG. 3, and
FIG. 5 shows the front view of a modified snow chain with a back corresponding to FIG. 1 .
WAYS OF EMBODYING THE INVENTION
In the figures, 1 is a so-called fat tire, in other words a t;re that takes up a great deal of space and in many cases excludes the use of snow chains, parts of which project well beyond the tire flanks. The inner mounting 2 of the snow chain fitted on the tire 1 is formed by a sprung steel hoop which makes the fitting of the chain exceptionally easy. In order to enable the sprung steel hoop to be inverted over the tire 1 , it has to be spread open. The distance between the ends 4 , 5 of the sprung steel hoop, bridged by a tensioning strand 3 guided in the manner of a block and tackle, assumes substantial values here, so that there is no avoiding the use of comparatively long tensioning strands 3 . The problem arising from the circumstances indicated lies in the fact that, after fitting is complete and the tensioning strand 3 has been drawn tight, its excess length, which is situated at the front of the tire, has to be secured. In practice, this is customarily done in known snow chains by wrapping the end of the tensioning strand several times around the outer mounting, usually formed by a side chain, and then eventually suspending a hook arranged on the end of the tensioning strand in a member of the outer mounting. It is understood that the wrapping of a tensioning strand around a side chain situated in the region of the tire flank undesirably increases the overall width of the snow chain and of the tire, which is wide in any case. As is apparent from FIG. 2, the problem described can be solved in that the end of the tensioning strand to be secured is accommodated outside the flank region, dispensing with a deflection of the tensioning strand in the region of the front tire flank. To this end, the outer mounting consists of a flat disc 8 provided with recesses 6 , 7 . The disc 8 has holes 9 distributed over its circumference, into which the end links 10 of chain strand sections 11 , 12 can be suspended, resilient connecting elements also being suitable as end links. In the region where the tensioning strand 3 enters the central region of the disc 8 , the latter is provided with a cutout 13 , in order to prevent the tensioning strand 3 from projecting further above the tire flank than the end links 10 of the chain strand sections 11 , 12 . The ring formed by the sections 14 , 15 of the disc 4 is bridged by a crosspiece 16 , which receives the chain strand end to be secured. The crosspiece 16 , having lateral webs 17 , 18 , is provided with an anti-return device 19 with a plurality of deflection elements 20 for the tensioning strand 3 . A hook 21 arranged at the end of the tensioning strand 3 may be suspended in one of a plurality of recesses 22 .
It can be seen from the section shown in FIG. 3 that the disc 8 is provided with an annular collar 23 projecting, for its positional adjustment, within the rim bowl of the wheel and simultaneously serving to increase the rigidity of the disc 8 , preferably manufactured from plastic. To increase the rigidity of the disc, the latter—as indicated in FIG. 4 —can also be provided with beads 24 .
Instead of a crosspiece 16 , it is also possible to use a reel 26 provided with a circumferential groove 25 to secure the end of the tensioning strand 3 —as is shown in FIG. 5 —the reel being connected via spoke-like, flat webs 27 to the sections of a modified disc 28 which form a ring and being designed to be either fixed or rotatable.
In both cases described, the discs 8 and 28 , respectively, in addition to their function as an outer mounting and wind-up device for the end of the tensioning strand 3 , also perform the function of rim protection, which is particularly desirable if light metal rims are used. | The invention relates to an anti-skid chain with a travelling net, held by an inner and outer holding device. The outer holding device is designed as a flat disk ( 8 ), at least in the area of the tire flank. Furthermore, the outer holding device has means for accomodating a tension rod ( 3 ) for the inner holding device outside the wheel flanks. | 1 |
RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/609,219, filed Sep. 9, 2004, titled SKATEBOARD DECK CONSTRUCTION; and of U.S. Provisional Application No. 60/612,003, filed Sep. 10, 2004, titled SKATEBOARD DECK CONSTRUCTION; and of U.S. Provisional Application No. 60/662,118 filed Mar. 16, 2005, titled SKATEBOARD DECK CONSTRUCTION. The entire contents of each of the above-mentioned provisional patent applications are hereby incorporated by reference herein and made a part of this specification.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Certain embodiments disclosed herein relate to skateboard deck construction.
[0004] 2. Description of the Related Art
[0005] Skateboard decks constructed from laminated wood are well known. However, these and other known skateboard decks suffer from drawbacks in terms of strength, weight, durability, etc.
SUMMARY OF THE INVENTION
[0006] According to one embodiment, a skateboard deck comprises a core member comprising a hollow carbon fiber structure, and a generally rigid exterior portion encasing the core member. The exterior portion can optionally comprise a core surround which surrounds a perimeter edge of said core member, and an upper layer overlying said core member. The exterior portion can further optionally comprise a lower layer underlying the core member. The core member can optionally have a skateboard shape. The core member may further optionally comprise a reduced-size skateboard disposed within the exterior portion.
[0007] According to another embodiment, a method of making a skateboard deck comprises forming a core member from carbon fiber; imparting a skateboard shape to the core member; and after the imparting, building an exterior portion onto the skateboard-shaped core member. The core member can optionally be hollow. The exterior portion can optionally comprise a core surround and an upper layer. The exterior portion can further optionally comprise a lower layer.
[0008] According to another embodiment, a skateboard deck comprises a core member comprising a carbon fiber structure having an internal longitudinal beam, and a generally rigid exterior portion encasing the core member.
[0009] According to another embodiment, a core member for a skateboard deck comprises a carbon fiber shell surrounding a longitudinally-extending interior space, and a longitudinal beam disposed within the interior space. The longitudinal beam can optionally be bonded to at least one inner surface of the shell. The longitudinal beam can optionally define a first beam surface bonded to a first inner surface of the shell, and a second beam surface bonded to a second inner surface of the shell.
[0010] According to another embodiment, a skateboard deck comprises a carbon-fiber shell surrounding a longitudinally-extending interior space. The carbon-fiber shell has an upper inner surface and a lower inner surface opposite the upper inner surface; and a longitudinal beam disposed within the interior space. The longitudinal beam has an upper flange bonded to the upper inner surface of the shell, a lower flange bonded to the lower inner surface of the shell, and a web interconnecting the upper flange and the lower flange. The skateboard deck further comprises a generally rigid exterior portion encasing the core member. The exterior portion comprises at least one layer of wood disposed above or below the shell.
[0011] According to another embodiment, a core member for a skateboard deck comprises a carbon-fiber shell surrounding a longitudinally-extending interior space. The carbon-fiber shell has an upper inner surface and a lower inner surface opposite the upper inner surface. The core member further comprises a longitudinal beam disposed within the interior space. An upper portion of the longitudinal beam is bonded to the upper inner surface of the shell, a lower portion of the longitudinal beam is bonded to the lower inner surface of the shell. The longitudinal beam has a longitudinal cross section with an “S” configuration.
[0012] According to another embodiment, a skateboard deck comprises a carbon-fiber shell surrounding a longitudinally-extending interior space. The carbon-fiber shell has an upper inner surface and a lower inner surface opposite the upper inner surface, a longitudinal beam disposed within the interior space, and first and second truck blocks disposed within the interior space. The first and second truck blocks are located at first and second ends of the longitudinal beam. The skateboard deck further comprises a generally rigid exterior portion encasing the core member. The exterior portion comprises at least one layer of wood disposed above or below the shell.
[0013] Certain objects and advantages of the invention are described herein. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
[0014] All of the embodiments summarized above are intended to be within the scope of the invention herein disclosed. However, despite the foregoing discussion of certain embodiments, only the appended claims (and not the present summary) are intended to define the invention. The summarized embodiments, and other embodiments of the present invention, will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an exploded view of the construction of a skateboard deck.
[0016] FIG. 2 is an exploded view of the construction of a core member of the skateboard deck of FIG. 1 .
[0017] FIG. 3 is an exploded view of the construction of a core surround of the skateboard deck of FIG. 1 .
[0018] FIG. 4 is a perspective view of another embodiment of a core member suitable for use in the skateboard deck of FIG. 1 , with an upper portion of a shell of the core member partially cut away and a center layer of the core member removed for clarity.
[0019] FIG. 5 is a top view of the core member of FIG. 4 , with the upper portion of the shell partially cut away for clarity.
[0020] FIG. 6 is a cross sectional view of the core member of FIG. 4 , taken along the line 6 - 6 in FIG. 5 .
[0021] FIG. 7 is a cross sectional view of the core member of FIG. 4 , taken along the line 7 - 7 in FIG. 5 .
[0022] FIG. 8 is a perspective view of a skateboard deck incorporating a version of the core member of FIGS. 4-7 .
[0023] FIG. 9 is a top view of the skateboard deck of FIG. 8 .
[0024] FIG. 10 is a side view of the skateboard deck of FIG. 8 .
[0025] FIG. 11 is a sectional view of the skateboard deck of FIG. 8 , taken along the line 11 - 11 in FIG. 9 .
[0026] FIG. 11A is a detail view of the indicated portion of FIG. 11 .
[0027] FIG. 11B is a schematic detail view of the indicated portion of FIG. 11 , showing the construction of the longitudinal beam and its position in the center layer of the core member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] FIG. 1 depicts one embodiment of a skateboard deck 50 , which generally comprises a core member 60 , a core surround 70 which surrounds the periphery of the core member 60 , upper layers 80 which overlie the top of the core member 60 and core surround 70 , and lower layers 90 which underlie the bottom of the core member 60 and core surround 70 .
[0029] In the embodiment depicted in FIG. 1 , the core member 60 may have a skateboard shape, i.e. it may comprise a miniature skateboard unto itself. Thus the core member 60 may have upturned front and rear ends 62 , 64 , a slightly concave upper surface, a slightly convex lower surface, and a planform having a shape approximating an elongated oval. In one embodiment, the core member may comprise a skateboard-shaped member or miniature skateboard deck formed from carbon fiber.
[0030] The core member 60 may be further configured as shown in FIG. 2 , with a foam (e.g., polyester foam) center layer 66 and upper and lower carbon fiber layers 67 , 68 which wrap around the center layer 66 . The core member 66 may be constructed by wrapping the carbon fiber layers 67 , 68 around the center layer 66 , with resin and/or other adhesives between the carbon fiber layers 67 , 68 (and/or between the carbon fiber layers 67 , 68 and the center layer 66 ), so that the “wrapped” assembly takes on the approximate, elongated-oval planform of the center layer 66 . After wrapping, the core member 66 is pressed into the “skateboard” shape described above and depicted in FIG. 1 .
[0031] Thus, in the embodiment depicted in FIG. 1 , the core member 60 comprises a hollow, enclosed multi-layer carbon fiber member with a “skateboard” shape. (The core member 60 is “hollow” in that its center is an empty space or is occupied by a material other than carbon fiber, or by a material which is less dense than carbon fiber.) The core member 60 thus achieves great strength and light weight with a minimum of carbon fiber material, as compared to a simple single layer or layered “sandwich” of multiple carbon fiber layers.
[0032] In one embodiment, the carbon fiber layers 67 , 68 may comprise three upper and three lower layers, and each of the six layers may be 0.5 mm thick. The resulting core member 60 has a thickness of 0.185 inches.
[0033] FIG. 3 depicts the construction of the core surround 70 in greater detail. A number (e.g., 3 , as depicted) of sheets of wood, fiberglass, plastic, etc. are glued and pressed together to form an enlarged (as compared to the core member 66 ) skateboard shape within the perimeter of the core surround 70 . From within this enlarged skateboard shape is cut out a smaller skateboard shape approximating the size of the core member 66 . Thus is formed an inner edge 72 of the core surround 70 , which inner edge 72 closely abuts the outer edge of the core member 66 when the core member 66 is placed inside the core surround 70 . The core surround 70 thus extends outward from the perimeter of the core member 60 , in the completed deck 50 .
[0034] Upon placement of the core member 60 inside the core surround 70 , the upper and lower layers 80 , 90 are pressed and bonded together with the core-member-core-surround assembly disposed between them, so that the upper and lower layers 80 , 90 conform closely to the contoured shape defined by the core-member-core-surround assembly. The resulting structure is then permitted to cure for an appropriate length of time, and the upper and lower layers 80 , 90 and core surround 70 are cut to create a skateboard planform for the overall deck 50 . One example of a cut pattern is shown with the dashed lines 92 . Any suitable molding and/or lamination processes may be used to join the core member 60 , core surround 70 and upper and lower layers 80 , 90 .
[0035] After cutting, the completed deck 50 comprises the core member 66 , encased by the core surround 70 and the upper and lower layers 80 , 90 . Thus the deck 50 comprises a “skateboard within a skateboard” (the skateboard-shaped core member 66 disposed within the layers 80 , 90 and the core surround 70 ). Trucks, wheels, rails, etc. may be added to the deck 50 to create a complete skateboard.
[0036] In one embodiment, the core surround 70 may comprise three layers of North American hard maple wood, of 0 . 062 inches thickness each, to create a core surround 70 of 0.0185 inches thick. In this embodiment the upper and lower layers 80 , 90 may also be formed from North American hard maple wood, with the uppermost upper layer 80 and the lowermost lower layer 90 0.062 inches thick, and the balance of the layers 80 , 90 0.042 inches thick. The overall thickness of the deck 50 may be about 0.393 inches.
[0037] FIGS. 4-7 depict another embodiment of a core member 160 , which can be generally similar to the core member 60 , except as further described below. As with the core member 60 described above, the core member 160 of FIGS. 4-7 generally comprises a foam center layer 166 surrounded and enclosed by a carbon fiber shell 110 . In one embodiment the shell 110 may be formed by wrapping a number of upper and lower layers of carbon fiber material around the center layer 166 and pressing and bonding together the resulting structure, e.g. as shown and described above with regard to the core member 60 .
[0038] In the depicted embodiment the core member 160 also includes a pair of hardpoints or truck blocks 112 which reside within the shell 110 and are situated in suitable spaces or openings formed in the center layer 166 . The truck blocks are positioned on the longitudinal centerline of the core member 160 , and are preferably formed from a rigid and resilient material (e.g. wood, heavy plastic, fiber-reinforced plastic) to receive screws (not shown) that are driven into the deck 50 to hold a pair of trucks to the deck. To accommodate assembly of the center layer 166 around the truck blocks 112 , the material of the center layer may be divided into halves by a longitudinal seam 114 . As best seen in FIG. 6 , in one embodiment the truck blocks may each comprise two stacked layers of wood. Preferably, each of the truck blocks extend from an inner upper surface 116 of the shell 110 to an inner lower surface 118 thereof, so that the blocks abut the shell material at each of the surfaces 116 , 118 .
[0039] As best seen in FIGS. 4 and 7 , in one embodiment the core member 160 may further comprise a longitudinal beam 120 that extends generally along the longitudinal centerline of the member 160 , from one of the truck blocks 112 to the other. (In another embodiment, the longitudinal beam 120 can further extend longitudinally from each truck block 112 to the adjacent end of the core member 160 (see FIG. 9 ).) The depicted longitudinal beam 120 has an “S” cross section along its entire length, thereby forming upper and lower flanges 122 , 124 interconnected by a web 126 . In other embodiments, the beam 120 may have a different cross section, such as an “I,” “T,” “U,” etc., or a box section.
[0040] During construction of the core member 160 the upper flange 122 may be securely bonded to the inner upper surface 116 of the shell 110 , and the lower flange 124 securely bonded to the inner lower surface 118 , to impart great strength and rigidity to the core member.
[0041] In one embodiment, the core member 160 may have the following dimensions: overall length of 740 mm; overall width of 140 mm; overall thickness of 4 mm; truck block length of 90 mm; truck block width of 70 mm; and center layer thickness of 3 mm. In this embodiment, the longitudinal distance between the truck blocks is preferably 320 mm.
[0042] Further details of the construction of one embodiment of the deck 50 and core member 160 may be seen in FIGS. 8-11B . (The deck 50 and core member 160 of FIGS. 8-11B can be similar to the deck 50 and core members 60 , 160 depicted in FIGS. 1-7 , except as further described below.) In this embodiment, the center layer 166 of the core member 160 is situated between upper layers 167 a, 167 b, 167 c and lower layers 168 a, 168 b, 168 c (see FIG. 11A ). The upper layers 167 a, 167 b and the lower layers 168 a, 168 b preferably comprise carbon fiber material, and more preferably comprise layers of VTM246 200 gsm unidirectional “prepreg” carbon fiber fabric, trimmed to the profile of the center layer 166 with 10 mm overlap on the edges. The innermost upper layer 167 c and lower layer 168 c preferably also comprise carbon fiber material, and more preferably comprise layers of MTM56 200 gsm 2/2 twill prepreg carbon fiber fabric, trimmed to the profile of the center layer 166 with 10 mm overlap on the edges. In addition, the center layer 166 preferably comprises 3 mm thick polyester foam with a density of 80 kg per cubic meter.
[0043] In the embodiment of FIGS. 8-11B , the longitudinal beam 120 can have a 3-layer configuration as shown in FIG. 11B , with an inner layer 121 a situated between two outer layers 121 b. The inner layer 121 a preferably comprises carbon fiber material, and more preferably comprises a layer of MTM56 200 gsm 2/2 twill prepreg carbon fiber fabric, trimmed to a width of 40 mm. The outer layers 121 b preferably comprise carbon fiber material, and more preferably comprise layers of VTM246 200 gsm unidirectional prepreg carbon fiber fabric, trimmed to a width of 40 mm.
[0044] The core member 160 can be constructed by a lay-up process. This process preferably comprises: (a) preparing the truck blocks or hardpoints 112 with appropriately sized (e.g., 90 mm×70 mm) plywood blocks wrapped in adhesive film (e.g., MTM26 resin adhesive film); (b) cutting openings in the material of the center layer 166 to accommodate the truck blocks 112 ; (c) positioning the longitudinal rib 120 between the two halves of the center layer 166 as shown in FIG. 11B (preferably overlapping the upper and lower faces of the center layer 166 by a distance D of 15 mm); (d) inserting the prepared truck blocks into the openings in the center layer 166 ; (e) applying the innermost lower layer 168 c with overlap as shown in FIG. 11A ; (f) applying the innermost upper layer 167 c with overlap over the innermost lower layer 168 c as shown in FIG. 11A ; (g) applying the next lower layer 168 b with overlap over the underlying layers 167 c, 168 c as shown in FIG. 11A ; (h) applying the next upper layer 167 b with the depicted overlap; (i) applying the next lower layer 168 a with the depicted overlap; and (j) applying the next upper layer 167 a with the depicted overlap.
[0045] After layup, the core member 160 can be placed in a matched-pair mold under vacuum (preferably 1 ATM) and cured at a temperature of 120 C for 15 minutes. After molding and curing, the core member 160 is permitted to cool and is trimmed as necessary for attachment of the upper and lower layers 80 , 90 and the core surround 70 . The core member 160 may be sanded or otherwise roughened to eliminate any “glossy” spots and improve the adhesion of the core member 160 to the upper and lower layers 80 , 90 .
[0046] Once the completed core member 160 is ready, the upper and lower layers 80 , 90 and the core surround 70 can be built onto the core member as discussed above with reference to FIG. 1 , to create a complete skateboard deck 50 .
[0047] Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular embodiments described above, but should be determined only by a fair reading of the claims that follow. | According to one disclosed embodiment, a skateboard deck comprises a carbon-fiber shell surrounding a longitudinally-extending interior space. The carbon-fiber shell has an upper inner surface and a lower inner surface opposite the upper inner surface; and a longitudinal beam disposed within the interior space. The longitudinal beam has an upper flange bonded to the upper inner surface of the shell, a lower flange bonded to the lower inner surface of the shell, and a web interconnecting the upper flange and the lower flange. The skateboard deck further comprises a generally rigid exterior portion encasing the core member. The exterior portion comprises at least one layer of wood disposed above or below the shell. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for screen adaptation and apparatus thereof, which relates to terminal display technology.
PRIOR ART
[0002] With development of mobile communication technology, more and more types of mobile device increases. Different mobile devices are different in operating system and screen size.
[0003] In prior art, primary layer differences among operating systems can be shielded by mobile insert software technology, which realizes rapid developing of crossing-system. A client can be assured to be run in different systems with one set of UI (user interface) which is developed by a developer.
[0004] The prior art has at least following disadvantages: due to different mobile devices, screen sizes of the devices are different; a developer requires to make different UI according to different screen sizes; the UI must be processed by resetting high-fidelity picture, slicing process, coding and testing so as to adapt different mobile devices, which lead to heavy working load of screen adaptation and low efficiency of screen adaptation.
SUMMARY OF THE INVENTION
[0005] The object of the present invention is to provide a method for screen adaptation and a device thereof, by which workload of the screen adaptation is light and efficiency of the screen adaptation is high.
[0006] Therefore, according to one aspect of the present invention, a method for screen adaptation is provided, which includes following steps:
[0007] A1) obtaining, by a client, UI (user interface) data packet/package from a server, parsing the UI data packet, obtaining drawing information of respective modules and drawing information of respective components, the modules of the UI being arranged in vertical direction, each module containing one or a plurality of components;
[0008] A2) determining, by the client, screen orientation of a device on which the client is, if the screen orientation is portrait screen, executing step A3; if the screen orientation is landscape screen, executing step A4;
[0009] A3) setting, by the client, display width of respective modules to be screen width of the device, obtaining display width, display height and display coordinates of the respective components according to display width of the respective modules, the drawing information of the respective modules and the drawing information of the respective components; drawing the respective components according to the display width, display height and display coordinates of the respective components and resource files required to be filled in the respective components and executing step A5;
[0010] A4) setting, by the client, the display width of the respective module to be screen height of the device, obtaining display width, display height and display coordinates of the respective components according to display width of the respective modules, the drawing information of the respective modules and the drawing information of the respective components; drawing the respective components according to the display width, display height and display coordinates of the respective components and resource files required to be filled in the respective components and executing step A5; and
[0011] A5) monitoring, by the client, screen orientation of the device, going back to step A2 when detecting that screen orientation of the device changes.
[0012] According to another aspect of the present invention, another method for screen adaptation is provided, which includes following steps:
[0013] E1) obtaining, by the client, a UI data packet, parsing the UI data packet, obtaining drawing information of a global module and drawing information of respective components,
[0014] E2) determining, by the client, screen orientation of a device on which the client is, if the screen orientation is portrait screen, executing step E3; if the screen orientation is landscape screen, executing step E4;
[0015] E3) setting, by the client, display width of the global module to be screen width of the device, obtaining display height of the global module according to display width of the global module and drawing information of the global module, executing Step E5;
[0016] E4) setting, by the client, the display height of the global module to be screen width of the device, obtaining the display width of the global module according to the display height of the global module and the drawing information of the global module, executing Step E5;
[0017] E5) obtaining display width, display height and display coordinates of the respective components according to the display width of the global module, the display height of the global module, the drawing information of respective components; drawing the respective components according to the display width, display height and display coordinates of the respective components and resource files required to be filled in the respective components and executing Step E6;
[0018] E6) monitoring, by the client, the screen orientation of the device, going back to Step E2 when detecting that screen orientation of the device changes.
[0019] According to another aspect of the present invention, another method for screen adaptation is provided, which includes following steps:
[0020] H1) obtaining, by a client, UI data packet from a server, parsing the UI data packet, obtaining drawing information of respective modules and drawing information of respective components;
[0021] H2) according to screen size of a device on which the client is, drawing information of the respective modules and drawing information of the respective components, obtaining, by the client, portrait screen display information and landscape screen display information of the respective components;
[0022] H3) determining, by the client, screen orientation of a device on which the client is, if the screen orientation is portrait screen, executing step H4; if the screen orientation is landscape screen, executing step H5;
[0023] H4) drawing, by the client, the respective components according to the portrait screen display information of the respective components and executing step H6;
[0024] H5) drawing, by the client, the respective components according to the landscape screen display information of the respective components and executing step H6
[0025] H6) monitoring, by the client, screen orientation of the device, going back to step H7 when detecting that screen orientation of the device changes;
[0026] H7) determining, by the client, the screen orientation of the device on which the client is, if the screen orientation is portrait screen, executing Step H8; if the screen orientation is landscape screen, executing step H9;
[0027] H8) drawing, by the client, the respective components according to the portrait screen display information of the respective components, executing step H6; and
[0028] H9) drawing, by the client, the respective components according to the landscape screen display information of the respective components, executing step H6.
[0029] The advantages of the present invention at least include that: UI is drawn according to screen size and screen orientation of the device, the drawing information of the respective components in UI so that screen adaptation and landscape-portrait screen switching is performed among different screen sizes of the device, which improves smoothness, reduces workload of screen adaptation and improves screen adaptation efficiency.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0030] FIG. 1 is a flow diagram of a method for screen adaptation of Embodiment 1 of the present invention;
[0031] FIG. 2 is a flow diagram of another method for screen adaptation of Embodiment 2 of the present invention;
[0032] FIG. 3 is a flow diagram showing that a client obtains and stores portrait screen display information of respective components of UI in embodiments of the present invention;
[0033] FIG. 4 is a flow diagram showing that the client obtains and stores landscape screen display information of respective components of UI in embodiments of the present invention; and
[0034] FIG. 5 is a flow diagram of another method for screen adaptation of Embodiment 3 of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The technical solutions of the embodiments of the disclosure are described clearly and completely in conjunction with the accompanying drawings as follows. Apparently, the described embodiments are merely a part of but not all of the embodiments according to the disclosure. Based on the described embodiments of the disclosure, other embodiments obtained by those skilled in the art without any creative work belong to the scope of the disclosure.
[0036] The present invention is applied to a system including a server and a client; the client installed on a device is configured to draw UI on the device; UI can be divided into a plurality of modules; the modules are arranged vertically; each module includes one or more components. The server generates and stores a UI packet; and the UI packet includes drawing information of respective modules and drawing information of respective components of the modules.
[0037] Correspondingly, the client obtains the UI packet, parses the UI packet, obtains the drawing information of the respective modules and drawing information of the respective components and drawing UI according to the drawing information above.
[0038] In this case, the drawing information of the module can be wide-height aspect ratio or height-wide aspect ratio of the module; the drawing information of the component includes relative coordinates of the component, relative width of the component and relative height of the component, and the relative coordinates of the component includes relative abscissa of the component and relative ordinate of the component.
[0039] Correspondingly, the format of the drawing information of the component is: (relative abscissa of the component, relative ordinate of the component, relative width of the component and relative height of the component), the content of the drawing information can be represented in form of percentage.
[0040] In each embodiment, a wide-height aspect ratio of the module is ratio between width of the module in a UI effective picture and height of the module in the UI effective picture, the height-width aspect ratio is ratio between height of the module in the UI effective picture and width of the module in the UI effective picture. The relative abscissa of the component is ratio between abscissa of a module to which the component belongs and the width of the module in the effective picture; the relative ordinate of the component is ratio between the ordinate of the module to which the component belongs and height of the module in the UI effective picture; the relative width of the component is the ratio between the width of the component in the UI effective picture and the width of the module, in which the component belongs, in the UI effective picture; the relative height of the component is ratio between the height of the component in the UI effective picture and the height of the component of the module, in which the component belongs, in the effective picture.
[0041] In this case, the width of respective modules in the UI effective picture is total width of the UI effective picture; the abscissa of the component in the module is the left top corner of the component by taking the left top corner of the module as coordinate origin; the ordinate of the component in the module is the ordinate of the left top corner of the component by taking the left top corner of the module as coordinate origin.
[0042] As shown in FIG. 1 , a flow process diagram of the method for screen adaptation according to the present invention is provided. The method comprises following steps:
[0043] Step 101 , the client initiates, obtains a UI data packet from the server, parses the UI packet, obtains drawing information of respective modules in the UI and drawing information of respective components.
[0044] For example, the UI is divided into module 1, module 2 and module 3; in this case, module 1 includes component 1 and component 2; module 2 includes component 3; module 3 includes component 4, component 5 and component 6; the client parses the data UI packet and obtains drawing information (width-height aspect ratio) of the module 1, module 2 and module 3 which are respectively 40%, 30% and 30%, the drawing information of component 1 (20%, 10%, 70%, 30%), the drawing information of component 2 (20%, 50%, 70%, 40%) and drawing information of component 3 (20%, 10%, 70%, 80%), drawing information of component 4 (10%, 10%, 40%, 90%), drawing information of component 5 (60%, 10%, 30%, 30%) and drawing information of component 6 (60%, 60%, 30%, 40%).
[0045] Step 102 , the client obtains attribution information of the device.
[0046] In this case, the attribution information of the device includes information such as type information, screen size, screen orientation and screen resolution, etc. of the device; the screen size includes screen width and screen height.
[0047] In Embodiment 1, the client can invoke function UI_USER_INTERFACE_IDIOM to obtain type information of the device, takes value of size attribution in [UIScreen mainScreen] bounds as screen size of the device; invokes function of UIInterfaceOrientationIsPortrait in order to obtain screen orientation of the device; takes value of size attribution in [UIScreen mainScreen] currentMode as screen resolution of the device.
[0048] For example, the type information of the device is “iPhone4”, the screen size of the device is 251 pt*141 pt; the screen orientation of the device is landscape, the screen resolution is 1136 px*640 px.
[0049] Step 103 , the client determines whether the device is preset type device, if yes, execute Step 104 ; if no, execute Step 121 .
[0050] Specifically, the client can determine that whether the device is preset type device according to type information of the device; in this case, the prest type device can be a cellphone.
[0051] For example, the type information of the device is “iPhone4”, the client can determine that the device is cellphone.
[0052] Step 104 , the client selects the module on the top of UI as the current module, sets the display width of the current module as screen width of the device, sets the display coordinates of the current module as left top corner of the device screen.
[0053] For example, the screen size of the device is 251 pt*141 pt; when the left top corner of the device screen is coordinate origin, the client selects module 1 on the top of UI as the current module, sets the display width of the current module as 141 pt, sets the display coordinate of the current module as (0,0).
[0054] Step 105 , the client obtains the display height of the current module according to the drawing information and display width of the current module.
[0055] Specifically, when the drawing information of the current module is width-height aspect ratio, the client can obtain a result of dividing the display width of the current module by the width-height aspect ratio of the current module, take the result as the display height of the current module; when the drawing information of the current module is height-width aspect ratio, the client can obtain a result of multiplying the display width of the current module by the height-width ratio of the current module, taking the result as the height of the current module.
[0056] For example, the drawing information of the current module is width-height aspect ratio; the width-height aspect ratio is 40%; the display width of the current module is 141 pt; the display height of the current module calculated by the client=141 pt/40%=352.5 pt.
[0057] Step 106 , the client selects a component which is not drawn as the current component, obtains the display width, display height and display coordinates of the current component according to the display width, display height and the drawing information of the current component.
[0058] In this case, the display coordinates of the current component is coordinates of the left top corner of the current component, which include the display ordinate and the display abscissa of the current component, by taking the left top corner of the current module as coordinate origin.
[0059] Correspondingly, the client can obtain a product of display width of the current module and relative width of the current component, take the product as the display width of the current component, obtain a product of the display height of the current module and the relative height of the current component, take the product as the display height of the current component; obtain a product of the display width of the current module and the relative abscissa of the current component, take the product as the display abscissa of the current component; obtain a product of display height of the current module and relative ordinate of the current component, take the product as the display ordinate of the current component.
[0060] For example, the client selects component 1 of the current module as the current component, the display width of the current module is 141 pt; the display height of the current module is 352.5 pt; the display coordinates of the current module is (0, 0); the drawing information of the current component is (20%, 10%, 70%, 30%); the display width of the current component calculated by the client=70%*141 pt=98.7 pt; the calculated display height of the current component=30%*352.5 pt=105.75 pt; the calculated display abscissa of the current component=20%*141 pt=28.2 pt; the calculated display ordinate of the current component=10%*352.5 pt=35.25 pt.
[0061] Step 107 , the client determines whether a picture is required to be filled in the current component, if yes, execute Step 109 ; otherwise, execute Step 108 .
[0062] Specifically, the client can determine whether the content of the current component includes picture information, if yes, that the picture is required to be filled in the current component; if no, that the picture is not required to be filled in the current component is determined.
[0063] For example, the name of the current component is Label; the content of the component includes following information: Label.Pic=@“demo.png”; the client determines that the content of the current component includes picture information “demo.png”.
[0064] Step 108 , the client obtains resource file of the current component required to be filled in the current component according to the content of the current component; and draws the current component according to the obtained resource file and the display width, display height and display coordinates of the current component, then execute Step 118 .
[0065] Specifically, the client can take the left top corner of the current module as coordinate origin, locate the current component according to the display width, display height and display coordinates and fill the obtained resource file in the current component, display the current component and implement drawing of the current component.
[0066] In this case, the resource file can be files such as video, words, etc.
[0067] Step 109 , the client determines whether screen density of the device is more than a preset density value, if yes, executes Step 110 ; otherwise, execute Step 114 .
[0068] Specifically, the client can obtain screen density of the device directly and determine whether the screen density of the device is more than a preset density value; the client can also obtain screen resolution and screen size of the device, obtain screen density of the device according to the screen resolution and the screen size of the device and determine whether the screen density of the device is more than the preset density value.
[0069] In the Embodiment 1, the client can calculate screen density PPI of the device according to following formula:
[0000]
PPI
=
dp
di
=
wp
2
+
hp
2
di
[0070] In the formula, dp is resolution of screen diagonal of the device, wp is screen lateral resolution of the device, hp is screen vertical resolution of the device, di is length of screen diagonal of the device.
[0071] For example, when the screen resolution of the device is 1136 px*640 px, the screen size of the device is 251 pt*141 pt and the preset density value is 300 ppi, the client calculates out that the size density of the device is 326 ppi according to the screen resolution and screen size of the device and determines that the screen desity of the device is more than the preset density value.
[0072] Step 110 , the client obtains a corresponding high resolution picture according to content of the current component.
[0073] Specifically, the client can obtain the high resolution picture, which is corresponding to information of the picture, from a locally stored material package or by network asynchronously; the client can generate the high resolution picture, which is corresponding to information of the picture dynamically.
[0074] In the Embodiment 1, the locally stored material package can store a high resolution picture and a low resolution picture which are correspond to a same picture information.
[0075] For example, the content of the current component includes picture information “demo.png”; the locally stored material package stores the high resolution picture “demo@2x.png” and the low resolution picture ““demo.png” which are corresponding to “demo.png”; the client obtains the high resolution picture “demo@2x.png” from the locally stored material package.
[0076] Step 111 , the client determines whether other resource files required to be filled in the current component except for the picture, if yes, execute Step 113 ; otherwise, execute Step 112 .
[0077] Specifically, the client can determine whether the content of the current component includes information of other picture information except for the information of the picture; if yes, the client determines that other source files are required to be filled in the current component except for the picture; otherwise, the client determines that other source files are not required to be filled in the current component except for the picture.
[0078] Step 112 , the client draws the current component according to the obtained high resolution picture, the display width, the display height and the display coordinates of the current component; execute Step 118 .
[0079] Specifically, the client can take the left top corner of the current module and locate the current component according to the display width, display height and display coordinates of the current component, and fill the obtained high resolution picture in the current component, display the current component so as to implement the drawing of the current component.
[0080] For example, the display coordinates of the current component is (28.2, 35.25), the display width is 98.7 pt, the display height is 105.75 pt; the client obtains the high resolution picture “demo@2x.png” of the current component required to be filled in the current component, generates component with size of (98.7, 105.75) at position of coordinates of (28.2, 35.25) and fills the high resolution picture “demo@2x.png” in the component.
[0081] Step 113 , the client obtains other resource files except for the picture according to the content of the current component, draws the current component according to the display width, display height and display coordinates of the current component, the obtained high resolution picture and other resource files except for the picture; execute Step 118 .
[0082] Specifically, the client can take the left top corner of the current module as coordinate origin, locate the current component according to the display width, display height and display coordinates of the current component, fill the obtained high resolution picture and other resource files in the current component, display the current component so as to draw the current component.
[0083] Step 114 , the client obtains a corresponding low resolution picture according to the content of the current component.
[0084] Specifically, the client can obtain the low resolution picture, which is corresponding to information of the picture, from a locally stored material package or by network asynchronously; the client can dynamically generate the low resolution picture, which is corresponding to information of the picture.
[0085] In Embodiment 1, the locally stored material package can store the high resolution picture and the low resolution picture, which are corresponding to the same picture information.
[0086] For example, the content of the current component includes picture information “demo.png”; the locally stored material package stores the high resolution picture “demo@2x.png” and the low resolution picture “demo.png” which are corresponding to “demo.png”; the client obtains the low resolution picture “demo@2x.png” from the locally stored material package.
[0087] Step 115 , the client determines whether other resource files are required to be filled in the current component except for the current component, if yes, execute Step 117 ; otherwise, execute Step 116 .
[0088] Step 116 , the client draws the current component according to the obtained low resolution picture, the display width, the display height and the display coordinates of the current component; execute Step 118 .
[0089] Specifically, the client can take the left top corner of the current module and locate the current component according to the display width, display height and display coordinates of the current component, and fill the obtained low resolution picture in the current component, display the current component so as to implement the drawing of the current component.
[0090] Step 117 , the client obtains other resource files except for the picture according to the content of the current component, draws the current component according to the display width, display height and display coordinates of the current component, the obtained low resolution picture and other resource files except for the picture; execute Step 118 .
[0091] Specifically, the client can take the left top corner of the current module as coordinate origin, locate the current component according to the display width, display height and display coordinates of the current component, fill the obtained high resolution picture and other resource files in the current component, display the current component, so as to draw the current component.
[0092] Step 118 , the client determines whether the current module includes the component, which is not drawn, if yes, go back to Step 106 ; otherwise, execute Step 119 .
[0093] Step 119 , the client determines whether UI includes the unprocessed module, if yes, execute Step 120 ; otherwise, execute Step 139 .
[0094] Step 120 , the client obtains a result of adding the display ordinate of the current module to the display height of the current module, select a module, which is adjacent to the current module and located below the current module, as a updated current module in the UI, sets the display ordinate of the updated current module to be the result, sets the display abscissa of the updated current module to be zero, sets the display width of the updated current module to be the screen width of the device, go back to Step 105 .
[0095] For example, when the screen size of the device is 251 pt*141 pt, the current module is module 1, the display coordinates of the current module is (0, 0) and the display height of the current module is 352.5 pt, the client obtains a result of adding the display ordinate of the current module to the display height of the current module, i.e. 0+352.5 pt=352.5 pt, selects module 2, which is adjacent to module 1 and below to the module 1, in the UI as the updated current module, sets the display coordinates of the updated current module to be (0, 352.5 pt) and sets the display width of the updated current module to be 141 pt.
[0096] Step 121 , the client determines orientation of the device, if the screen orientation is portrait screen, go back to Step 104 ; if the screen orientation is landscape screen, execute Step 122 .
[0097] Step 122 , the client select the module on the top of the UI, sets the display width of the current module to be screen height of the device and sets the display coordinates of the current module to be left top corner of the device screen.
[0098] For example, when the screen size of the device is 251 pt*141 pt and the left top corner of the device screen is coordinate origin, the client selects module 1 on the top of the UI as the current module, sets the display width of the current module to be 251 pt and sets the display coordinates of the current module to be (0, 0).
[0099] Step 123 , the client obtains the display height of the current module according to the drawing information and the display width of the current module.
[0100] Step 124 , the client selects a component, which is not drawn, as the current component from the current module, obtains the display width, display height and display coordinates of the current component according to the display width and display height of the current module and the drawing information of the current component.
[0101] Step 125 , the client determines whether requires to fill a picture in the current component, if yes, execute Step 127 ; otherwise, execute Step 126 .
[0102] Step 126 , the client obtains a resource file required to be filled in the current component according to the content of the current component, and draws the current component according to the obtained resource file and the display width, display height and display coordinates of the current component; execute Step 136 .
[0103] Step 127 , the client determines whether the screen density of the device is more than a preset density value, if yes, execute Step 128 ; otherwise, execute Step 132 .
[0104] Step 128 , the client obtains a corresponding high resolution picture according to the content of the current component.
[0105] Step 129 , the client determines whether other resource files are required to be filled in the current component except for the picture, if yes, execute Step 131 ; otherwise, execute Step 130 .
[0106] Step 130 , the client draws the current component according to the obtained high resolution picture, the display width, display height and display coordinates of the current component; execute Step 136 .
[0107] Step 131 , the client obtains other resource file except for the picture according to the content of the current component, draws the current component according to the display width, display height and display coordinates of the current component, the obtained high resolution picture and other resource files except for the picture; execute Step 136 .
[0108] Step 132 , the client obtains a corresponding low resolution picture according to the content of the current component.
[0109] Step 133 , the client determines whether other resource files except for the picture are required to be filled in the current component, if yes, execute Step 135 ; otherwise, execute Step 134 .
[0110] Step 134 , the client draws the current component according to the obtained low resolution picture, the display width, display height and display coordinates of the current component; execute Step 136 .
[0111] Step 135 , the clients obtains other resource files except for the picture according to the content of the current component, draws the current component according to the display width, display height and display coordinates of the current component, the obtained low resolution picture and other resource files except for the picture; execute Step 136 .
[0112] Step 136 , the client determines whether the current module includes a component, which is not drawn, if yes, execute Step 124 ; otherwise, execute Step 137 .
[0113] Step 137 , the client determines whether UI includes an unprocessed module, if yes, execute Step 138 ; otherwise, execute Step 139 .
[0114] Step 138 , the client obtains a result of adding the display ordinate of the current module to the display height of the current module, select a module, which is adjacent to the current module and located below the current module, as a updated current module in the UI, sets the display ordinate of the updated current module to be the result, sets the display abscissa of the updated current module to be zero, sets the display height of the updated current module to be the screen width of the device, then goes back to Step 123 .
[0115] Step 139 , the client monitors the screen orientation of the device.
[0116] Step 140 , the client determines whether the screen orientation of the device changes, if yes, go back to Step 121 ; otherwise, go back to Step 139 .
[0117] In Embodiment 1, the client draws UI according to screen size and screen orientation of the device, the drawing information of the respective components in UI so that screen adaptation and landscape-portrait screen switching is performed among different screen sizes of the device, which improves smoothness, reduces workload of screen adaption and improves screen adaption efficiency.
[0118] In other embodiments of the present invention, the client can obtain and store the portrait screen display information and landscape screen display information of respective components at backend in advance, select corresponding display information according to screen orientation of the device, draw the respective components in the UI according to the selected display information.
[0119] As shown in FIG. 2 , a flow diagram for another method for screen adaption of the present invention is provided, which includes:
[0120] Step 201 , the client initiates, obtains a UI data packet from the server, parses the UI data packet and obtains drawing information of respective modules and drawing information of respective components in the UI.
[0121] In this case, the drawing information of the module can be width-height aspect ratio or height-width aspect ratio of the module, the drawing information of the component includes relative coordinates of the component, relative width of the component and relative height of the component; the relative coordinate of the component includes relative abscissa coordinates and relative ordinate of the component.
[0122] Step 202 , the client obtains screen size and screen orientation of the device.
[0123] In this case, the screen size includes screen width and screen height.
[0124] Step 203 , the client obtains and stores portrait screen display coordinates and landscape screen display coordinates of respective modules and portrait screen display information and landscape display information of respective components according to the screen size of the device, the drawing information of respective modules and the drawing information of respective components in the UI.
[0125] In this case, the portrait display information of the component includes portrait screen display coordinates of the component, the portrait screen display width of the component and the portrait screen display height of the component; the portrait screen display coordinates of the component includes portrait screen display abscissa of the component and portrait screen display ordinate of the component; the landscape screen display information of the component includes landscape screen display coordinates of the component, the landscape display width of the component and the landscape screen display height of the component; the landscape screen display coordinates of the component includes landscape screen display abscissa of the component and landscape screen display ordinates of the component.
[0126] Step 204 , the client determines screen orientation of the device, if the screen orientation is portrait screen, execute Step 205 ; if the screen orientation is landscape screen, execute Step 206 .
[0127] Step 205 , the client draws UI according to the portrait screen display coordinates of respective modules and portrait screen display information of the respective components, execute Step 207 .
[0128] Specifically, the client can take the left top corner of a module, to which respective components belongs, as coordinate origin, locate the respective components according to the portrait screen display width, portrait screen display height and portrait screen display coordinates of respective components, fill the corresponding resource file in respective components, display respective components so as to realize drawing of UI.
[0129] Step 206 , the client draws the UI according to the landscape screen display coordinates and the landscape screen display information of respective components; execute Step 207 .
[0130] Specifically, the client can take the left top corner of a module, to which respective components belongs, as coordinate origin, locate the respective components according to the landscape screen display width, landscape screen display height and landscape screen display coordinates of the respective components, fill the corresponding resource file in the respective components, display the respective components so as to realize drawing of UI.
[0131] Step 207 , the client monitors screen orientation of the device and the component attribution information of the respective components; when the component attribution information changes, execute Step 208 ; when the screen orientation of the device changes, execute Step 209 .
[0132] Step 208 , the client stores the changed component attribution information; go back to Step 207 .
[0133] For example, when the user enters “123” in an input box of UI, the client monitors that the content attribution of input box component changes and stores the content attribution “123”.
[0134] Step 209 , the client determines the screen orientation of the device, if the screen orientation is portrait screen, execute Step 210 ; and if the screen orientation is landscape screen, execute Step 213 .
[0135] Step 210 , the client draws the UI according to the portrait screen display coordinates of respective modules and the portrait screen display information of the respective components.
[0136] Step 211 , the client determines whether the component attribution information is stored by itself, if yes, execute Step 212 ; otherwise, execute Step 207 .
[0137] Step 212 , the client modifies attribution of the corresponding component according to the component attribution information stored by itself; go back to Step 207 .
[0138] For example, when the client has stored content attribution “123” of the input box component, the client modified the content attribution of the corresponding input box component to be “123”.
[0139] Step 213 , the client draws the UI according to the landscape screen display coordinates of respective modules and the landscape screen display information of the respective components; go back to Step 211 .
[0140] In Embodiment 2, the user interface can includes a plurality of modules and respective modules in the user interface are arranged vertically, each module includes one or a plurality of components; the portrait display information of the respective components includes the portrait screen display width, portrait screen display height and portrait screen display coordinates of the respective components; the landscape display information of the respective components includes the landscape screen display width, landscape screen display height and landscape screen display coordinates of the respective components.
[0141] Correspondingly, in above process, operation that the client obtains and stores the portrait screen display information of the respective components can be detailed as shown in flow diagram of FIG. 3 , which includes the following steps:
[0142] Step 301 , the client selects the module on the top of the UI as the current module, sets the portrait display width of the current module to be screen width of the device, takes the portrait screen display coordinates of the current module to be the left top corner of the device screen and stores the portrait screen display coordinates of the current module.
[0143] Step 302 , the client obtains the portrait screen display height of the current module according to the current drawing information and portrait display width of the current module.
[0144] Specifically, when the drawing information of the current module is width-height aspect ratio, the client can obtain a result got by dividing the portrait screen display width of the current module by the width-height aspect ratio of the current module; when the drawing information of the current module is height-width aspect ratio, the client can obtain a result got by multiplying the portrait screen display width of the current module with the height-width aspect ratio of the current module, takes the result as the portrait screen display height of the current module.
[0145] Step 303 , the client obtains and stores the portrait screen display width, portrait screen display height and portrait screen display coordinates of the respective components in the current module according to the portrait screen display width and portrait screen display height of the current module and drawing information of the respective components in the current module.
[0146] Specifically, the client obtains respective products of the portrait screen display width of the current module and relative width of respective components in the current module, takes the obtained products as portrait screen display width of respective components; the client obtains respective products of the portrait screen display height of the current module and relative height of respective components in the current module, takes the obtained products as portrait screen display height of respective components in the current module; the client obtains products of the portrait screen display width of the current module and the relative abscissas of respective components in the current module, takes the obtained products as portrait screen display abscissas of respective components in the current module; the client obtains products of the portrait screen display height of the current module and the relative ordinates of respective components in the current module, takes the obtained products as portrait screen display ordinates of respective components.
[0147] Step 304 , the client determines whether UI includes an unprocessed module, if yes, execute Step 305 ; otherwise, obtaining portrait screen display information is determined to be completed.
[0148] Step 305 , the client obtains a result of adding the portrait screen display ordinate of the current module to the portrait screen display height of the current module, selects a module, which is adjacent to the current module and located below the current module, as a updated current module in the UI, sets the portrait screen display ordinate of the updated current module to be the result, sets the portrait screen display abscissa of the updated current module to be zero, sets the portrait screen display width of the updated current module to be the screen width of the device, go back to Step 302 .
[0149] Correspondingly, operation that the client obtains and stores operation of landscape screen display information of the respective components in the UI can be detailed as shown in flow diagram of FIG. 4 , which includes the following steps:
[0150] Step 401 , the client selects the module on the top of UI as the current module, sets the landscape screen display width of the current module to be the screen height of the device and sets the landscape screen display coordinates of the current module as left top corner of the device screen.
[0151] Step 402 , the client obtains the landscape display height of the current module according to the drawing information and landscape screen display width of the current module.
[0152] Specifically, when the drawing information of the current module is width-height aspect ratio, the client can obtain a result of dividing the landscape screen display width of the current module by the width-height aspect ratio of the current module and takes the result as the landscape screen display height of the current module; when the drawing information of the current module is height-width aspect ratio, the client obtains a result of multiplying the landscape screen display width of the current module by the height-width aspect ratio of the current module and takes the result as the landscape display height of the current module.
[0153] Step 403 , the client obtains and stores the landscape screen display width, landscape display height and landscape display coordinates of respective components in the current module according to the landscape screen display width and landscape screen display height of the current module and the drawing information of the respective components of the current module.
[0154] Specifically, the client obtains respective products of the landscape screen display width of the current module and relative width of respective components in the current module, takes the obtained products as landscape screen display width of respective components; the client obtains respective products of the landscape screen display height of the current module and relative height of respective components in the current module, takes the obtained products as landscape screen display height of respective components in the current module; the client obtains products of the landscape screen display width of the current module and the relative abscissas of respective components in the current module, takes the obtained products as landscape screen display abscissas of respective components in the current module; the client obtains products of the landscape screen display height of the current module and the relative ordinates of respective components in the current module, and takes the obtained products as landscape screen display ordinates of respective components.
[0155] Step 404 , the client determines whether UI includes an unprocessed module, if yes, execute Step 405 ; otherwise, obtaining landscape screen display information is determined to be completed.
[0156] Step 405 , the client obtains a result of adding the landscape screen display ordinate of the current module to the landscape screen display height of the current module, selects a module, which is adjacent to the current module and located below the current module, as an updated current module in the UI, sets the landscape screen display ordinate of the updated current module to be the result, sets the landscape screen display abscissa of the updated current module to be zero, sets the landscape screen display width of the updated current module to be the screen height of the device, go back to Step 402 .
[0157] In the present embodiment, the client obtains and stores portrait screen display information and landscape screen display information according to the screen size of the device and drawing information of the respective components in the UI, uses the portrait screen display information or the landscape screen display information to draw the respective components according screen orientation of the device, so that screen adaptation and landscape-portrait screen switching is performed among different screen sizes of the device, which improves smoothness of screen adaptation and landscape-portrait screen switching, reduces workload of screen adaptation and improves screen adaptation efficiency.
[0158] It should be noted that, in other embodiments of the present invention, the UI further can includes only one global module; the global module includes all components in the UI. The server generates and stores the UI which includes drawing information of global module and the drawing information of the respective components in the global module.
[0159] In this case, the drawing information of the global module can be width-height aspect ratio or height-width aspect ratio of the global module. The drawing information of the component includes the relative coordinates of the component, the relative width of the component and the relative height of the component; the relative coordinates of the component include the relative abscissa of the component and the relative ordinate of the component.
[0160] In the present embodiment, the width-height aspect ratio of the global module is ratio between the width of the global module in the UI effective picture and the height of the global module in the UI effective picture; the height-width aspect ratio of the global module is ratio between the height of the global module in the UI effective picture and the width of the global module in the UI effective picture. The relative abscissa of the component is ratio between the abscissa of the component in the global module and the width of the global module in the UI effective picture; the relative ordinate of the component is ratio between the ordinate of the component in the global module and the height of the global module in the UI effective picture; the relative width of the component is the ratio between the width of the component in the UI effective picture and the width of the global module in the UI effective picture; and the relative height of the component is ratio between the height of the component in the UI effective picture and the height of the global module in the UI effective picture.
[0161] In this case, the width of the global module in the UI effective picture is total width of the UI effective picture; the height of the global module in the UI effective picture is total height of the UI effective picture; the abscissa of the component in the global module is abscissa of the left top corner of the component by taking the left top corner of the global module as coordinate origin; the ordinate of component in the global module is ordinate coordinate of the left top corner of the component by taking the left top corner of the global module as coordinate origin.
[0162] Correspondingly, the embodiment of the present invention provides another method for screen adaptation. As shown in FIG. 5 , the method includes the following steps.
[0163] Step 501 , the client initiates, obtains a UI data packet from the server, parses the UI data packet and obtains drawing information of the global module and drawing information of the respective components in the UI.
[0164] Step 502 , the client sets central point of global module to be the same as central point of UI view and sets the background of the UI view to be black.
[0165] Specifically, the client can set the central point of global module to be the same as the central point of UI view by setting center attribution of the global module to be the same as center attribution of UI view; the client can set the background of the UI view to be black by setting Background attribution of the UI view to be a preset value, in which the preset value can be “Black Color”.
[0166] Step 503 , the client obtains attribution information of the device.
[0167] In this case, the attribution information of the device can includes type information, screen size, screen orientation, screen resolution, etc. of the device; the screen size includes screen width and screen height.
[0168] Step 504 , the client determines the screen orientation of the device, if the screen orientation is portrait screen, execute Step 505 ; and if the screen orientation is landscape screen, execute Step 509 .
[0169] Step 505 , the client determines the width-height aspect ratio of the global module according to the drawing information of the global module; if the width-height aspect ratio of the global module is less than screen width-height aspect ratio of the device, execute Step 506 ; if the width-height aspect ratio of the global module is equal to the screen width-height ratio of the device, execute Step 507 ; if the width-height aspect ratio of the global module is more than the screen width-height aspect ratio of the device, execute Step 508 .
[0170] Step 506 , the client sets the display height of the global module as screen height of the device, obtains the display width of the global module according to the display height and drawing information of the global module; execute Step 513 .
[0171] Step 507 , the client sets the display height of the global module as screen height of the device, sets the display width of the global module as screen width of the device; execute Step 513 .
[0172] Step 508 , the client sets the display width of the global module as screen width of the device, obtains display height of the global module according to the display width and drawing information of the global module; execute Step 513 .
[0173] Step 509 , the client determines the width-height aspect ratio of the global module according to the drawing information of the global module; if the width-height aspect ratio of the global module is less than the screen height-width aspect ratio of the device, execute Step 510 ; if the width-height aspect ratio of the global module is equal to the screen height-width aspect ratio of the device, execute Step 511 ; if the width-height aspect ratio of the global module is more than the screen height-width aspect ratio of the device, execute Step 512 .
[0174] Step 510 , the client sets the display height of the global module as screen width of the device, and obtains the display width of the global module according to the display height and drawing information of the global module, obtains the display width of the global module; execute Step 513 .
[0175] Step 511 , the client sets the display height of the global module as screen width of the device and sets the display width of the global module as screen height of the device; execute Step 513 .
[0176] Step 512 , the client sets the display width of the global module as screen height of the device and obtains the display height of the global module according to the display width and drawing information of the global module; execute Step 513 .
[0177] Step 513 , the client selects a component, which is not drawn, as the current component from the global module, obtains display width, display height and display coordinates of the current component according to the display width and display height of the global module and the drawing information of the current component.
[0178] Step 514 , the client determines whether requires to fill a picture in the current component, if yes, execute Step 516 ; otherwise, execute Step 515 .
[0179] Step 515 , the client obtains a resource file required to be filled in the current component according to the content of the current component, draws the current component according to the obtained resource file and the display width, display height and display coordinate of the current component; execute Step 525 .
[0180] Step 516 , the client determines whether the screen density of the device is more than a preset density value, if yes, execute Step 517 ; otherwise, execute Step 521 .
[0181] Step 517 , the client obtains a corresponding high resolution picture according to content of the current component.
[0182] Step 518 , the client determines whether other resource files are required to be filled in the current component except for the picture; if yes, execute Step 520 ; otherwise, execute Step 519 .
[0183] Step 519 , the client draws the current component according to the obtained high resolution picture, the display width, display height and display coordinates of the current component; execute Step 525 .
[0184] Step 520 , the client obtains other resource files except for the picture according to the content of the current component, draws the current component according to the display width, display height and display coordinates of the current component, the obtained high resolution picture and other resource files except for the picture; execute Step 525 .
[0185] Step 521 , the client obtains a corresponding low resolution picture according to the content of the current component.
[0186] Step 522 , the client determines whether requires to fill other resource files in the current component except for the picture; if yes, execute Step 524 ; otherwise, execute Step 523 .
[0187] Step 523 , the client draws the current component according to the obtained low resolution picture, the display width, display height and display coordinates of the current component, execute Step 525 .
[0188] Step 524 , the client obtains other resource files except for the picture according to the content of the current component, draws the current component according to the display width, display height and display coordinates of the current component, and the obtained high resolution picture and other resource files except for the picture; execute Step 525 .
[0189] Step 525 , the client determines whether the global module includes the component, which is not drawn, if yes, go back to the Step 513 ; otherwise, execute Step 526 .
[0190] Step 526 , the client monitors the screen orientation of the device.
[0191] Step 527 , the client determines whether the screen orientation of the device changes, if yes, go back to Step 504 ; otherwise, go back to Step 526 .
[0192] In Embodiment 3, the client draws UI according to screen size and screen orientation of the device, the drawing information of the module and components in UI so that screen adaptation and landscape-portrait screen switching is performed among different screen sizes of the device, which improves smoothness, reduces workload of screen adaptation and improves screen adaptation efficiency and user experience according to pictures corresponding to screen density.
[0193] It can be understood that all of or part of the steps in the above embodiments can be realized by hardware, a soft module executed by a processor or combination of both. The soft module can be stored in RAM (random-access memory), memory, ROM (read-only memory), electrically programmable read-only memory, electrically erasable programmable read-only memory, register, hard disc, mobile disc, CD-ROM (Compact Disc Read-Only Memory) or any other public known forms of storage media in the prior art.
[0194] The described embodiments are only preferred embodiments of the application and the embodiments are not intended to limit the application. Any alteration or change easily obtained by those skilled in the art based on the application should fall in the scope of protection of the application. | A screen adaptation method and apparatus. A client obtains a user interface data package from a server end and parses the user interface data packet to obtaining drawing information about each module and component; the modules of the user interface are arranged vertically and each module contains one or more components. According to the screen direction of the device where the client is located, the client acquires the display attributes of each component, and draws each component in the user interface according to said attributes and to a resource file required to be filled into each component. | 6 |
This is a Divisional Application of Ser. No. 09/506,099, filed Feb. 17, 2000.
BACKGROUND OF THE INVENTION
This invention relates to a fuel delivery rail assembly for an internal combustion engine, especially for an automotive engine, equipped with an electronic fuel injection system. The fuel delivery rail assembly delivers pressurized fuel supplied from a fuel pump toward intake passages or chambers via associated fuel injectors. The assembly is used to simplify installation of the fuel injectors and the fuel supply passages on the engine. In particular, this invention relates to sectional constructions of a fuel conduit (fuel rail) having a fuel passage therein and connecting constructions between the conduit and sockets for receiving fuel injectors.
Fuel delivery rails are popularly used for electronic fuel injection systems of gasoline engines. There are two types of fuel delivery rails; one is a return type having a return pipe and another is a returnless (non-return) type. In the return type, fuel is delivered from a conduit having a fuel passage therein to fuel injectors via cylindrical sockets and then residual fuel goes back to a fuel tank via the return pipe. Recently, for economical reasons, use of the returnless type is increasing and new problems are arising therefrom. That is, due to pressure pulsations and shock waves which are caused by reciprocal movements of a fuel pump (plunger pump) and injector spools, the fuel delivery rail and its attachments are vibrated thereby emitting uncomfortable noise.
Japanese unexamined patent publication No. Hei 11-2164 entitled “a fuel delivery” refers to this problem and discloses a method of manufacturing the fuel delivery body by a steel press process for lowering the co-vibrating rotation caused by the pressure pulsation below the idling rotation and thereby limiting the rigidity and contents of the delivery body within a preselected range. However, in view of the fact that delivery bodies are ordinarily formed by a steel pipe having a circular section or rectangular section, it is rather difficult to adopt the method from the view points of specifications, strength or cost of the engine.
Japanese examined patent publication No. Hei 3-62904 entitled “a fuel rail for an internal combustion engine” refers to an injector lapping noise and discloses a construction of diaphragm which divides an interior of the conduit into a socket side and a tube side thereby absorbing pressure pulsations and injector residual actions by its flexibility. However, in order to arrange the flexible diaphragm within the longitudinal direction of the conduit, seal members and complex constructions become necessary, so that overall configurations are relatively restricted. As the results, there are defects that it cannot be applied to miscellaneous specifications of many types of engines.
Japanese unexamined patent publication No. Sho 60-240867 entitled “a fuel supply conduit for a fuel injector of an internal combustion engine” discloses a construction that at least one wall of a fuel supply conduit is comprised of a flexible wall so as to dampen fuel pressure pulsations, and the flexible wall is fixed to a rigid wall. However, since the flexible wall is fixed to the rigid wall, its flexibility is not sufficient for obtaining preferable dampening results.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a fuel delivery rail assembly which can reduce the pressure fluctuations within the fuel passages caused by fuel injections, and also to reduce the vibrations caused by fuel reflecting waves (shock waves), to thereby eliminate emission of uncomfortable noise and miscellaneous defects.
A conventional type of fuel delivery rail assembly comprises an elongate conduit having a longitudinal fuel passage therein, a fuel inlet pipe fixed to an end or a side of the conduit, and a plurality of sockets vertically fixed to the conduit adapted to communicate with the fuel passage and so formed as to receive tips of fuel injectors at their open ends.
According to the characteristics of the invention, outer walls of the fuel conduit include at least one flat or arcuate (arched) flexible first absorbing surface. The first absorbing surface is smoothly and integrally connected to an arcuate second absorbing surface. The first absorbing surface or the second absorbing surface faces fuel inlet ports of sockets, which are adapted to receive tips of fuel injectors. Thus, fuel pressure pulsations and shock waves are reduced by abrupt enlargements (spatial expansions) of fuel passages and bendings of the absorbing surfaces.
Several embodiments of the invention are exemplified as follows:
(A) Each section of the conduit is formed in a flat configuration comprised of flat portions and arcuate portions.
(B) Each section of the conduit is formed in a telephone receiver configuration.
(C) Each section of the conduit is formed in a character “T” configuration.
(D) Each section of the conduit is formed in a corrugation.
(E) Each section of the conduit is formed in a dumbbell configuration.
(F) Each section of the conduit is formed in a reverse eye mask configuration.
(G) The second absorbing surface is an arcuate flexible end cap fixed to a longitudinal end of the conduit.
As the results of the above constructions of the invention, in a fuel delivery rail assembly having a fuel conduit made by steel, stainless steel or press materials, it has been found that it becomes possible to eliminate the emission of uncomfortable noise due to the vibration and pressure pulsations which are caused by the reflecting waves of injections and lack of dampening performance of the conduit.
In a theoretical principle, when shock waves produced by the fuel injections flow into the fuel inlet of the sockets or flow away therefrom by momentary back streams, flexible absorbing surfaces absorb the shock and pressure pulsations. In addition, when thin plates having small spring constant are deflected and deformed, the space of contents varies, namely expands or shrinks, thereby absorbing pressure fluctuations.
In a preferred embodiment, an inner end of the fuel inlet pipe terminates and opens near the center of the longitudinal conduit. This position is adapted to obtain maximum deflections of the conduit, whereby deflections of the absorbing surfaces are increased so as to enhance shock absorbing performance. However, the position is preferably offset from the center of the socket in order to avoid direct transmission of fuel pressure pulsations.
In this invention, thickness of each wall of the conduit, ratio of the horizontal size to the vertical size, and the range of clearance between the fuel inlet of the socket and its confronting surface are preferably defined by experiments or calculations such that, especially during idling of the engine, the vibrations and pressure pulsations are minimized.
Since the present invention is directed essentially to the sectional construction of the conduit and connecting construction of the conduit and the sockets, interchangeability with the prior fuel delivery rails are maintained as far as the mounting dimensions are kept constant.
Other features and advantages of the invention will become apparent from descriptions of the embodiments, when taken in conjunction with the drawings, in which, like reference numerals refer to like elements in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a frontal view of the fuel delivery rail assembly according to the invention.
FIG. 2 is a side view of the assembly of FIG. 1 and vertical sectional view along the socket.
FIG. 3 is a frontal view of the fuel delivery rail according to another embodiment.
FIG. 4 is a side view of the assembly of FIG. 3 and vertical sectional view along the socket.
FIG. 5 is a vertical sectional view illustrating several embodiments of the connection between the socket and rail sections.
FIG. 6 is a frontal view of the fuel delivery rail assembly according to another embodiment.
FIG. 7 is a vertical sectional view of the assembly of FIG. 6 along the socket.
FIG. 8 is a frontal view of the fuel delivery rail assembly according to another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a preferable embodiment of the present invention, a fuel delivery rail assembly 1 of the so called “top feed type”, adapted to three cylinders on one side of an automotive V-6 engine. The fuel conduit (rail) 11 comprised of flat steel pipes extends along a longitudinal direction of a crank shaft (not shown) of an engine. At the side of the conduit 11 , a fuel inlet pipe 2 is fixed with an intermediate connector 5 by brazing or welding. Although at an end of the conduit 11 it is possible to provide a fuel return pipe for transferring residual fuel back to a fuel tank, the present invention is directed to non-return type having fuel pressure pulsation problems, so that the fuel return pipe is not provided.
At the bottom side of the conduit 11 , three sockets 3 for receiving tips of fuel injectors are located corresponding to the number of cylinders at predetermined angles and distances from each other. To the conduit 11 , two thick and rigid brackets 4 are fixed transversely so as to mount the assembly 1 onto the engine body. Fuel flows along the arrows thereby being discharged from the socket 3 and fuel injectors (not shown) into an air intake passage or cylinders of the engine.
FIGS. 2A and 2B illustrate the side view of the assembly 1 of FIG. 1 and vertical section of the socket 3 . Outer walls of the conduit 11 comprise a flat upper plate 12 a , right and left arcuate side plates 12 b , 12 c which are smoothly and integrally connected to the upper plate 12 a , and a flat bottom plate 12 d which is brazed or welded to the side plates 12 b , 12 c . The lower surface of the flat plate 12 a faces a fuel inlet port 13 of the socket 3 . As the characteristics of the invention, the flat plate 12 a provides a flexible first absorbing surface and the right and left arcuate side plates 12 b , 12 c provide flexible second absorbing surfaces.
The vertical and horizontal dimensions of the conduit 11 can be defined such that each wall thickness is 1.5 mm, the height H is 5 mm, and the width W is 46 mm. The spring constant of the flat construction 11 is about 40 kgf/cm square/mm. The clearance S between the fuel inlet port 13 and the lower surface of the flat plate 12 a is less than 2 mm. As the results of continuous experiments, in which the dimensions are varied, it becomes apparent that the ratio of horizontal dimension relative to the vertical dimension is preferably 5 to 10, and that the clearance S is preferably between 0.5 to 3 mm. If the ratio is less than 5, the spring constant becomes larger and its flexibility is reduced, whereby absorbing performance of pressure pulsations becomes defective. If the ratio exceeds 10, a larger space becomes necessary for accommodating the fuel delivery rail assembly. If the clearance S is less than 0.5 mm, starting performance of the engine and accelerating performance become defective. If the clearance S is more than 3 mm, flexible performance becomes weak for deflecting the flat plate.
In addition, if the length L 1 , L 2 from the center of the outer sockets 3 to each free end of the conduit 11 is larger than 30 mm, the deflections of the flat plates relative to the corresponding sockets 3 caused by the reflecting waves of the injection are smoothly enlarged thereby enhancing the shock absorbing performance.
According to the embodiment of FIGS. 1, 2 A and 2 B, when shock waves flow into the fuel inlet port 13 of the sockets or flow away therefrom by momentary back streams, the pressure pulsations are absorbed at the moment of release into the horizontal enlarged space. In addition, when thin absorbing surfaces 12 a , 12 b , 12 c are deflected and deformed, the space of contents varies thereby absorbing pressure fluctuations.
FIG. 3 illustrates a fuel delivery rail assembly 20 according to another embodiment of the invention. FIGS. 4A and 4B show a side view of the assembly 20 of FIG. 3 and vertical sectional view along the socket. A fuel conduit 21 is made in a flatly compressed arcuate section through the process in which a circular sectional stainless pipe is compressed vertically. The lower surface of an arcuate plate 22 a faces the fuel inlet port 13 of the socket 3 . At the end of the conduit 11 , a fuel inlet pipe 2 is fixed with an intermediate connector 24 by brazing or welding.
As the characteristics of the invention, the flat portion 22 a provides a flexible first absorbing surface and right and left arcuate side portions 22 b , 22 c , which are smoothly and integrally connected to the flat surface 22 a , provide flexible second absorbing surfaces. Further, a bottom portion 22 d also provides a flexible third absorbing surface. In this embodiment, the flat portion 22 a faces the fuel inlet port 13 of the sockets 3 .
The vertical and horizontal dimensions of the conduit 21 can be defined such that each wall thickness is 1.2 mm, the height H is 6.4 mm, and the width W is 32 mm. The spring constant of the flat construction 21 is about 65 kgf/cm square/mm. The clearance S between the fuel inlet port 13 and the lower surface of the flat plate 22 a is less than 3 mm. As the results of continuous experiments, in which the dimensions are varied, it becomes apparent that the ratio of horizontal dimension relative to the vertical dimension is preferably 5 to 10, and that the clearance S is preferably between 0.5 to 3 mm.
In addition, if the length L from the center of the left socket 3 to the free end of the conduit 21 is larger than 30 mm, the deflections of the flat portions relative to the corresponding socket caused by the reflecting waves of the injection are smoothly enlarged thereby enhancing the shock absorbing performance.
According to the embodiment of FIGS. 3, 4 A and 4 B, when shock waves flow into the fuel inlet port 13 of the sockets or flow away therefrom by momentary back streams, the pressure pulsations are absorbed at the moment of release into the horizontal enlarged space. In addition, when thin absorbing surfaces 22 a , 22 b , 22 c , 22 d are deflected and deformed, the space of contents would vary and thereby absorb pressure fluctuations.
FIGS. 5A-D illustrate several embodiments of sectional constructions between the rail sections and the socket. FIG. 5A shows a third embodiment of the invention, in which the vertical section of a conduit 31 is formed in a telephone receiver configuration which includes a thin flat portion 32 a and downwardly convex portions 32 b , 32 c connected to both sides of the flat portion 32 a . The flat portion 32 a provides a flexible first absorbing surface and the right and left downwardly convex portions 32 b , 32 c , which are smoothly and integrally connected to the flat portion 32 a , provide flexible second absorbing surfaces. In this embodiment, the flat portion 32 a faces the fuel inlet port 13 of the socket 3 .
FIG. 5B shows a fourth embodiment of the invention, in which the section of a conduit 41 is formed in a character “T” which includes thin flat portions 42 a , 42 b , 42 c , 42 d and arcuate portions 43 a , 43 b , 43 c connected to the sides of the flat portions. The flat portion 42 a provides a flexible first absorbing surface and the arcuate portion 43 a , which is smoothly and integrally connected to the flat portion 42 a , provides a flexible second absorbing surface, and other portions also provide flexible third or further absorbing surfaces. In this embodiment, the flat portion 42 a faces the fuel inlet port 13 of the socket 3 .
FIG. 5C shows a fifth embodiment of the invention, in which the section of the conduit 51 is roughly formed in a corrugation. That is, a thin convex arcuate portion 52 a is formed in a corrugation, and is smoothly and integrally connected to right and left arcuate portions 52 b , 52 c . The arcuate portion 52 a provides a flexible first absorbing surface and the arcuate portions 52 b , 52 c provide flexible second absorbing surfaces. The first absorbing surface 52 a faces the fuel inlet port 13 of the socket 3 .
FIG. 5D shows a sixth embodiment of the invention, in which the section of a conduit 61 is formed in a dumbbell configuration. That is, a thin flat neck portion 62 a of the conduit 61 is connected smoothly and integrally to a right and left semi-circular portions 62 b , 62 c thereby providing a dumbbell configuration. The flat portion 62 a provides a flexible first absorbing surface and the semi-circular portions 62 b , 62 c provide flexible second absorbing surfaces. The first absorbing surface 62 a faces the fuel inlet port 13 of the socket 3 .
According to the embodiments of FIGS. 5A to 5 D, when shock waves flow into the fuel inlet port 13 of the sockets or flow away therefrom by momentary back streams, the pressure pulsations are absorbed at the moment of release into the horizontal enlarged space. In addition, when thin absorbing surfaces 62 a , 62 b , 62 c are deflected and deformed, the space of contents varies thereby absorbing pressure fluctuations.
FIG. 6 illustrates a fuel delivery rail assembly 70 according to another embodiment of the invention. FIG. 7 shows a vertical section of the assembly 70 of FIG. 6 along the socket. In this embodiment, the section of the a 71 is formed in a reverse eye mask configuration. That is, a central arcuate neck portion 72 a is connected smoothly and integrally to a right and left arcuate portions 72 b , 72 c thereby providing a reverse eye mask configuration. The arcuate portion 72 a provides a flexible first absorbing surface and the arcuate portions 72 b , 72 c provide flexible second absorbing surfaces. The first absorbing surface 72 a faces the fuel inlet port 13 of the socket 3 . To the lateral side of the conduit 71 , a fuel inlet pipe 74 is fixed by brazing or welding.
According to the embodiment of FIGS. 6 and 7, when the shock waves flow into the fuel inlet port 13 of the sockets or flow away therefrom by momentary back streams, the pressure pulsations are absorbed at the moment of release into the horizontal enlarged space. In addition, when the thin absorbing surfaces 72 a , 72 b , 72 c are deflected and deformed, the space of contents varies thereby absorbing pressure fluctuations.
As another characteristic of the invention, an inner end 74 a of the fuel inlet pipe 74 terminates and opens near the center of the longitudinal conduit 71 , and the fuel discharge position 74 a is distant from the center of the socket 3 by a dimension of more than half the width of the conduit 71 . This arrangement intends to locate the fuel discharge at a maximum deflecting position of the conduit 71 to thereby enhance the pulsation absorbing performance. However, if the fuel discharge position 74 a is located too close to the fuel inlet port 13 of the socket 3 , the pressure pulsations will be directly transmitted into the socket 3 without being reduced. The vertical and horizontal dimensions of the conduit 71 can be defined such that each wall thickness is 1.2 mm, the height is 13 mm, and the width is 30 mm.
In addition, if the length L from the center of the left socket 3 to the free end of the conduit 71 is larger than 30 mm, the deflections of the conduit 71 relative to the socket 3 caused by the reflecting waves of the injection are smoothly enlarged thereby enhancing the shock absorbing performance.
FIG. 8 illustrates a fuel delivery rail assembly 80 according to another embodiment of the invention. In this embodiment, the section of a conduit 81 is formed in a rectangular or circular configuration, which includes an upper surface 82 a of flexible thin plate, and a rigid bottom plate 82 b . At the longitudinal end of the conduit 81 , a flexible cap member 85 is connected smoothly and integrally to the thin plate 82 a . The thin plate 82 a provides a flexible first absorbing surface and the cap member 85 provides a flexible second absorbing surface. The first absorbing surface 82 a faces the fuel inlet port 13 of the socket 3 . To the distal end of the conduit 81 , a fuel inlet pipe 84 is fixed by brazing or welding, and its inner end 84 a extends through the conduit 81 .
According to the embodiment of FIG. 8, when the shock waves flow into the fuel inlet port 13 of the sockets or flow away therefrom by momentary back streams, the pressure pulsations are absorbed at the moment of release into the horizontal enlarged space. In addition, when the thin absorbing surface 82 a is deflected and deformed, the space of contents varies thereby absorbing pressure fluctuations.
As another characteristic of the invention, the inner end 84 a of the fuel inlet pipe 84 terminates and opens near the center of the longitudinal conduit 81 , and the fuel discharge position 84 a is distant from the center of the socket 3 by a dimension of more than half the width of the conduit 81 . This arrangement intends to locate the fuel discharge at a maximum deflecting position of the conduit 81 to thereby enhance the pulsation absorbing performance.
The cap member 85 is made from plate materials such as SPCC, SPHC, SUS through plastic working such as restriction working. The radius of curvature of the cap 85 is preferably more than 3 mm, from the view points of elasticity and strength. The vertical and horizontal dimensions of the conduit 81 can be defined such that thin plate thickness is 1.2 mm, the height is 25 mm, and the width is 20 mm. | A fuel delivery rail assembly for supplying fuel to a plurality of fuel injectors in an engine is provided. The assembly comprises an elongate conduit having a longitudinal fuel passage therein, a fuel inlet pipe, and a plurality of sockets. Outer walls of the conduit include at least one flat or arcuate flexible first absorbing surface, which is smoothly and integrally connected to an arcuate second absorbing surface. The first absorbing surface or the second absorbing surface faces fuel inlet ports of the sockets. The sectional configuration of the conduit can be flat, a telephone receiver shape, a character “T” shape, a corrugation shape, a dumbbell shape or a reverse eye mask shape. Thus, fuel pressure pulsations and shock waves are reduced by abrupt enlargements of fuel passages and bendings of the absorbing surfaces. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/868,892, filed Aug. 22, 2013, which application is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to a bearing assembly including a retaining ring disposed in respective grooves in a housing and an outer race for the bearing assembly and arranged to fix a position of the outer race with respect to the housing. The coefficient of thermal expansion of the retaining ring is at least equal to the coefficient of thermal expansion of the housing to ensure that the retaining ring remains in the groove in the housing when the bearing assembly is subjected to elevated temperatures.
BACKGROUND
[0003] Bearing assemblies, for example for internal combustion engines, are known to include a housing made of a first material and an outer race radially enclosed by the housing and made of a second material. For proper functioning of the bearing assembly, the outer race must be axially fixed with respect to the housing. Typically, the first material, such as aluminum or aluminum alloy, has a first coefficient of thermal expansion and the second material, such as steel, has a second coefficient of thermal expansion less than the first coefficient of thermal expansion. As a result, when the bearing assembly is subjected to elevated temperatures (for example, the internal combustion engine is operating), the housing expands radially outward more than the outer race, breaking contact between the housing and the outer race, which prevents axial fixing of the outer race with respect to the housing.
[0004] It is known to install the outer race in the housing with a tight interference or press fit that results in high compressive force between the outer race and housing. However, this tight fit increases the difficulty of installing the bearing assembly and causes distortion that interferes with operation of the bearing assembly. U.S. Patent Application Publication No. 2012/0304813 discloses the use of retaining clips that add a great deal of complexity to the bearing assembly as well as increasing the cost and dimensions of the bearing assembly. U.S. Patent Application Publication No. 2009/0080824 discloses a thermal compensating element that is in direct contact with a housing and the roller elements of the bearing assembly. The thermal compensating element compensates for thermal expansion by applying pressure directly to the roller elements, which can interfere with operation of the roller elements. U.S. Patent Application Publication No. 2006/0160651 discloses the use of a shim engaged with an axial surface of a bearing race to accommodate thermal expansion in a differential gear by axially expanding to compress the bearing race. U.S. Pat. No. 8,286,533 discloses the use of retaining clips that add a great deal of complexity to the bearing assembly as well as increasing the cost and dimensions of the bearing assembly. U.S. Pat. No. 4,549,823 discloses the use of an elastomeric ring between a housing and an outer race of a bearing assembly.
SUMMARY
[0005] According to aspects illustrated herein, there is provided a bearing assembly, including: a housing with a first circumferentially disposed groove; a bearing including an outer race with a second circumferentially disposed groove; and a retaining ring disposed within the first and second circumferentially disposed grooves.
[0006] According to aspects illustrated herein, there is provided a method of retaining a bearing, including: locating a first portion of an annular retaining ring within a first circumferentially disposed groove for an outer race of the bearing; installing a housing radially about the outer race such that the housing contacts the outer race; locating a second portion of the retaining ring within a second circumferentially disposed groove for the housing; bringing respective temperatures of the housing and the outer race to a first level; fixing, with contact between the outer race and the housing, axial and radial positions of the outer race with respect to the housing; increasing the respective temperatures of the housing and the outer race to a second level, higher than the first level; creating a radial gap between the housing and the outer race; and fixing, with the retaining ring, the axial and radial positions of the outer race with respect to the housing.
[0007] According to aspects illustrated herein, there is provided a bearing assembly, including: a bearing including an annular outer race constructed of a first material with a first coefficient of thermal expansion and including a radially outer circumferential surface and a first circumferentially disposed groove in the radially outer circumferential surface; an annular housing radially disposed about the bearing, constructed of a second material having a second coefficient of thermal expansion greater than the first coefficient of thermal expansion, and including a radially inner circumferential surface and a second circumferentially disposed groove in the radially inner circumferential surface; and an annular retaining ring including a first portion disposed within the first circumferentially disposed groove and a second portion disposed within the second circumferentially disposed groove.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:
[0009] FIG. 1A is a perspective view of a cylindrical coordinate system demonstrating spatial terminology used in the present application;
[0010] FIG. 1B is a perspective view of an object in the cylindrical coordinate system of FIG. 1A demonstrating spatial terminology used in the present application;
[0011] FIG. 2 is a partial cross-sectional view of a bearing assembly with a retaining ring;
[0012] FIG. 3 is a perspective view of area 3 in FIG. 2 ;
[0013] FIG. 4A is a detail showing the housing and outer race of FIG. 2 at a low temperature;
[0014] FIG. 4B is a showing the housing and outer race of FIG. 2 at a high temperature;
[0015] FIG. 5 is a schematic front view of a bearing assembly with a retaining ring showing a two-part housing; and,
[0016] FIG. 6 is a partial cross-sectional view of a bearing assembly with a retaining ring.
DETAILED DESCRIPTION
[0017] At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the disclosure. It is to be understood that the disclosure as claimed is not limited to the disclosed aspects.
[0018] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present disclosure.
[0019] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure.
[0020] FIG. 1A is a perspective view of cylindrical coordinate system 80 demonstrating spatial terminology used in the present disclosure. The present disclosure is at least partially described within the context of a cylindrical coordinate system. System 80 has a longitudinal axis 81 , used as the reference for the directional and spatial terms that follow. The adjectives “axial,” “radial,” and “circumferential” are with respect to an orientation parallel to axis 81 , radius 82 (which is orthogonal to axis 81 ), and circumference 83 , respectively. The adjectives “axial,” “radial” and “circumferential” also are regarding orientation parallel to respective planes. To clarify the disposition of the various planes, objects 84 , 85 , and 86 are used. Surface 87 of object 84 forms an axial plane. That is, axis 81 forms a line along the surface. Surface 88 of object 85 forms a radial plane. That is, radius 82 forms a line along the surface. Surface 89 of object 86 forms a circumferential plane. That is, circumference 83 forms a line along the surface. As a further example, axial movement or disposition is parallel to axis 81 , radial movement or disposition is parallel to radius 82 , and circumferential movement or disposition is parallel to circumference 83 . Rotation is with respect to axis 81 .
[0021] The adverbs “axially,” “radially,” and “circumferentially” are with respect to an orientation parallel to axis 81 , radius 82 , or circumference 83 , respectively. The adverbs “axially,” “radially,” and “circumferentially” also are regarding orientation parallel to respective planes.
[0022] FIG. 1B is a perspective view of object 90 in cylindrical coordinate system 80 of FIG. 1A demonstrating spatial terminology used in the present disclosure. Cylindrical object 90 is representative of a cylindrical object in a cylindrical coordinate system and is not intended to limit the present disclosure in any manner. Object 90 includes axial surface 91 , radial surface 92 , and circumferential surface 93 . Surface 91 is part of an axial plane, surface 92 is part of a radial plane, and surface 93 is a circumferential surface.
[0023] FIG. 2 is a partial cross-sectional view of bearing assembly 100 with a retaining ring.
[0024] FIG. 3 is a perspective view of area 3 in FIG. 2 . The following should be viewed in light of FIGS. 2 and 3 . Assembly 100 includes axis of rotation AR, annular housing 102 , annular outer race 104 , and annular retaining ring 106 . Housing 102 includes radially inner circumferential surface 108 with circumferentially disposed groove 110 . That is, groove 110 intersects surface 108 . Race 104 includes radially outer circumferential surface 112 with circumferentially disposed groove 114 . That is, groove 114 intersects surface 112 . Ring 106 is disposed in grooves 110 and 112 . For example, radially outermost portion 106 A of ring 106 is disposed in groove 110 and radially innermost portion 106 B of ring 106 is disposed in groove 114 . Housing 102 is radially disposed about race 104 . As further described below, the retaining ring axially and/or radially restrains the outer race with respect to the housing. By “circumferentially disposed” we mean that the respective groove extends continuously about the housing or race in the circumferential direction defined above and has a depth in the radial direction as defined above and a width in the axial direction as defined above. In an example embodiment, one or both of grooves 110 and 114 extend 360 degrees in the circumferential direction. In an example embodiment, one or both of grooves 110 and 114 extend less than 360 degrees in the circumferential direction. For example, circumferential ends of groove 110 are separated by a portion of surface 108 .
[0025] In an example embodiment, housing 102 is constructed of a material, for example, aluminum or an aluminum alloy, with a particular coefficient of thermal expansion, and retaining ring 106 is constructed of a another material with a coefficient of thermal expansion equal to or greater than the coefficient of thermal expansion for housing 102 . In an example embodiment, housing 102 and ring 106 are constructed of the same material. In an example embodiment, race 104 is constructed of a material, for example, steel, having a coefficient of thermal expansion less than either of the respective coefficients of thermal expansion for the housing and the ring.
[0026] FIG. 4A is a detail showing the housing and outer race of FIG. 2 at a low temperature. The following should be viewed in light of FIGS. 2 through 4A . When housing 102 and outer race 104 are each substantially at a relatively low temperature, outer race 104 is axially and radially fixed, with respect to housing 102 , by contact between housing 102 and outer race 104 . For example, there is a compressive or frictional engagement between surfaces 108 and 112 which fixes the position of race 104 with respect to housing 102 . Thus, as shown in FIG. 4A , there is no radial gap between surfaces 108 and 112 . For example, when assembly 100 is used in an internal combustion engine, the low temperature can be considered a non-operating temperature for the engine, for example, the engine is not operating and is at ambient temperature, or the engine has begun operation, but has not yet heated up. The non-operating temperature also can be defined as a temperature at which thermal expansion of housing 102 and outer race 104 has not occurred or at which the respective thermal expansions of housing 102 and outer race 104 are substantially equal.
[0027] FIG. 4B is a detail showing the housing and outer race of FIG. 2 at a high temperature. The following should be viewed in light of FIGS. 2 through 4B . When housing 102 and outer race 104 are each substantially at a relatively high temperature, radial gap 116 is created between housing 102 and outer race 104 (between surfaces 108 and 112 ), and outer race 104 is axially and radially fixed, with respect to the housing 102 , by outer race 104 . For example, when assembly 100 is used in an internal combustion engine, the high temperature can be considered an operating temperature for the engine, for example, the engine is operating and the internal combustion process has raised the temperature of housing 102 and outer race 104 well above ambient temperature. The operating temperature also can be defined as a temperature at which thermal expansion of housing 102 has occurred or is occurring at a greater rate than the thermal expansion of outer race 104 .
[0028] As a result of the increase in temperature and differences between the respective coefficients of expansion for housing 102 and outer race 104 (coefficient is higher for housing 102 ), housing 102 expands at a greater rate than outer race 104 , creating gap 116 . Due to gap 116 , the compressive or frictional engagement of housing 102 and outer race 104 mentioned above is substantially nullified. Therefore, the engagement of housing 102 and outer race 104 is no longer sufficient to restrain outer race 104 with respect to housing 102 (fix axial and radial positions of outer race 104 with respect to housing 102 ). However, retaining ring 106 remains in contact with housing 102 and outer race 104 (disposed in grooves 108 and 112 ), to restrain outer race 104 with respect to housing 102 .
[0029] For example, as housing 102 expands to create gap 116 , portions 106 A and 106 B of remain in grooves 110 and 114 , respectively. Further, since the coefficient of thermal expansion for ring 106 is greater than the coefficient of thermal expansion for race 104 , portion 106 A expands within groove 114 to increase contact pressure (compressive or frictional) in axial and/or radial directions between portion 106 B and race 104 , which more firmly fixes ring 106 with respect to race 104 . Also, ring 106 expands radially outward, ensuring that portion 106 A remains disposed in groove 110 . In an example embodiment in which the coefficient of thermal expansion for ring 106 is greater than the coefficient of thermal expansion for housing 102 , portion 106 A expands within groove 110 , increasing contact pressure between portion 106 B and housing 102 in axial and/or radial directions. This increase in contact pressure further facilitates the fixing of ring 106 with respect to housing 102 and therefore, the fixing of race 104 with respect to housing 102 .
[0030] FIG. 5 is a schematic front view of bearing assembly 100 with a retaining ring showing a two-part housing. The following should be viewed in light of FIGS. 2 , 3 , and 5 . In an example embodiment, housing 102 includes separate portions 102 A and 102 B fixedly connected to each other by any means known in the art. Portions 102 A and 102 B facilitate fabrication of assembly 100 . For example, ring 106 can be fabricated with a discontinuity to enable ring 106 to be radially expanded to pass over race 104 to slide into groove 114 . Portions 102 A and 102 B can then be placed together such that groove 110 encloses ring 106 .
[0031] FIG. 6 is a partial cross-sectional view of bearing assembly 100 with a retaining ring. In FIG. 6 , assembly 100 is shown in an example configuration with inner race 118 , cage 120 , and roller element 122 . It should be understood that assembly 100 is not limited to use with the configuration of FIG. 6 .
[0032] It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | A bearing assembly, including a housing with a first circumferentially disposed groove; a bearing including an outer race with a second circumferentially disposed groove; and a retaining ring disposed within the first and second circumferentially disposed grooves. A method of retaining a bearing, including: locating a first portion of a ring within a groove in an outer race; installing a housing radially about the race to contact the race; locating a second portion of the ring within a groove in the housing; bringing temperature of the housing and the race to a first level; fixing, with contact between the race and the housing, the race with respect to the housing; increasing the temperature of the housing and race to a second higher level; creating a radial gap between the housing and the outer race; and fixing, with the retaining ring, a position of the race with respect to the housing. | 5 |
REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/148,623 filed on Sep. 4, 1998 now abandoned, which is based on provisional patent application No. 60/057,632 filed on Sep. 5, 1997, both of which are relied on and incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to deuterated derivatives of rapamycin and a method for using them in the treatment of transplantation rejection, host vs. graft disease, graft vs. host disease, leukemia/lymphoma, hyperproliferative vascular disorders, autoimmune diseases, diseases of inflammation, solid tumors, and fungal infections.
Rapamycin, known as sirolimusis, is a 31-membered macrolide lactone, C 51 H 79 NO 13 , with a molecular mass of 913.6 Da. In solution, sirolimus forms two conformational trans-, cis-isomers with a ratio of 4:1 (chloroform) due to hindered rotation around the pipecolic acid amide bond. It is sparingly soluble in water, aliphatic hydrocarbons and diethyl ether, whereas it is soluble in alcohols, halogenated hydrocarbons and dimethyl sulfoxide. Rapamycin is unstable in solution and degrades in plasma and low- , and neuteral −pH buffers at 37° C. with half-life of <10 h. the structures of the degradation products have recently been characterized. Rapamycin is a macrocyclic triene antibiotic produced by Streptomyces hygroscopicus, which was found to have antifungal activity, particularly against Candida albicans, both in vitro and in vivo [C. Vezina et al., J. Antibiot. 28, 721 (1975); S. N. Sehgal et al., J. Antibiot. 28, 727 (1975); H. A. Baker et al., J. Antibiot. 31, 539 (1978); U.S. Pat. Nos. 3,929,992; and 3,993,749].
Rapamycin alone (U.S. Pat. No. 4,885,171) or in combination with picibanil (U.S. Pat. No. 4,401,653) has been shown to have antitumor activity. R. Martel et al. [Can. J. Physiol. Pharmacol. 55, 48 (1977)] disclosed that rapamycin is effective in the experimental allergic encephalomyelitis model, a model for multiple sclerosis; in the adjuvant arthritis model, a model for rheumatoid arthritis; and effectively inhibited the formation of IgE-like antibodies.
The immunosuppressive effects of rapamycin have been disclosed in FASEB 3, 3411 (1989). Cyclosporin A and FK-506, other macrocyclic molecules, also have been shown to be effective as immunosuppressive agents, therefore useful in preventing transplant rejection [FASEB 3, 3411 (1989); FASEB 3, 5256 (1989); and R. Y. Calne et al., Lancet 1183 (1978)]. Although it shares structural homology with the immunosuppressant tacrolimus and binds to the same intracellular binding protein in lymphocytes, rapamycin inhibits S6p70-kinase and therefore has a mechanism of immunosuppressive action distinct from that of tacrolimus. Rapamycin was found to prolong graft survival of different transplants in several species alone or in combination with other immunosupressants. In animal models its spectrum of toxic effects is different from that of cyclosporin or FK-506., comprising impairment of glucose homeostasis, stomach, ulceration, weight loss and thrombocytopenia, although no nephrotoxicity has been detected.
Mono- and diacylated derivatives of rapamycin (esterified at the 28 and 43 positions) have been shown to be useful as antifungal agents (U.S. Pat. No. 4,316,885) and used to make water soluble prodrugs of rapamycin (U.S. Pat. No. 4,650,803). Recently, the numbering convention for rapamycin has been changed; therefore according to Chemical Abstracts nomenclature, the esters described above would be at the 31- and 42-positions. Carboxylic acid esters (PCT application No. WO 92/05179), carbamates (U.S. Pat. No. 5,118,678), amide esters (U.S. Pat. No. 5,118,678), (U.S. Pat. No. 5,118,678) fluorinated esters (U.S. Pat. No. 5,100,883), acetals (U.S. Pat. No. 5,151,413), silyl ethers (U.S. Pat. No. 5,120,842), bicyclic derivatives (U.S. Pat. No. 5,120,725), rapamycin dimers (U.S. Pat. No. 5,120,727) and O-aryl, O-alkyl, O-alkyenyl and O-alkynyl derivatives (U.S. Pat. No. 5,258,389) have been described.
Rapamycin is metabolized by cytochrome P-450 3A to at least six metabolites. During incubation with human liver and small intestinal microsomes, sirolimus was hydroxylated and demethylated and the structure of 39-O-demethyl sirolimus was identified. In bile of sirolimus-treated rats >16 hydroxylated and demethylated metabolites were detected.
In rapamycin, demethylation of methoxy group at C-7 Carbon will lead to the change in the conformation of the Rapamycin due to the interaction of the released C-7 hydroxyl group with the neighbouring pyran ring system which is in equilibrium with the open form of the ring system. The C-7 hydroxyl group will also interact with the triene system and possibly alter the immunosupressive activity of rapamycin. This accounts for the degradation of rapamycin molecule and its altered activity.
Stable isotopes (e.g., deuterium, 13 C, 15 N, 18 O) are nonradioactive isotopes which contain one additional neutron than the normally abundant isotope of the atom in question. Deuterated compounds have been used in pharmaceutical research to investigate the in vivo metabolic fate of the compounds by evaluation of the mechanism of action and metabolic pathway of the non deuterated parent compound. (Blake et al. J. Pharm. Sci. 64, 3, 367-391,1975). Such metabolic studies are important in the design of safe, effective therapeutic drugs, either because the in vivo active compound administered to the patient or because the metabolites produced from the parent compound prove to be toxic or carcinogenic (Foster et al., Advances in drug Research Vol. 14, pp. 2-36, Academic press, London, 1985).
Incorporation of a heavy atom particularly substitution of deuterium for hydrogen, can give rise to an isotope effect that can alter the pharmacokinetics of the drug. This effect is usually insignificant if the label is placed in a molecule at the metabolically inert position of the molecule.
Stable isotope labeling of a drug can alter its physicochemical properties such as pKa and lipid solubility. These changes may influence the fate of the drug at different steps along its passage through the body. Absorption, distribution, metabolism or excretion can be changed. Absorption and distribution are processes that depend primarily on the molecular size and the lipophilicity of the substance.
Drug metabolism can give rise to large isotopic effect if the breaking of a chemical bond to a deuterium atom is the rate limiting step in the process. While some of the physical properties of a stable isotope-labeled molecule are different from those of the unlabeled one, the chemical and biological properties are the same, with one important exception: because of the increased mass of the heavy isotope, any bond involving the heavy isotope and another atom will be stronger than the same bond between the light isotope and that atom. In any reaction in which the breaking of this bond is the rate limiting step, the reaction will proceed slower for the molecule with the heavy isotope due to kinetic isotope effect. A reaction involving breaking a C—D bond can be up to 700 percent slower than a similar reaction involving breaking a C—H bond.
More caution has to be observed when using deuterium labeled drugs. If the C—D bond is not involved in any of the steps leading to the metabolite , there may not be any effect to alter the behavior of the drug. If a deuterium is placed at a site involved in the metabolism of a drug , an isotope effect will be observed only if breaking of the C—D bond is the rate limiting step. There are evidences to suggest that whenever cleavage of an aliphatic C—H bond occurs, usually by oxidation catalyzed by a mixed-function oxidase, replacement of the hydrogen by deuterium will lead to observable isotope effect. It is also important to understand that the incorporation of deuterium at the site of metabolism slows its rate to the point where another metabolite produced by attack at a carbon atom not substituted by deuterium becomes the major pathway by a process called “metabolic switching”.
It is also observed that one of the most important metabolic pathways of compounds containing aromatic systems is hydroxylation leading to a phenolic group in the 3 or 4 position to carbon substituents. Although this pathway involves cleavage of the C—H bond, it is often not accompanied by an isotope effect, because the cleavage of this bond is mostly not involved in the rate-limiting step. The substitution of hydrogen by deuterium at the stereo center will induce a greater effect on the activity of the drug.
Clinically relevant questions include the toxicity of the drug and its metabolite derivatives, the changes in distribution or elimination (enzyme induction), lipophilicity which will have an effect on absorption of the drug. Replacement of hydrogen by deuterium at the site involving the metabolic reaction will lead to increased toxicity of the drug. Replacement of hydrogen by deuterium at the aliphatic carbons will have an isotopic effect to a larger extent. Deuterium placed at an aromatic carbon atom, which will be the site of hydroxylation, may lead to an observable isotope effect, although this is less often the case than with aliphatic carbons. But in few cases such as in penicillin, the substitution on the aromatic ring will induce the restriction of rotation of the ring around the C—C bond leading to a favorable stereo-specific situation to enhance the activity of the drug.
Approaching half a century of stable-isotope usage in human metabolic studies has been without documented significant adverse effect. Side-effects with acute D dosing are transitory with no demonstrated evidence of permanent deleterious action. The threshold of D toxicity has been defined in animals and is far in excess of concentrations conceivably used in human studies (Jones P J, Leatherdale S T Clin Sci (Colch) 1991 Apr;80(4):277-280). The possibility that D may have additional beneficial pharmacological applications cannot be excluded. For isotopes other than D, evidence of observed toxicity remains to be produced even at dosages far in excess of the range used in metabolic studies. Absence of adverse effect may be attributable to small mass differences and the similar properties of tracer and predominantly abundant isotopes. The precision of extrapolating toxicity thresholds from animal studies remains unknown. However, should perturbation of the delicate homoeostatic characteristic of living organisms occur with use of stable isotopes, it is almost undoubtedly at some level of administration greatly in excess of those administered currently in biomedical research.
In the prior art, no details are described regarding deuterated derivatives to improve the stability of rapamycin molecule and also about glycosylated deuterated rapamycin to improve the stability and also the solubility of the molecule in order to increase the bio-availability of the drug. We therefore defined the global objective of preparing a rapamycin derivative which is more stable, less prone to degradation, and more water soluble to improve the bioavailability.
SUMMARY OF THE INVENTION
Deuteration of the rapamycin molecule results in altered physicochemical and pharmacokinetic properties which enhance its usefulness in the treatment of transplantation rejection, host vs. graft disease, graft vs. host disease, leukemia/lymphoma, hyperproliferative vascular disorders, autoimmune diseases, diseases of inflammation, solid tumors, and fungal infections.
Deuterium isotope is selected based on the fact that if 13 C, 15 N or another heavy isotope differing from the light one by less than 10% in mass is incorporated at the site of metabolism, there may be a small isotope effect. In addition to this, there are secondary isotope effects away from the site of isotope substitution due to changes in electronic environment.
Substitution of deuterium in methyl groups of rapamycin will result in a slower rate of oxidation of the C—D bond relative to the rate of oxidation of a non deuterium substituted C—H bond. The isotopic effect acts to reduce formation of demethylated metabolites and thereby alters the pharmacokinetic parameters of the drug. Lower rates of oxidation, metabolism and clearance result in greater and more sustained biological activity. Deuteration is targeted at various sites of the rapamycin molecule to increase the potency of drug, reduce toxicity of the drug, reduce the clearance of the pharmacologically active moiety and improve the stability of the molecule.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the chemical structure of 7-deuteromethyl rapamycin showing sites of deuteration.
FIG. 2 is the chemical structure of epi-7 deuteromethyl rapamycin showing sites of deuteration.
FIG. 3 is the chemical structure of 7,43-d 6 -rapamycin showing sites of deuteration.
FIG. 4 is the chemical structure of 31,42-d 2 showing sites of deuteration.
FIG. 5 illustrates the preparation of glycosylated deuterorapamycin.
DETAILED DESCRIPTION OF THE INVENTION
Substitution of deuterium for ordinary hydrogen and deuterated substrates for protio metabolites can produce profound changes in biosystems. Isotopically altered drugs have shown widely divergent pharmacological effects. Pettersen et al., found increased anti-cancer effect with deuterated 5,6-benzylidene-dl-L-ascorbic acid (Zilascorb) [Anticancer Res. 12, 33 (1992)].
Substitution of deuterium in methyl groups of rapamycin will result in a slower rate of oxidation of the C—D bond relative to the rate of oxidation of a non deuterium substituted C—H bond. The isotopic effect acts to reduce formation of demethylated metabolites and thereby alters the pharmacokinetic parameters of the drug. Lower rates of oxidation, metabolism and clearance result in greater and more sustained biological activity. Deuteration is targeted at various sites of the rapamycin molecule to increase the potency of drug, reduce toxicity of the drug, reduce the clearance of the pharmacologically active moiety and improve the stability of the molecule.
Determination of the physicochemical, toxicological and pharmacokinetic properties can be made using standard chemical and biological assays and through the use of mathematical modeling techniques which are known in the chemical and pharmacological/toxicological arts. The therapeutic utility and dosing regimen can be extrapolated from the results of such techniques and through the use of appropriate pharmacokinetic and/or pharmacodynamic models.
The compounds of this invention may be administered neat or with a pharmaceutical carrier to an animal, such as a warm blooded mammal, and especially humans, in need thereof. The pharmaceutically effective carrier may be solid or liquid.
A solid carrier can include one or more substances which may also act as flavoring agents, lubricants, solubilizers, suspending agents, fillers, glidants, compression aids, binders or tablet-disintegrating agents; it can also be an encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active ingredient. In tablets, the active ingredient is mixed with a carrier having the necessary compression properties in suitable proportions and compacted in the shape and size desired. The powders and tablets may contain up to 99% of the active ingredient. Suitable solid carriers include, for example, calcium phosphate, magnesium stearate, talc, sugars, lactose, dextrin, starch, gelatin, cellulose, methyl cellulose, sodium carboxymethyl cellulose, polyvinylpyrrolidine, low melting waxes and ion exchange resins.
Liquid carriers are used in preparing solutions, suspensions, emulsions, syrups, elixirs and pressurized compositions. The active ingredient can be dissolved or suspended in a pharmaceutically acceptable liquid carrier such as water, an organic solvent, a mixture of both or pharmaceutically acceptable oils or fats. The liquid carrier can contain other suitable pharmaceutical additives such as solubilizers, emulsifiers, buffers, preservatives, sweeteners, flavoring agents, suspending agents, thickening agents, colors, viscosity regulators, stabilizers or osmo-regulators. Suitable examples of liquid carriers for oral and parenteral administration include water (partially containing additives as above, e.g. cellulose derivatives, possibly sodium carboxymethyl cellulose solution), alcohols (including monohydric alcohols and polyhydric alcohols, e.g. glycols) and their derivatives, and oils (e.g. fractionated coconut oil and arachis oil). For parenteral administration, the carrier can also be an oily ester such as ethyl oleate and isopropyl myristate. Sterile liquid carriers are useful in sterile liquid form compositions for parenteral administration. The liquid carrier for pressurized compositions can be halogenated hydrocarbon or other pharmaceutically acceptable propellent.
Liquid pharmaceutical compositions which are sterile solutions or suspensions can be utilized by, for example, intramuscular, intraperitoneal or subcutaneous injection. Sterile solutions can also be administered intravenously. The compound can also be administered orally either in liquid or solid composition form.
The pharmaceutical composition can be in unit dosage form, e.g. as tablets or capsules. In such form, the composition is sub-divided in unit dose containing appropriate quantities of the active ingredient; the unit dosage forms can be packaged compositions, for example, packeted powders, vials, ampoules, prefilled syringes or sachets containing liquids. The unit dosage form can be, for example, a capsule or tablet itself, or it can be the appropriate number of any such compositions in package form. The dosage to be used in the treatment must be subjectively determined by the attending physician.
In addition, the compounds of this invention may be employed as a solution, cream, or lotion by formulation with pharmaceutically acceptable vehicles administered to a fungally affected area.
EXAMPLES
FIGS. 1-4 show examples of sites for deuteration of the rapamycin molecule. Nonlimiting examples of deuterated rapamycin molecules include the compounds; 7-deuteromethyl rapamycin (FIG. 1 ), epi-7-deuteromethyl rapamycin (FIG. 2 ), 7,43-d 6 -rapamycin (FIG. 3) and 31,42-d 2 -rapamycin (FIG. 4) including the cis and trans isomers of the compounds shown in FIGS. 1-4. FIG. 5 shows the preparation and structure of the compound glycosylated deuterorapamycin.
Example 1
Preparation of 7-Deuteromethyl Rapamycin (FIG. 1)
5 mg of Rapamycin was dissolved in 2.5 ml of dichloromethane. 40 mg of deuterated methanol was added. 10 beads of NAFION® catalyst were added to the above solution. The contents were stirred under nitrogen at room temperature for 14 hours. The reaction was monitored by mass spectrum. The solution was filtered and concentrated The residue was dissolved in dry benzene and freeze dried. The white solid obtained was homogenous by mass spectrum analysis and characterized by LC/MS.
Example 2
Preparation of 31, 42 d 2 -7-deuterated Rapamycin (FIG.3) Rapamycin (11 mM) was dissolved in a mixture of cyclohexane and dichloromethane (1:1) 10 ml. The contents were cooled in ice bath and poly(vinylpyridinium)dichromate 0.5 grams was added. The reaction mixture was stirred overnight and the reaction was followed by mass spectrum. The reaction mixture was filtered, washed with water and dried using anhydrous magnesium sulphate. The organic solution was filtered and concentrated. The crude product was subjected to purification by silica column using chloroform-methanol (20:10) mixture. The pure fractions were collected and concentrated. The residue was dissolved in benzene and freeze dried. The product was characterized by LC/MS. M+(Na) 932. This material was dissolved in dry ether (10 ml). 10 equivalents of lithium aluminum deuteride was added. The reaction mixture was stirred for 24 hours. After the completion of the reaction, the excess of LiAlD 4 was decomposed by the addition of acetone. The complex was decomposed by adding ice cooled acetic acid. The mixture is filtered. The filtrate was diluted with ether and washed with water, dried, and concentrated. The crude mixture was subjected to column chromatography and the required material was eluted using chloroform-methanol solvent system. The pure fractions were collected and concentrated. The compound was tested by mass spectrum. M=(Na) 940. This compound was converted to the desired final compound (2) by following the procedure as described in Example 1.
Example 3
Preparation of Glycosylated deuteroRapamycin (FIG. 5)
Referring to FIG. 5, compound 10 prepared by example 1 (20 mg) was dissolved in 5 ml of dichloromethane. Dimethylaminopyridine (2.2 mg) was added to the above solution. The contents were cooled to −70 C. 4-Nitrophenylchloroformate in dichloromethane was added to the reaction mixture. The solution was stirred under nitrogen at room temperature for 14 hours. The reaction was followed by mass spectrum. After the completion of the reaction, the reaction mixture was diluted with dichloromethane and the organic solution was washed with water, 0.2M ice cold HCl solution. The organic layer was dried over anhydrous magnesium sulphate. After filtration, the organic solution was filtered and concentrated. The crude product was purified by LC/MS to provide the pure compound 30 (Yield 10 mg.) Compound 30 (0.9 m.mol)was dissolved in dry DMF(0.5 ml) To this mixture, a solution of 2-aminoethyl-a-D-glucopyranoside (7.2 m.mol) was added. The reaction mixture was stirred for 14 hours at room temperature. After the completion of the reaction, the mixture was diluted with dichloromethane. The organic solution was concentrated in vacuum. The residue was extracted with water and the aqueous solution was subjected to biogel column to get the required pure compound 50. This material was characterized by LC/MS. M+(Na)1185.
Further variations and modifications of the present invention will be apparent to those skilled in the art from the foregoing and are intended to be encompassed by the claims appended hereto. | The synthesis of deuterated analogues of rapamycin is disclosed together with a method for use for inducing immunosupression and in the treatment of transplantation rejection, graft vs host disease, autoimmune diseases, diseases of inflammation leukemia/lymphoma, solid tumors, fungal infections, hyperproliferative vascular disorders. Also described is a method for the synthesis of water soluble deuteratred rapamycin compounds and their use as described above. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation application of Ser. No. 13/620,539, filed Sep. 14, 2012, which is a continuation application of Ser. No. 12/944,600, filed Nov. 11, 2010, now U.S. Pat. No. 8,271,640, which is a divisional application of Ser. No. 11/869,746, filed Oct. 9, 2007, now U.S. Pat. No. 7,908,395, which is continuation of Ser. No. 10/461,761, filed Jun. 12, 2003, now U.S. Pat. No. 7,281,039, which is a continuation of Ser. No. 09/220,413, filed Dec. 24, 1998, now U.S. Pat. No. 6,609,153.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates in general to communications networks, and more particularly, to the operation of network devices that can operate in multiple virtual networks simultaneously.
[0004] 2. Description of the Related Art
[0005] Network Layering and Protocols
[0006] A communication network provides information resources transfer services that transfer information resources among devices attached to the network. Information resources, as the term is used herein, includes any form of information that can be transmitted over a network for use by or with any end station or network device connected to the network. Information resources, for example, may include computer programs, program files, web pages, data, database information, objects, data structures, program icons, graphics video information or audio information. Computer Networks and Internets, Douglas E. Comer, Prentice Hall, 1997, provides extensive information about communication networks.
[0007] Networks are built from devices or stations called nodes, and the communications channels that interconnect the nodes, called links. A set of nodes and links under one administrative authority is called a network domain. Communication between end stations attached to a network ordinarily is achieved through the use of a set of layered protocols. These protocols are generally described by reference to the Open Systems Interconnection (OSI) computer communications architecture. The standard OSI architecture includes seven layers: application, presentation, session, transport, network, data link and physical. A communication network may employ fewer than the full seven layers. However, the layer 2 and the layer 3 software protocols ordinarily play a prominent role in the transfer of information between interconnected networks and between end stations connected to the networks.
[0008] The physical layer is the lowest layer (layer 1) of the OSI model. There are numerous technologies that can be employed to build networks at layer 2. Layer 2 networks can be “connection oriented”, meaning that a connection must be established before data can flow between two stations; ATM. Frame Relay, and X.25 are examples of connection oriented layer 2 protocols. Layer 2 networks can also be connection-less, meaning data can be transmitted without establishing any connection in advance; Ethernet and FDDI are two examples of connection-less layer 2 protocols.
[0009] In order to provide services useful to end users, the devices in a network must perform higher layer functions to create what are called “virtual networks”. The “Internet” is one example of a very popular and public virtual network. The Internet uses the IP protocol to provide the higher layer (layer 3) functions required to support operation of the virtual network. There are many other private (virtual) networks that also uses the IP protocol. The term “internet” with a small “i” is used to differentiate between these less well known private internets, and the very popular and public large “I” Internet. There are many other protocols that can be used to construct virtual networks at layer 3, including IPX, DECnet, AppleTalk, CLNP, etc. There are many other private and public networks using these other layer 3 protocols, either independent of or in conjunction with the IP protocol.
[0010] Thus, networks can be built at many different layers. Each layer has its own function and its own type of nodes and links. Higher layer networks are built “on top of” lower layer networks. In other words, nodes at a given layer may use the services of the next lower layer to provide links for communication with peer nodes (i.e. nodes at the same layer on other devices). Routers are examples of nodes in a layer 3 network. Bridges are examples of nodes in layer 2 networks.
[0011] Network Domains
[0012] A network domain as the term is used herein refers to the set of nodes and links that are subject to the same administrative authority. A single administrative authority may administer several networks in separate domains, or several layers of the same network in a single domain, or any combination. There are actually several possible administrative domains in any large virtual network. The boundaries of a network domain can be defined along the lines dividing layers of the protocol stacks. For instance, the same layer 1 physical devices and physical connections may have several layer 2 network domains layered onto them. These layer 2 domains, in turn, may have one or more layer 3 domains layered on top of them. A network domain may even transcend the boundaries between layers such that a layer 2 network and a layer 3 network may be part of the same network domain.
[0013] The administration of even a single network domain can be quite complex. Virtual networks have administrative authorities associated with them to control their higher layer functions. The cost of administering a network, physical or virtual, can be enormous, and is often the largest cost item in the operations of a network.
[0014] When several virtual networks are layered on top of the same layer 2 service or another virtual network, the boundaries between network domains may be somewhat obscure. The boundaries between the domains of the overlaid virtual networks intersect at points where they must share physical or virtual resources. In practice, the administrators of the overlaid virtual networks are very concerned about sharing resources, especially when they are competing commercial entities. Concerns arise about integrity, privacy, and security of data and network control information flowing across the shared resources at the lower layers. The administrators of the underlying networks are called upon to solve complex administrative problems. The costs of administering these networks increases quickly with the number of virtual networks, their size, the complexity and compatibility of their individual policies, and increased demands for security, integrity, and isolation between domains.
[0015] Network Devices and Databases
[0016] The term network device is used here to refer to the collection of mechanisms (e.g. computer and communications hardware and software) used to implement the functions of a station in a network. A network device contains some capacity to store and operate on information in databases in addition to the ability to transmit and receive information to and from other devices on the network. Examples of network devices include but are not limited to routers, bridges, switches, and devices that perform more than one of these functions (e.g. a device that does both routing and bridging).
[0017] A router is an example of a network device that serves as an intermediate station. An intermediate station is a network device that interconnects networks or subnetworks. A typical router comprises a computer that attaches to two or more networks and that provides communication paths and routing functions so that data can be exchanged between end stations attached to different networks. A router can route packets between networks that employ different layer 2 protocols, such as Token Ring, Ethernet or FDDI, for example. Routers use layer 3 protocols to route information resources between interconnected networks. Nothing precludes a network device that operates as an intermediate station from also operating as an end station. An IP router for example typically also operates as an end station.
[0018] A router can understand layer 3 addressing information, and may implement one or more routing protocols to determine the routes that information should take. A multiprotocol router runs multiple layer 3 protocols such as IP, IPX or AppleTalk for example. A router also be characterized as being multiprotocol if it runs multiple adaptive routing protocols such as RIP, BGP or OSPF all feeding a single IP layer.
[0019] The network device router configuration of FIG. 1A depicts what is often referred to in industry as a multi-protocol bridge/router. In this illustrative example, there are separate databases for three layer 2/3 networking protocols: bridging, IP routing, and IPX routing. The example IP database employs both the OSPF and RIP dynamic routing protocols. Thus, the intermediate station node of FIG. 1A includes both multiple networking protocols and multiple routing protocols.
[0020] A bridge is another example of a network device that serves as an intermediate station. A typical bridge comprises a computer used to interconnect two local area networks (LANs) that have similar layer 2 protocols. It acts as an address filter, picking up packets from one LAN that are intended for a destination on another LAN and passing those packets on. A bridge operates at layer 2 of the OSI architecture.
[0021] The term network database will be used to refer to all the control information housed in a network device required to support the device's operation in a set of one or more networks. Each device in a network holds its own network database. In order for the network at large to operate properly, the network databases of all network devices in a network domain should be consistent with each other. The network database control information defines the behavior of its network device. For example, not only might it determine whether the network device will function as a router or a bridge or a switch, but also it will determine the details of how the device will perform those functions.
[0022] When a network device is deployed to operate in multiple domains, its network database can become quite complex. The cost of administering the network device increases significantly when the network database is more complex. The cost of administration is already the most significant cost of operating many networks, and the trend toward greater complexity through greater use of virtual networking continues unabated.
[0023] The information found in a typical network database includes, but is not limited to, data used to configure, manage, and/or monitor operations of:
[0024] Communications Hardware (e.g. layer 1 transceivers/drivers/chips etc.)
[0025] Computer Hardware
[0026] Computer Software
[0027] Layer 2 Addressing
[0028] Layer 2 Connections (Layer 2 interfaces)
[0029] Traffic filter policies
[0030] Bridging (IEEE 802.1D)
[0031] Bridge filters and/or policies
[0032] Network (layer 3) Addressing
[0033] Layer 3 Connections (Layer 3 interfaces)
[0034] (Network/layer 3) Address Translation (NAT) policies
[0035] Access Control (e.g. user names and password)
[0036] Access policies (e.g. what user can use what services)
[0037] Routing (IETF RFC 1812)
[0038] Routing Protocols (e.g., BGP, OSPF, RIP, IGRP, etc.)
[0039] Route filters and policies (e.g. route leaking)
[0040] Tunneling
[0041] Tunneling Protocols (e.g., L2TP, GRE, PPTP, etc.)
[0042] A single network device can operate in one or more (virtual) network domains. For each domain in which a device operates, it needs to store information about that domain in some database form.
[0043] Much of the information in a network database must be configured manually; particularly the policy information as it must reflect the administrator's subjective wishes for how the network should operate. Manual configuration involves human effort, which can become expensive, especially as the number of policies and their complexity increases. Network administrative chores include the assignment of user names, passwords, network addresses or other user identifiers, and configuration of policy databases. This configuration and management may be used to establish traffic filtering policies such as what kind of information payloads will be carried. Traffic and Route filtering policies may be established to determine what paths through the network will be used for each payload carried. Access control policies may be to dictate which users at which end stations have access to which services at other end stations. Security policies may be established to ensure the integrity of the information payloads. Each configured bit of policy somehow finds its way into the network database of the device implementing the policy.
[0044] Cisco Router Configuration by A. Leinwand, B. Pinsky and M. Culpepper, published by MacMillan Technical Publishing, Indianapolis, Ind., 1998 provides an extensive treatment of the configuration of the databases of Cisco System routers. This is just one example of a network device database.
[0045] Building Virtual Networks
[0046] The layering of software protocols in accordance with the ISO architecture makes possible the creation of “virtual networks”. Virtual networks are to be contrasted with physical networks. Two physical networks which have no physical devices or links in common, can be said to be physically isolated from each other. Physical isolation may be required in order to ensure that a network has the highest levels of security and integrity.
[0047] Physical networks are defined at layer 1 of the OSI model. Virtual networks, on the other hand, are created at higher layers. It is possible to create multiple virtual networks all sharing common physical resources. A network is definitely virtual if it shares a common physical medium or device, such as an intermediate station, with any other (virtual) network. There are many conventional technologies and many commercially available products which can be used to build many types of virtual networks. For example, virtual circuits are a layer 2 construct that can be employed to create virtual networks.
[0048] It has been common practice in the industry for phone companies to offer connection oriented layer 1 and 2 services to Internet Service Providers (ISPs), corporations, and residential customers. These customers may build one or more higher layer (layer 3 and above) virtual networks on top of such publicly available layer 1 and 2 services. The higher layer virtual networks share a common set of layer 1 and 2 services, each having it's private set of virtual circuits.
[0049] A PC or a server are examples of end stations. End stations located at home or business, for example, may connect into an internet through an internet service provider (ISP). There are regional, local and global ISPs. In most cases, local ISPs connect into the regional ISPs which in turn connect into other regional or national ISPs. FIG. 1B illustrates an example of a connections to an ISP. In the example, home user end stations may connect via modems over dial-up lines to an ISP's router or remote access server (RAS). This data link often runs the PPP (Point-to-Point Protocol) which encapsulates and delivers packets to the ISP's site. Business user end systems may connect to the ISP through leased lines such as T1 lines or T3 lines depending on bandwidth requirements for example. Other examples of typical connection options between home or business users and an ISP include ISDN, T1, fractional T1, various optical media, and xDSL. ISPs may also offer tunnel mode or transport mode services that help businesses set up virtual private networks (VPNs) between remote end stations and virtual dial-up services for remote and mobile end stations.
[0050] The ISP serves as a conduit for information transmitted between the end stations in the home and other end stations connected to the Internet.
[0051] A virtual circuit is a dedicated communication channel between two end stations on a packet-switched or cell-relay network. ATM, Frame Relay, and X.25 are all different types of virtual circuit based networking technologies. A virtual circuit follows a path that is programmed through the intermediate stations in the network.
[0052] There are permanent and switched virtual circuits. A permanent virtual circuit (PVC) is permanent in the sense that it is survives computer reboots and power cycles. A PVC is established in advance, often with a predefined and guaranteed bandwidth. A switched virtual circuit (SVC) is “switched” in the sense that it can be created on demand analogous to a telephone call. Both PVCs and SVCs are “virtual” circuits in that they typically are not allocated their own physical links (e.g. wires), but share them with other virtual circuits running across the same physical links.
[0053] “Tunneling” is one mechanism for building higher layer networks on top of an underlying virtual network. Tunneling has already gained acceptance in the industry and several technologies are either in operation or under development. Some of the tunneling protocols used in IP networks for example include L2TP, GRE, PPTP, and L2F. There are many other Tunneling technologies used in IP and other protocols.
[0054] Referring to FIGS. 2A-2B , there are shown network graphs representing two illustrative networks. Network A is represented by three nodes (NA 1 , NA 2 , and NA 3 ), and three links (LA 1 , LA 2 , and LA 3 ). Network B is represented by four nodes (NB 1 , NB 2 , NB 3 , and NB 4 ) and four links (LB 1 , LB 2 , LB 3 , and LB 4 ). As used herein, the term node may represent any end station or intermediate station, and the term link means any connection between nodes. If these are physical nodes and links, Networks A and B are physically isolated from each other. If these are virtual (circuit) links which actually depend on a shared physical medium, then the two (virtual) networks are said to be virtually isolated from each other.
[0055] Illustrative Networks A and B each may be part of different network domains. Independent administrative control may be exercised over each of the Network A and B domains, for example, through the configuration and management of intermediate stations such as bridges and routers.
[0056] Referring to FIGS. 2A and 2B , it will be appreciated that the independent administration of the Network A and Network B domains may result in incompatible policies as between the two domains. This is not a problem provided that the domains remain isolated from each other. Referring to FIG. 3 , however, there is shown a network graph of Network C which comprises Networks A and B joined by link LJ. The isolation between Networks A and B, whether physical or virtual, is lost when they are joined in Network C. This joining of the two Networks A and B may create challenges to the administration of combined Network C. For example, despite the joining of the two networks, there still may be a need to apply different or even conflicting policies to each of Networks A and B. In essence, the administrative challenge is to maintain the administrative integrity of the Network A domain and the administrative integrity of the Network B domain despite the fact that both of these networks are part of Network C and are no longer physically isolated from each other.
[0057] FIG. 4 is an illustrative drawing of a segment of a single physical medium capable of carrying multiple information flows, each in its own virtual circuit (or channel). The physical medium may for instance be a cable or a wire or an optical fiber. The segment shown is carrying four independent information flows on four different virtual circuits; VC 1 , VC 2 , VC 3 , and VC 4 . These virtual circuits, for example, may be implemented using X.25, ATM, Frame Relay, or some other virtual circuit (or channelized) service.
[0058] FIG. 5 is an illustrative drawing representing an example of two virtual networks (VN 1 , and VN 2 ) each made up of two independent network segments (VN 1 . 1 and VN 1 . 2 for VN 1 , and VN 2 . 1 and VN 2 . 2 for VN 2 ). All segments connect to shared physical network resources. In this example, the shared network resources of FIG. 5 provide a virtual circuit service. A virtual circuit connection to an end station or intermediate station connection to a virtual circuit is called a virtual channel connection (VCC). VN 1 connects at VCC 1 and VCC 4 ; and VN 2 connects at VCC 2 and VCC 3 . The shared network resources also provide virtual circuit service that connect VCC 1 and VCC 4 so as to join VN 1 . 1 and VN 1 . 2 into VN 1 and so as to join VN 2 . 1 and VN 2 . 2 into VN 2 .
[0059] FIG. 6 is an illustrative drawing that provides additional details of some of the physical constituents of the virtual networks of FIG. 5 . An intermediate station labeled VN 1 . 1 .VCC 1 in VN 1 connects segment VN 1 . 1 to the VC service at VCC 1 . An intermediate station labeled VN 1 . 2 .VCC 4 in VN 1 connects segment VN 1 . 2 to the VC service at VCC 4 . The VC service connects VCC 1 to VCC 4 , linking VN 1 . 1 to VN 1 . 2 at the virtual circuit level. More specifically, physical media segments PM 2 , PM 1 and PM 5 and intermediate stations IS-A and IS-B provide the requisite physical infrastructure upon which the virtual circuit connection linking VN 1 . 1 and VN 1 . 2 is carried. This first virtual circuit connection serves as a network link between the VN 1 . 1 .VCC 1 and VN 1 . 2 .VCC 4 intermediate stations, to create one virtual network from the two segments VN 1 . 1 and VN 1 . 2 .
[0060] Similarly, VCC 2 and VCC 3 are connected by the virtual circuit service, which connects intermediate stations VN 2 . 1 .VCC 2 and VN 2 . 2 .VCC 3 , joining the VN 2 . 1 and VN 2 . 2 segments to form the virtual network labeled VN 2 . More particularly, physical media segments PM 4 , PM 1 and PM 3 and intermediate stations IS-A and IS-B provide the virtual connection linking VN 2 . 1 and VN 2 . 2 . The second virtual circuit connection serves as a network link between the VN 2 . 1 .VCC 2 and VN 2 . 2 .VCC 3 intermediate stations, to create one virtual network from the two segments VN 2 . 1 and VN 2 . 2 .
[0061] FIG. 7 is an illustrative drawing shows the logical or higher level view of the two virtual networks VN 1 and VN 2 of FIGS. 5 and 6 . It will be appreciated from the view of FIG. 6 that they share physical resources, and it will be appreciated from the view of FIG. 7 that they are logically or virtually separate.
[0062] In the illustrative example of FIG. 8 , two virtual networks are layered on top of a third virtual network. The sharing of a common set of physical or virtual network resources by several virtual networks increases the challenges of maintaining isolation and security of the individual virtual networks. Nevertheless, end user requirements for information resources, technology advances, economics, politics, and regulations surrounding the networking industry are driving commercial, private and government entities to share common physical and virtual network infrastructure. Therefore, there are ever increasing demands imposed upon network administrators, and vendors of networking equipment.
[0063] In the illustrative drawing of FIG. 8 , three separate network domains intersect at node IN 1 : i) that of the Internet itself (including or subsuming that of the underlying VC service supporting the Internet); ii) that of private virtual network VN 1 ; and iii) that of private virtual network VN 2 . This intersection of three network domains creates the potential for the kinds of administration and policy challenges discussed above. It will be noted that these networks are represented by different network “clouds” that symbolize the multifarious nodes and links in each of the networks.
[0064] The illustrative drawing of FIG. 8 illustrates an example of building two virtual networks on top of another virtual network similar to the previous example in FIGS. 5 , 6 and 7 . As before, the virtual networks being overlaid are each composed of two segments. Using a tunneling protocol or some other higher layer (layer 3 or above) mechanism, connections are made between nodes IN 1 . 1 and IN 1 . 2 to form a link to tie the two segments of VN 1 together. This link is shown as T 1 in FIGS. 9 and 10 . Link T 2 is similar, formed between nodes IN 2 . 1 and IN 2 . 2 , to tie the two segments of VN 2 together. The logical view of the two virtual networks in FIG. 9 is shown in FIG. 10 , which bears a very strong resemblance to FIG. 7 . The important difference to note between the examples is that in FIG. 7 a layer 2 VC network was used as the underlying network shared resources, and in FIG. 10 another virtual network was used as the underlying network shared resources; specifically, a tunneled service across the Internet. Thus, it will be appreciated that different virtual networks can be formed in different layers using the same underlying physical (or virtual) network resources.
[0065] Connections are established between nodes at the edge of the segments where they interface or connect to the shared (Internet) resources which are analogous to the virtual circuits in FIGS. 5 , 6 , and 7 . These may be tunneled connections, or connections built using some other (connection-less) technology.
[0066] If we assume T 1 and T 2 are tunnels, the network databases of IN 1 . 1 , IN 1 . 2 , IN 2 . 1 , and IN 2 . 2 would be augmented with data structures to manage the tunneling protocol at those endpoints, and the links made up from the tunnels. The network database of IN 1 . 1 of FIG. 8 is depicted in FIG. 11 which highlights the “Tunneling Database” and the “IP Database”.
[0067] Network Database Organization
[0068] If we examine the information in the network database for IN 1 , we will see that it should include configuration and policy information for three separate domains. Furthermore, since the information from the three domains must all coexist in the same physical device, there should be some way to structure the information and control its usage, such that the IN 1 device operates correctly in all three domains. If all information for the device IN 1 were stored in one monolithic from as is done conventionally, in addition to all the policies for each domain, inter-domain policies would also be required to ensure that information should be is kept private to its own domain.
[0069] The illustrative drawing of FIG. 12 is a generalized drawing of a conventional monolithic structure for a database that can be used to implement node IN 1 of FIG. 7 . The drawing depicts, in a conceptual fashion, an example of the typical organization of information within such a device. The illustrative device includes a first interface attached to VN 1 . 1 , a second interface attached to VN 2 . 2 and a third interface attached to the Internet as the shared network resources. To illustrate the complexities in the database design, assume that both the virtual networks being overlaid on the Internet are also (private) IP networks (internets). Therefore all three networks/domains operate using the IP protocol, each having its own independent IP information to be stored in IN 1 's network database.
[0070] The database includes information such as rules used to articulate and implement administrative policies. The policies as articulated in the information and rules, for example, may include security rules, restrictions on access and dynamic routing protocols. In this illustrative router, the policy information and policy rules used to control the layer 3 IP protocol routing for all three networks are included in a single monolithic database.
[0071] However, as explained above, different network domains may have different or perhaps even conflicting policies. In order to provide at least some degree of isolation, additional and complicated “inter-domain” policy mechanisms must be added to manage the conflicts between policies on similar data from different domains. These mechanisms are configured and managed by an administrative authority. The dotted lines in FIG. 12 represent the points at which these inter-domain policy mechanisms would be introduced. The policies would attempt to divide the monolithic network database of node IN 1 into three separate domain-specific sections. These dotted lines indicate that separation policy mechanisms are implemented, to provide at least some isolation of the information pertaining to VN 1 from the information pertaining to VN 2 , and also from the information pertaining to the Internet (i.e. shared network resources).
[0072] It will be appreciated that the complexity and difficulty in defining and administering the policy mechanisms used to achieve isolation can be great. There is potential for a wide range of policies to be defined between domains. Everything in the spectrum from almost complete openness and sharing of all information between domains, to the other extreme of not sharing anything at all are possible. Certain pieces of a domain's database may want to be kept private (e.g. access control policy configuration), while other parts are shared to some extent (e.g. summarized routing and addressing information). The types of data, and the extent to which they can all be shared, are all subject to restriction through definition of inter-domain policies.
[0073] If we consider each boundary between a pair of domains (i.e. each dotted line through the network database of IN 1 in FIG. 12 ) as a separate policy object, it will also be appreciated that the number of policy objects increases much faster than the number of domains. If D is the number of domains, then P, the number of policy objects can be calculated approximately as:
[0000] P =( D ( D− 1))/2
[0074] Thus, the number of policy objects increases approximately as (a proportion of) the square of the number of domains. In other words, the number of policy objects ordinarily increases much faster than the number of domains, especially as the number of domains gets large.
[0075] Another challenge in the administration of virtual networks arises because home or business end station users may wish to change the nature of their connections to the network from time to time. For instance, an end use may wish to utilize a more expensive higher bandwidth connection for business use and a less expensive lower bandwidth connection for home or personal use. Alternatively, for instance, an end user may wish opt to receive a video transmission on a higher bandwidth connection while still receiving other transmissions on lower bandwidth connections. An end user may even wish to change the ISP that he or she uses. Unfortunately, these changes often require intervention by a network administration authority to change the higher level binding between the end user station and the network. More specifically, the binding (or association) between the layer 2/1 virtual circuit service and a layer 3 intermediate device is ‘hard’, not dynamic, and the higher layer interface generally must be reconfigured by a network administrator to change the binding.
[0076] Thus, there has been a need for improved organization of network domain databases and improvements in the ability of a network user to change network domain. The present invention meets these needs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0077] FIG. 1A is a generalized diagram of a multi-protocol bridge/router;
[0078] FIG. 1B is an illustrative example of the topology of and connections;
[0079] FIGS. 2A and 2B are network graphs of two illustrative example networks;
[0080] FIG. 3 is a network graph of an illustrative network in which the networks of FIGS. 2A and 2B are joined;
[0081] FIG. 4 is an illustrative drawing of a segment of a single physical medium capable of carrying multiple information flows, each in its own virtual circuit (or channel);
[0082] FIG. 5 is an illustrative drawing of two virtual networks each made up of two independent network segments;
[0083] FIG. 6 is an illustrative drawing that provides additional details of some of the physical constituents of the virtual networks of FIG. 5 ;
[0084] FIG. 7 is an illustrative drawing which shows the logical or higher level view of the two virtual networks VN 1 and VN 2 of FIGS. 5 and 6 ;
[0085] FIG. 8 is an illustrative drawing that shows that the Internet can provide the shared network resources of FIGS. 5 and 6 ;
[0086] FIG. 9 is an illustrative drawing that shows tunneling through the Internet to provide the shared resources of FIGS. 5 and 6 ;
[0087] FIG. 10 is a logical or high level view of the two virtual networks of FIG. 9 ;
[0088] FIG. 11 is a generalized illustrative drawing of the organization of node IN 1 to achieve tunneling;
[0089] FIG. 12 is a conceptual drawing of one possible router configuration that can be used to implement intermediate node IN 1 of FIG. 7 ;
[0090] FIG. 13 is a generalized block diagram of a network device that instantiates multiple virtual network machine routers in electronic memory in accordance with one embodiment of the invention;
[0091] FIG. 14 is a generalized block diagram of a network device that instantiates a virtual network machine with multiple layer 2 sub-interface data structures and multiple layer 3 interfaces and binding data structures that associate layer 2 sub-interface data structures and layer 3 interfaces;
[0092] FIG. 15 is a generalized block diagram of the network device of FIG. 14 , except that one binding data structure has been removed and another binding data structure has been created;
[0093] FIG. 16 is a generalized block diagram of a network device that implements a virtual network machine router and a virtual network machine bridge;
[0094] FIG. 17 is a generalized block diagram of the network device as in FIG. 16 , except that one binding data structure has been removed and another binding data structure has been created;
[0095] FIG. 18 is a generalized block diagram of the network device of FIG. 14 , except that one binding data structure has been eliminated and another binding data structure has been created;
[0096] FIG. 19 is a generalized block diagram of a network device which comprises a computer which instantiates multiple virtual network machines in accordance with an embodiment of the invention;
[0097] FIG. 20 is a generalized block diagram of the network device of FIG. 19 except that one binding data structure has been removed and another binding data structure has been created; and
[0098] FIG. 21 is a generalized block diagram of a subscriber management system in accordance with a presently preferred embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
[0099] The present invention comprises a novel apparatus and method for managing operation of network devices that can operate in multiple virtual network domains. The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of particular applications and their requirements. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0100] Virtual Network Machines
[0101] A Virtual Network Machine (VNM) as the term is used herein to describe the collection of processes and mechanisms that operate on a network device to implement the functions of a node in a virtual network. The preferred embodiment for the VNM is as a set of computer programs and related data structures encoded in electronic memory of a network device and used to operate on information, consuming some portion of a network device's computer and memory storage capacity. The functionality of a virtual network machine can be that of a router, bridge or switch, depending on what is configured in its network database. The native resources of a network device include its processor(s), memory, I/O, communication hardware and system software. The native resources of a network device, for example, may include peripheral devices or even a server computer which may, for instance, provide information about end user privileges or virtual network configurations.
[0102] Referring to the illustrative drawing of FIG. 13 , there is shown a generalized block diagram of a new structure for the network database of node IN 1 from FIGS. 8 and 12 in accordance with one embodiment of the invention that supports creation of multiple virtual network machines. In this case, the networks device IN 1 supports three virtual network machines VNM 0 , VNM 1 and VNM 2 . In the embodiment of FIG. 13 , assuming again that all three virtual networks operate using the IP protocol, each virtual network machine implements the functionality of an IP router, each operating in its own network domain. Each virtual network machine is allocated a portion of the device's native resources. Each virtual network machine runs the IP protocol stack. Each virtual network machine stores its address, policy and control information separately from the others. Thus, each virtual network machine can operate independently of the other virtual network machines, even though it shares native computer resources with the other virtual network machines. This virtual network machine based organization of information therefore provides greater isolation between network domains.
[0103] Each virtual network machine has its own network database that contains its control information. VNM 0 has a network database that causes it to operate as a router that routes information within the Internet network domain. VNM 1 has a network database that causes it to operate as a router that routes resource information within network domain VN 1 . VNM 2 has a network database that causes it to operate as a router that routes resource information within network domain VN 2 . 1 . High Speed Networks, TCP/IP and ATM Design Principles, by William Stallings, Prentice Hall, 1998 provides detailed discussion of router functions and the functions of other network devices.
[0104] The VNMs of FIG. 13 may employ multiple different kinds of layer 1 (physical) media to attach to one or more networks. In a presently preferred embodiment, these physical connections include ATM OC-3c/STM1, ATM DS-3/E3, DS-3 Clear Channel, HSSI and 10/100 Base-2 T TX. Resource information is transmitted across these physical connections such as phone lines, DSL or ADSL for example to and from VNM 0 , VNM 1 and VNM 2 using layer 2 (data link) protocols. There are layer 2 LAN (local area network) technology and layer 2 WAN (wide area network) technology protocols. Examples of LAN technologies include Ethernet and IEEE 802.3, Fast Ethernet, Token Ring and Fiber Distributed Data Interface. Examples of WAN technologies include Asynchronous Transfer Mode (ATM), Frame Relay, X.25, Point-to-Point (PPP), Integrated Services Digital Network (ISDN) and High-Level Data Link Control (HDLC). Intermediate stations communicate with each other using layer 3 protocols. Layer 3 protocols include Internet Protocol (IP), AppleTalk and Inter Packet Exchange (IPX). Thus, for example, VNM 0 , VNM 1 and VNM 2 each employ one or more layer 3 protocols to communicate with other stations of the network(s) to which they are attached.
[0105] Thus, the three virtual network machines and the different network domains associated with them are isolated from each other in the network device intermediate station of FIG. 13 , and the task of exercising administrative control can be simplified significantly. Since there is no monolithic database that must be maintained to control information transfers across all of the networks to which the three VNMs are attached, the task of administering each database is simplified.
[0106] The virtual network machine based organization also simplifies the administration, lowering the cost of operating all three networks. The organization of information along network domain boundaries eliminates the notion of information from two domains residing under a single monolithic structure, and thereby eliminates the need to define inter-domain policies to manage the separation of information within a monolithic database structure. The separation policy mechanisms represented by the dotted lines cutting through the database of FIG. 12 are gone, and a whole set of administrative chores disappears with them. There will be no need to define the complicated inter-domain policies, and no cost associated with administering them. The amount of information that needs to be configured by the administrators is greatly reduced in size and complexity using this method of database organization.
[0107] Other benefits can be realized through greater efficiencies in the implementation of such network devices that are possible with this method of network database organization. Further efficiencies are realized through the elimination of the complicated inter-domain policies in virtually all functions of the device. Essentially, each of the virtual network machines VNM 0 , VNM 1 and VNM 2 operates a separate/independent network device, performing networking functions its own domain.
[0108] Dynamic Binding
[0109] The drawing of FIG. 14 shows another illustrative embodiment of the invention. The IP network device of FIG. 14 implements a router that includes three network interfaces NIF 3 - 0 , NIF 3 - 1 and NIF 3 - 2 . The network device also has a layer 1/2 connection to art Ethernet service. The network device also has a layer 1/2 connection to a virtual circuit service. An Ethernet service sub-interface data structure Eth 1 provides the layer 2 Ethernet connection such as sub-interface data structure provides the layer 2 VCC 1 connection. For example, the VCC 1 sub-interface data structure of FIG. 14 may be kept in a table that identifies all virtual circuit connections, each defining the encapsulation protocol, the packet or cell, data compression technique and the particular layer 2 protocol used on that circuit. The Ethernet sub-interface data structure may include the Ethernet address of the local connection and other parameters to control transmit and receipt of information on the Ethernet segment. A binding data structure B 3 - 0 binds the Ethernet sub-interface data structure to NIF 3 - 0 . A binding data structure B 3 - 2 binds the VCC 1 sub-interface data structure to NIF 3 - 2 . The Ethernet and VCC 1 sub-interface data structures are labeled with the prefix “sub” because they are layer 2 constructs which are below the layer 3 interface constructs in the ISO scheme.
[0110] Referring to FIG. 14 , binding data structure B 3 - 0 establishes a layer 2/3 connection between the Ethernet sub-interface data structure and NIF 3 - 0 , and binding data structure B 3 - 2 establishes a layer 2/3 connection between VCC 1 sub-interface data structure and IF 3 - 2 . Binding data structure B 3 - 0 causes information transferred across the Ethernet connection to be processed through to NIF 3 - 0 . An IP Forwarding/Routing database controls routing of the information out the correct interface. Binding data structure B 3 - 2 causes the information transferred across the VCC 1 connection to be processed through NIF 3 - 2 .
[0111] The VCC 1 sub-interface data structure instantiates a virtual circuit connection to the network device of FIG. 14 . A virtual circuit connection such as that in FIG. 14 can be created in accord with any of several technologies. A sub-interface data structure like that in FIG. 14 stores the network device's identity of the virtual circuit attached to it. Many virtual circuits can be established across a single physical connection, and many virtual circuits can be connected to a single network device.
[0112] FIG. 15 depicts the same intermediate station as in FIG. 14 , except the binding B 3 - 0 has been eliminated, and binding B 3 - 1 has been created. Binding B 3 - 1 associates the Ethernet sub-interface data structure Eth- 1 with interface NIF 3 - 1 . Interface NIF 3 - 2 remains bound to the sub-interface data structure VCC 1 . The interface NIF 3 - 0 is not bound to any layer 2 construct. It should be noted that an unbound interface construct generally would represent a mis-configuration in a typical earlier intermediate station.
[0113] FIG. 16 depicts yet another illustrative embodiment of the invention. The network device of FIG. 16 implements an IP router function and a bridging function. The router includes two interfaces NIF 4 - 1 and NIF 4 - 2 . The bridge includes a bridge interface BR 4 - 0 . A network database that implements the bridge function includes a list of network stations reachable through each of the bridge's interfaces. The network device also has a layer 1/2 connection to an Ethernet service. The network device also has a layer 1/2 connection to a virtual circuit service VCC 1 . An Ethernet service sub-interface data structure Eth 1 provides information concerning the Ethernet connection such as a VCC 1 sub-interface data structure provides information concerning the VCC 1 connection. A binding data structure B 4 - 0 binds the Ethernet sub-interface data structure to NIF 4 - 0 . A binding data structure B 4 - 2 binds the VCC 1 sub-interface data structure to NIF 4 - 2 . NIF 4 - 1 is unbound.
[0114] FIG. 17 depicts the same network device as in FIG. 16 , except the binding B 4 - 0 has been eliminated, and binding B 4 - 1 has been created. Binding B 4 - 1 associates the Ethernet sub-interface data structure with interface NIF 4 - 1 of virtual router VM 4 . Interface NIF 4 - 2 remains bound to the sub-interface data structure VCC 1 . The interface BR 4 - 0 is not bound to any layer 2 construct. These changes in binding effectively redefines the service available on the Ethernet segment from a bridged or layer 2 service, to a routed or layer 3 service. In a presently preferred embodiment of the invention, these bindings can be changed without reconfiguration of any other interface construct or circuit construct. In a typical earlier intermediate station, the bindings between the higher and lower layers are implicit, and a change in the implicit bindings applied to the bridge and router interface constructs typically would have required a modification of these interface constructs. A present embodiment of the invention does not require such modification.
[0115] FIG. 18 depicts the same network device as in FIG. 14 , except the binding B 3 - 0 has been eliminated and binding B 3 - 2 A has been created. Binding B 3 - 2 A associates the Ethernet sub-interface data structure with the NIF 3 - 2 interface. Binding B 4 - 2 associates the VCC 1 sub-interface data structure with NIF 3 - 2 . Interfaces NIF 3 - 0 and NIF 3 - 1 are unbound. This change in bindings causes both the Ethernet and the virtual circuit lower layer services to be associated with a single higher layer IP construct, NIF 3 - 2 .
[0116] FIG. 19 shows a network device which comprises a computer which instantiates multiple virtual network machines VNM 5 and VNM 6 . VNM 5 implements IP router functionality. It includes network interfaces NIF 5 - 0 and NIF 5 - 1 . VNM 6 also implements IP router functionality. It includes two interfaces NIF 6 - 0 and NIF 6 - 1 . The network device of FIG. 19 has two layer 1/2 connections to a virtual circuit service. Sub-interface data structure VCC 1 instantiates one of the connections to the device. Sub-interface VCC 2 instantiates the other connection to the device. A binding data structure B 5 - 0 binds the VCC 1 sub-interface data structure to NIF 5 - 0 of VNM 5 . A binding data structure B 6 - 2 binds the VCC 2 sub-interface data structure to interface NIF 6 - 1 of VNM 6 . VNM 5 and VNM 6 each use the IP protocol suite to communicate with other stations of the network(s) to which they are attached.
[0117] FIG. 20 depicts the same network device as in FIG. 19 , except the binding B 5 - 0 has been eliminated and binding B 6 - 0 has been created. The binding B 6 - 0 data structure associates VCC 1 sub-interface data structure with NIF 6 - 0 of VNM 6 . Binding data structure B 6 - 1 binds sub-interface data structure VCC 2 to NIF 6 - 1 . Neither of the VNM 5 interfaces NIF 5 - 0 and NIF 5 - 1 are bound.
[0118] In FIGS. 14 to 20 , bindings are shown as data structures connected to other data structures by line segments. In one preferred embodiment, the line segments each represent a pair of bi-directional pointers; the first pointer points from the binding to the higher or lower layer data structures and the second is opposite the first, pointing from the higher or lower layer data structure to the binding data structure. Alternatively, the binding could be implemented as indices or identifiers in a table, for example. Dynamic binding is accomplished by creating and/or deleting binding data structures and/or changing the values of the pointers or indices so they operate on different data structures. It will be appreciated that actual changing of the bindings can be accomplished through entries in a command line interface to the network device or automatically by snooping the information flow through the device, for example.
[0119] The illustrative drawing of FIG. 21 is a generalized block diagram of a subscriber management system in accordance with a presently preferred embodiment of the invention. A subscriber is a user of network services. The system includes a computer with layer 1/2 connections to subscriber end stations and with layer 1/2 connections to network devices that provide access to other networks.
[0120] The system can form a multiplicity of layer 1/2 subscriber end station connections. In a present embodiment, the layer 1/2 connections to subscriber end stations include virtual circuit connections. The system memory stores a multiplicity of sub-interface data structures that instantiate the multiplicity of virtual circuit connections through which subscriber end stations communicate with the subscriber management system.
[0121] The system instantiates in memory a plurality of virtual network machines. Each VNM of the embodiment of FIG. 21 implements the functionality of a router. There are nine illustrative VNM routers shown in FIG. 21 labeled VNMr- 1 -VNMr- 9 . Each VNM router includes interfaces in its database. Each VNM router runs at least one layer 3 protocol suite. Each VNM router may run one or more adaptive routing algorithms. The interfaces of each VNM router provide access to a network that is isolated from the networks accessed through the interfaces of the other VNM routers. For example, the interface to VNMr- 4 provides layer 3 access to the network that includes ISP# 2 . The interface to VNMr- 5 provides layer 3 access to the network that includes Corporate-Private-Network #A. The interface to VNMr- 6 provides layer 3 access to the network that includes ISP# 4 . The networks with ISP# 2 , Corporate-Private-Network #A and ISP# 4 are isolated from each other. The databases associated with VNMr- 4 , VNMr- 5 and VNMr- 6 to control access to networks across these respective interfaces. Each of these three VNM databases can be administered separately. In operation a subscriber might establish a point-to-point connection with the subscriber management system. A server that runs software that runs authentication, authorization and accounting protocols (AAA) searches for a record that identifies the user. Authentication is the process of identifying and verifying a user. For instance, a user might be identified by a combination of a username and a password or through a unique key. Authorization determines what a user can do after being authenticated, such as gaining access to certain end stations information resources. Accounting is recording user activity. In the present embodiment, AAA involves client software that runs on the subscriber management system and related access control software that runs either locally or on a remote server station attached to the network. The present embodiment employs Remote Authentication Dial-In User Service (RADIUS) to communicate with a remote server. An example of an alternative AAA protocol is Terminal Access Controller Access Control System (TACACS+). RADIUS and TACACS+ are protocols that provide communication between the AAA client on a router and access control server software.
[0122] The subscriber record includes information concerning the network to which the subscriber's virtual circuit connection should be bound. Typically, the subscriber will employ a PVC. Based upon the information in the subscriber record, a binding data structure, like that described in reference to FIGS. 14 to 20 , will be created to associate the sub-interface data structure that instantiates the PVC in the subscriber management system memory with the interface to the VNM router that accesses the network identified for the subscriber in the subscriber record.
[0123] Moreover, the subscriber record may provide multiple possible binding options for the subscriber. For instance, the subscriber may specify the creation of a binding that is which is to be employed during business hours and which binds the subscriber to VNMr- 5 which provides layer 3 network access to the Corporate-Private-Network #A. The same record may specify another binding which is to be employed only during non-business hours and which binds to VNM# 4 which provides layer 3 network access to ISP# 2 . Thus, the bindings can be changed. They are dynamic.
[0124] Various modifications to the preferred embodiments can be made without departing from the spirit and scope of the invention. Thus, the foregoing description is not intended to limit the invention which is described in the appended claims in which: | A method and device for communicating information resources between subscriber end stations and nodes belonging to different network domains is described. The device instantiates different virtual network machines for different network domains using separate independently administrable network databases. Each of the administrable chores of the separate independently administrable network databases includes the assignment of access control and the configuration of the policies for those network databases. The policies include traffic filtering policies to indicate what kind of information payloads can be carried, traffic and route filtering policies to indicate what paths through the network will be used for each payload carried. Each of the network domains includes one of the different virtual network machines and each of the different network domains is virtually isolated from other network domains. | 7 |
This invention relates to poly(arylene sulfide) compositions. In one aspect this invention relates to electronic components made from poly(arylene sulfide) compositions. In another aspect this invention relates to electronic components encapsulated with poly(arylene sulfide) components. In yet another aspect this invention relates to poly(arylene sulfide) compositions containing at least one silane.
BACKGROUND AND OBJECTS
Poly(arylene sulfide) compositions can be used in the manufacture of electronic components such as, for example, connectors, bobbins, coils, relays, etc. Poly(arylene sulfide) compositions can also be used to encapsulate electronic components.
High insulation resistance is a much desired characteristic in such poly(arylene sulfide) compositions. One of the objects of this invention is to provide a poly(arylene sulfide) composition having high insulation resistance. Another object of this invention is to provide electronic components made from or encapsulated with a poly(arylene sulfide) composition of high insulation resistance.
Although my invention is well suited for use in the area of electronic components and encapsulation thereof, the scope of my invention is not limited thereto. Accordingly, it is also an object of this invention to provide a novel poly(arylene sulfide) composition. Many uses for poly(arylene sulfide) compositions (especially poly(phenylene sulfide) compositions) are known; others have yet to be discovered.
Other objects, advantages and aspects of this invention will become apparent to persons skilled in the art upon study of this disclosure and the appended claims.
BRIEF SUMMARY OF THE INVENTION
The composition of this invention is made from poly(arylene sulfide) and at least one silane selected from a specifically defined group. The composition can additionally contain, as desired, reinforcements, fillers, zinc oxide, processing aids, pigments, additives, etc. The composition can be used in the manufacture of electronic components as an encapsulation composition and the invention includes, as one of its aspects, electronic components made from or encapsulated therewith. The silane imparts to the poly(arylene sulfide) composition an increase in insulation resistance that makes the composition well suited for electronic applications. The invention, however, includes the composition per se and is not limited to electronic applications. This invention is further, and more completely, described in the disclosure and claims which follow.
DETAILED DESCRIPTION OF THE INVENTION
1. The Composition
The composition of this invention is a combination of poly(arylene sulfide) and at least one silane within formula I given below: ##STR1##
The number of sulfur atoms (S) linking the two aromatic groups is determined by the value of n which represents a positive integer and ranges from 1 to 30. A subgenus within the scope of this invention is represented by formula I wherein n ranges from 1 to 10. The preferred value for n is from 1 to 5.
Each of R 1 and R 2 is H or an alkyl group having from 1 to 30 carbon atoms. Each of R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 is an alkyl group having from 1 to 30 carbon atoms. The alkyl groups associated with R 1 , R 2 , R 5 , R 6 , R 7 , R 8 , R 9 and R 10 can be linear (e.g. n-propyl) or branched (e.g. tert-butyl). Examples of alkyl groups within the scope of this invention include, but are not limited to, the following: ##STR2##
A subgenus within the scope of this invention is represented by formula I wherein each of R 1 and R 2 is H or an alkyl group having from 1 to 10 carbon atoms and each of R 5 , R 6 , R 7 , R 8 , R 9 and R 10 is an alkyl group having from 1 to 10 carbon atoms. Preferably, each of R 1 and R 2 is H or an alkyl group having from 1 to 5 carbon atoms and each of R 5 , R 6 , R 7 , R 8 , R 9 and R 10 is an alkyl group having from 1 to 5 carbon atoms. In an embodiment of this invention each of R 1 and R 2 represents a methyl group (--CH 3 ) and each of R 5 , R 6 , R 7 , R 8 , R 9 and R 10 represents an ethyl group (--CH 2 CH 3 ).
Each of the letters x and y represents either 1 or 0. When x=0, R 3 is absent from formula I and the Si bond extends to a carbon member of the corresponding aromatic ring. When x=1, R 3 is as defined below. In a similar manner when y=0, R 4 is absent from formula I and the Si bond extends to a carbon member of the corresponding aromatic ring. When y=1, R 4 is as defined below.
Each of R 3 and R 4 , when present (i.e. when x=1, y=1), is an alkylene group having from 1 to 30 carbon atoms. The alkylene group can be linear or branched. Examples of alkylene groups within the scope of this invention include, but are not limited to, the following: ##STR3##
A subgenus within the scope of this invention is represented by formula I wherein each of R 3 and R 4 (when present) is an alkylene group having from 1 to 10 carbon atoms. Preferably, each of R 3 and R 4 (when present) is an alkylene group having from 1 to 5 carbon atoms. In an embodiment of this invention each of R 3 and R 4 is present (i.e. x=1 and y=1) and represents an ethylene group (i.e. --CH 2 CH 2 --).
R 1 and R 3 (or Si when x=0) can be bonded to any available carbon atom of the corresponding aromatic ring. The position of R 1 with respect to the sulfur substituent can be ortho, meta or para. The position of R 3 (or Si when x=0) with respect to the sulfur substituent can be ortho, meta or para. In a similar manner R 2 and R 4 (or Si when y=0) can be bonded to any available carbon atom of the corresponding aromatic ring. The position of R 2 with respect to the sulfur substituent can be ortho, meta or para. The position of R 4 (or Si when y=0) with respect to the sulfur substituent can be ortho, meta or para. Examples of various orientations within the scope of this invention include, but are not limited to, the following. ##STR4##
The preferred silane compounds of this invention are defined by the following chemical formula: ##STR5## where n is an integer from 1 to 5. Included are all positional isomers of the above. Examples include, but are not limited to, the following: ##STR6##
The composition can contain more than one silane within the scope of formula I. By way of non-limiting example the poly(arylene sulfide) composition can contain the compounds VII, VIII and IX above. In one embodiment of this invention the poly(arylene sulfide) composition contains two or more silanes defined by ##STR7## wherein the average value of n for the mixture is about 2 to about 4 and preferably about 2.8.
For the purposes of this disclosure and the appended claims the term poly(arylene sulfide) is intended to designate arylene sulfide polymers. Uncured or partially cured poly(arylene sulfide) polymers whether homopolymer, copolymer, terpolymer, and the like, or a blend of such polymers, can be used in the practice of my invention. The uncured or partially cured polymer is a polymer the molecular weight of which can be increased by either lengthening of a molecular chain or by cross-linking or by combination of both by supplying thereto sufficient energy, such as heat. Suitable poly(arylene sulfide) polymers include, but are not limited to, those described in U.S. Pat. No. 3,354,129, incorporated by reference herein.
Some examples of poly(arylene sulfide) suitable for the purposes of our invention include poly(2,4-tolylene sulfide), poly(4,4'-biphenylene sulfide) and poly(phenylene sulfide). Because of its availability and desirable properties (such as high chemical resistance, nonflammability, and high strength and hardness) poly(phenylene sulfide) is the presently preferred poly(arylene sulfide).
In addition to poly(arylene sulfide) and at least one silane the composition can also include, if desired, other materials such as, but not limited to, fillers, reinforcements, processing aids, flow improvers, additives, pigments, etc.
Fillers can be used to improve the dimensional stability, thermal conductivity and mechanical strength of the composition. Some suitable fillers include, for example, talc, silica, clay, alumina, calcium sulfate, calcium carbonate, mica and so on. The fillers can be in the form of, for example, powder, grain or fiber. In selecting a filler for an encapsulation composition the following factors should be considered:
(1) the electrical conductivity of the filler (the lower the better);
(2) the thermal stability of the filler at encapsulation temperatures; and
(3) the level of ionic impurities in the filler.
Suitable reinforcements include fibers of glass or calcium silicate (e.g. wollastonite). Examples of other reinforcements include, but are not limited to glass or calcium silicate in nonfibrous form (e.g. beads, powders, grains, etc.) and fibers of other materials such as asbestos, ceramics, etc.
Although this invention is not limited thereto, a hydrogenated conjugated diene/monovinyl-substituted aromatic copolymer can be included in the poly(arylene sulfide) composition. An example of such a copolymer is hydrogenated butadiene/styrene copolymer. Others are known to persons skilled in the art.
The electrical properties of the encapsulation composition of this invention can also be improved by the addition of zinc oxide.
Besides reinforcements, fillers, copolymers and zinc oxide the compositions can optionally contain relatively small amounts of other ingredients such as, but not limited to, pigments, flow improvers, and processing aids.
There is no maximum limit nor minimum limit to the amount of silane (formula I) that can be employed in the composition of this invention. It is contemplated, however, that the weight ratio of poly(arylene sulfide) to silane will generally be greater than about 2 to 1 and less than about 5,000 to 1. More typically this weight ratio will be greater than about 7 to 1 and less than about 500 to 1. The weight ratio is the ratio of the weight of poly(arylene sulfide) in the composition to the weight of silane in the composition. This weight ratio is calculated with disregard to the presence or absence of other materials, if any, in the composition. If a plurality of silanes is employed the sum of the weights of these silanes is used to calculate the weight ratio.
When other materials are included in the composition the composition will consist of (a) poly(arylene sulfide), (b) at least one silane (formula I) and (c) materials other than (a) or (b) (i.e. "other materials"). Generally, the amount of other materials in the composition will not exceed about 90 weight percent of the composition. More typically the amount of other materials in the composition will not exceed about 75 weight percent. The above weight percentages are calculated on the basis of the total weight of (a), (b) and (c). ##EQU1##
The amount of silane (formula I) to be employed in the composition can also be defined in functional language as the amount sufficient to impart improved insulation resistance to the composition. Improved insulation resistance means that the composition having the silane has better insulation resistance than a composition which does not have the silane but which is otherwise identical in type to the first composition. Insulation resistance can be measured in accordance with the procedure used in the example of this specification.
2. Article of Manufacture
In accordance with one aspect of this invention electronic components such as, but not limited to, connectors, bobbins, coils, relays, etc. are at least partially made from the poly(arylene sulfide) composition of this invention. This aspect of the invention includes all electronic components that can be at least partially made from a resinous composition such as a poly(arylene sulfide) composition.
In accordance with another aspect of this invention electronic components are encapsulated with the poly(arylene sulfide) composition of this invention. The electronic components to be encapsulated in accordance with our invention broadly include all electronic components (i.e. devices, parts, etc.) for which encapsulation is desired. The term electronic component is intended to be broadly construed and includes, by way of non-limiting example, the following:
capacitors,
resistors,
resistor networks,
integrated circuits,
transistors,
diodes,
triodes,
thyristors,
coils,
varistors,
connectors,
condensers,
transducers,
crystal oscillators,
fuses,
rectifiers,
power supplies, and
microswitches.
The definition of each of the above-identified electronic components is similarly intended to be broad and comprehensive. The term integrated circuit, for example, is intended to include, but is not limited to,
large scale integrated circuits,
TTL (transistor transistor logic),
hybrid integrated circuits,
linear amplifiers,
operational amplifiers,
instrumentation amplifiers,
isolation amplifiers,
multipliers and dividers,
log/antilog amplifiers,
RMS-to-DC converters,
voltage references,
transducers,
conditioners,
instrumentation,
digital-to-analog converters,
analog-to-digital converters,
voltage/frequency converters,
synchro-digital converters,
sample/track-hold amplifiers,
CMOS switches and multiplexers,
data-acquisition subsystems,
power supplies,
memory integrated circuits,
microprocessors,
and so on.
The composition used to make or encapsulate the electronic component is broadly described in 1. above. A composition especially well suited for use in the manufacture of electronic components includes about 50 to 70 weight percent poly(arylene sulfide), about 30 to about 50 weight percent reinforcement (e.g. glass fibers) and about 0.1 to about 5 weight percent silane (formula I). The above weight percentages are based upon the total weight of poly(arylene sulfide), reinforcement and silane in the composition. An example of such a composition is given as composition B in the example. Special encapsulation compositions are described in 3. below.
3. Special Encapsulation Compositions
Poly(arylene sulfide) compositions, which are especially well suited for successful use as encapsulation compositions, comprise the following:
(a) poly(arylene sulfide),
(b) at least one silane (formula I),
(c) reinforcement, and
(d) filler.
These compositions can optionally contain, in addition to (a), (b), (c) and (d) above, relatively small amounts of other components such as, for example, hydrogenated conjugated diene/monovinyl-substituted aromatic copolymers, zinc oxide, organosilanes, pigments, flow improvers, additives, processing aids, etc. These compositions are described in more detail in A and B below.
It should be noted that the first list of electronic components given in 2. above includes both active components (such as, for example, integrated circuits, transistors and diodes) and passive components (such as, for example, capacitors, resistors and resistor networks). The distinction is frequently important and is often determinative of the type of poly(arylene sulfide) encapsulation composition best suited for encapsulation of the component. Accordingly, compositions for the encapsulation of active and passive components are described separately in A and B below.
A. Compositions for the Encapsulation of Active Components
Compositions used for the encapsulation of active components can be prepared in accordance with the following weight percentages:
(a) Poly(arylene sulfide): about 25 to about 45 wt % broad range, about 32 to about 38 wt % preferred range.
(b) At least one silane (formula I): about 0.1 to about 10 wt % broad range, about 0.5 to about 5 wt % preferred range.
(c) Reinforcement: about 5 to about 30 wt % broad range, about 10 to about 20 wt % preferred range.
(d) Filler: about 40 to about 60 wt % broad range, about 45 to about 55 wt % preferred range.
The above weight percentages are based upon the total amount of (a), (b), (c) and (d) in the composition. Other components, including those previously identified, can optionally be present.
The broad ranges represent the ranges within which the composition should be confined in order to obtain good results. The preferred ranges are preferred because they define a composition possessing the physical, chemical and electrical properties best suited for its intended encapsulation purposes.
Although our invention is not limited thereto the viscosity of the composition used for encapsulation of active components should generally not exceed about 800 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec) -1 ). Encapsulation of active electronic components with compositions having viscosities in excess of about 800 poise can cause damage to the components. It is contemplated that the viscosity of the composition will generally range from about 150 to about 500 poise for active components other than very delicate components such as, for example, integrated circuits with wire leads. With respect to very delicate components such as, for example integrated circuits with wire leads, the viscosity of the encapsulation composition should be below about 150 poise (as tested on a capillary rheometer at 650° F. at a shear rate of 1000 (sec) -1 ). Encapsulation of integrated circuits with compositions any higher in viscosity can cause wire wash (i.e., breaking of the wires of the integrated circuit). It is contemplated that the viscosity of the composition for the encapsulation of such integrated circuits and the like will generally range from about 75 to about 150 poise.
Although viscosity of the composition depends on a number of factors, to obtain composition viscosities below about 800 poise the viscosity of the poly(arylene sulfide) should generally not exceed about 130 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec) -1 ). It is contemplated that the viscosity of the poly(arylene sulfide) will, in most applications, range up to about 70 poise. To obtain composition viscosities within the desired range for delicate active components such as, for example, integrated circuits with wire leads, the viscosity of the poly(arylene sulfide) should generally be less than about 25 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec) -1 ).
The reinforcements can be, for example, glass fibers of calcium silicate fibers.
The filler can be, for example, silica. The silica can be amorphous silica or crystalline silica. Silica is commercially available as a finely ground material having a relatively narrow particle size distribution ranging from about 1 to about 100 micrometers.
Other fillers include, for example, talc, glass, clay, mica, calcium sulfate and calcium carbonate.
The preferred encapsulation composition for active components is prepared from:
(a) about 32 to about 38 wt % poly(phenylene sulfide) (viscosity less than about 130 poise as tested on a capillary rheometer at 650° F. and at a shear rate of about 1000 (sec) -1 ),
(b) about 0.5 to about 5 wt % silane (formula I),
(c) about 10 to about 20 wt % glass fibers or calcium silicate fibers, and
(d) about 45 to about 55 wt % silica.
The above weight percentages are based upon the total amount of (a), (b), (c) and (d) in the composition. Other components, including those previously identified, can optionally be present.
If the viscosity of the poly(phenylene sulfide) is below about 25 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec) -1 ) this composition is especially well suited for the encapsulation of integrated circuits with wire leads. Accordingly, integrated circuits encapsulated with this composition, represent one embodiment of my invention.
B. Compositions for the Encapsulation of Passive Components
Compositions used for the encapsulation of passive components can be prepared in accordance with the following weight percentages:
(a) Poly(arylene sulfide): about 25 to about 45 wt % broad range, about 32 to about 38 wt % preferred range.
(b) At least one silane (formula I): about 0.1 to about 10 wt % broad range, about 0.5 to about 5 wt % preferred range.
(c) Reinforcement: about 20 to about 50 wt % broad range, about 25 to about 45 wt % preferred range.
(d) Filler: about 18 to about 38 wt % broad range, about 23 to about 33 wt % preferred range.
The above weight percentages are based upon the total amount of (a), (b), (c) and (d) in the composition. Other components, including those previously identified, can optionally be present.
The broad ranges represent the ranges within which the composition should be confined in order to obtain good results. The preferred ranges are preferred because they define a composition possessing the physical, chemical and electrical properties best suited for its intended encapsulation purposes.
Although our invention is not limited thereto the viscosity of the composition used for encapsulation of passive components should generally not exceed about 1200 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec) -1 ). Encapsulation of passive electronic components with compositions having viscosities in excess of about 1200 poise can cause damage to the components. It is contemplated that the viscosity of the composition will generally range from about 500 to about 800 poise.
To obtain composition viscosities within the desired ranges the viscosity of the poly(arylene sulfide) should generally not exceed about 300 poise (as tested on a capillary rheometer at 650° F. and at a shear rate of 1000 (sec) -1 ). It is contemplated that the viscosity of the poly(arylene sulfide) will generally range from about 190 to about 300 poise.
The reinforcements can be, for example, glass fibers or calcium silicate fibers.
The preferred filler is talc because of its availability and ability to improve the dimensional stability, thermal conductivity and mechanical strength of the composition. In place of talc, or in combination with talc, other fillers can be used. Examples of such suitable fillers include, silica, calcium sulfate, calcium carbonate, clay, glass and mica. Calcium sulfate is especially useful in compositions used to encapsulate connectors.
The preferred encapsulation composition for passive components is prepared from:
(a) about 32 to about 38 wt % poly(phenylene sulfide) (viscosity less than about 300 poise as tested on a capillary rheometer at 650° F. and at a shear rate of about 1000 (sec) -1 ),
(b) about 0.5 to about 5 wt % silane (formula I),
(c) about 25 to about 45 wt % glass fibers or calcium silicate fibers, and
(d) about 23 to about 33 wt % talc.
The above weight percentages are based upon the total amount of (a), (b), (c) and (d) in the composition. Other components, including those previously identified, can optionally be present.
This composition is especially well suited for, but not limited to, the encapsulation of capacitors. Accordingly, capacitors, encapsulated with this composition, represent an embodiment of my invention.
4. How to Make
Suitable silanes can be obtained from Union Carbide Corporation under the product name Union Carbide Organofunctional Polysulfide Silane Y-9194. Silane Y-9194 is a mixture of compounds within formula I wherein R 1 and R 2 are --CH 3 ; wherein R 3 and R 4 are --CH 2 CH 2 --; wherein R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are --CH 2 CH 3 ; wherein x=1 and y=1; and wherein the average value of n is about 2.8. Use of Silane Y-9194 represents the best mode of this invention as presently contemplated by the inventor. Other compounds within the scope of formula I can be made by modification of Silane Y-9194 or through separate synthesis routes. Persons skilled in the art can employ known techniques of silicon esterification, aromatic substitution, etc. to produce the compounds of formula I in a variety of ways. The method employed in making the silanes of formula I is immaterial to the practice of this invention.
The compositions of this invention can be made in accordance with any method wherein the poly(arylene sulfide), silane(s) (formula I) and other components (if any) are combined to form a mixture. Many suitable methods are well known to those of skill in the art. By way of example, the components of the composition can be mixed together at room temperature in a rotating drum blender or in an intensive mixer such as a Henschel mixer and then extrusion compounded at a temperature above about the melting point of the poly(arylene sulfide) to produce a uniform blend.
Once made, the composition can be used to encapsulate electronic components in accordance with any encapsulation method suitable for thermoplastic encapsulation compositions. Such methods are well known in the art. The composition can be heated to a temperature of at least about the melting point of the poly(arylene sulfide) and then used to encapsulate electronic components. The composition can, for example, be introduced into an injection molding apparatus to produce a melt which is extruded into an injection mold wherein the electronic component to be encapsulated is positioned. Transfer molding processes are also acceptable.
The following example is presented to facilitate disclosure of this invention and should not be interpreted to unduly limit its scope.
EXAMPLE
In this example four poly(phenylene sulfide) compositions (identified as A, B, C and D) are compared. Compositions A and C were prepared without the silane. Compositions B and D were prepared using Silane Y-9194. Since Y-9194 is a mixture of silanes within formula I wherein R 1 and R 2 are --CH 3 ; wherein R 3 and R 4 are --CH 2 CH 2 --; wherein R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are --CH 2 CH 3 ; wherein x=1 and y=1; and wherein the average value of n for the mixture is about 2.8. The components of each composition are given below in Table 1.
TABLE 1______________________________________ Weight Percentages.sup.g Composition:Components A B C D______________________________________poly(phenylene sulfide).sup.a 60 59 35 35fiberglass.sup.b 40 40 35 35Silane Y-9194.sup.c 1 1talc.sup.d 28.6 27.6polyethylene.sup.e .25 .25pigment.sup.f 1.15 1.15______________________________________ .sup.a Ryton ®, Phillips Chemical Company .sup.b Owens Corning Grade 197 .sup.c Union Carbide Organofunctional Polysulfide Silane Y9194 .sup.d Type 2620 Talc, Riblin, Dallas, Tx. .sup.e Marlex ®, Phillips Chemical Company .sup.f Mixture of inorganic pigments .sup.g The weight percentages are based on the total weight of the components in the composition.
Each composition was prepared as follows. The specified components were charged to a Henschel mixer and mixed until completely dispersed. The mixture was passed through a Buss-Condux cokneader extruder at 570°-600° F. and pelletized. The pelletized product was injection molded using a 35 ton Arbrug molding machine (650° F. stock temperature, 6000 psi and 275° F. mold temperature into flat test specimens (2.5 inches×2.5 inches×0.125 inches).
The flat test specimens were used to determine the electrical insulation resistance of the composition. Three holes, each 0.25 inches in diameter and located in a triangular pattern about 1.25 inches apart, were drilled in the disc. A metal bolt (with nut and washer) was attached through each hole. A single tinned copper wire was attached to each bolt. The wired specimens were conditioned for 48 hours in a 95±1% relative humidity chamber at 90° C. After the 48 hours exposure the resistance between each pair of leads at a potential of 500 volts AC was measured using a Gen Rad Megohmeter (type 1864) having the capability to measure resistance up to 2×10 14 ohm. For each pair of leads two measurements were made, i.e. a first measurement and a second measurement about 1 minute after the first. After all three pairs of leads had been measured the average value of the first measurements was calculated and the average value of the second measurements was calculated. Resistance readings were again taken after 192 hrs., 384 hrs. and 787 hrs. The average electrical insulation resistance for the 1 minute measurement is shown in Table II.
TABLE II______________________________________Insulation Resistance ΩComposition 48 hrs. 192 hrs. 384 hrs. 787 hrs.______________________________________A 4.5 × 10.sup.10 2.5 × 10.sup.9.sup. 6.1 × 10.sup.8.sup. 2.3 × 10.sup.8.sup.B 5.3 × 10.sup.13 7.5 × 10.sup.12 3.2 × 10.sup.12 1.9 × 10.sup.12C 1.6 × 10.sup.11 5.5 × 10.sup.10 4.1 × 10.sup.10 3.1 × 10.sup.10D 4.7 × 10.sup.13 1.1 × 10.sup.13 5.6 × 10.sup.12 4.1 × 10.sup.12______________________________________
The data clearly show that compositions B and D which contained Silane Y-9194 consistently exhibited signficantly higher insulation resistance than compositions A and C. | At least one of certain silanes is added to a poly(arylene sulfide) composition. The silane increases the electrical insulation resistance of the composition. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to swarf collecting apparatus and methods and more specifically to a method of controlling a swarf collecting conveyor to clear swarf obstructions which cause excessive conveyor motor and drive component loading.
Many industries routinely employ lathes, drills, mills and other machinery having specially configured cutting bits to shape metal work pieces by removing metal “chips” therefrom. The chips which are removed come in many different shapes and sizes which are collectively referred to as swarf.
Many work piece shaping processes require a plurality of machines arranged at sequential work stations along a machine line. In these instances, after shaping at one station, a work piece is conveyed to a subsequent station for further shaping, each station generating swarf during the process.
To remove swarf from machine stations, often a conveyor belt is positioned below or adjacent a machine line to automatically catch flushed swarf and convey the swarf to a collection bin at the end of the belt. When the bin is full it is emptied or replaced with another bin. To facilitate use of large collection bins and thereby increase the time between emptying or replacement, most conveyors include a section which conveys upwardly at an inclined angle (e.g. 45 degrees) so that a belt end can be located above an elevated bin wall. To maintain swarf on the belt during inclined conveying (i.e. impede swarf from falling off lateral edges of the conveyor), a conveyor housing including a roof section is typically provided along the inclined section. Conveyor belts are particularly useful where the number of work stations and associated metal removing machines is large.
To cool work pieces and machine cutting tools and to flush swarf away from cutting bits during machining, a liquid coolant is typically dispersed at or near the cutting bits. In addition, swarf inside the bin or on the belt may be cooled by direct coolant dispersion thereon.
Swarf conveyor belts are typically driven by a motor capable of driving the belt in at least a forward direction. During machining, the belt is continuously driven to convey swarf from work stations.
Unfortunately swarf removing systems of the above kind can become obstructed by swarf during operation in at least two different ways. First, swarf can cause conveyor clogging. Only a certain swarf volume can pass though a conveyor housing at any time. Where swarf accumulates adjacent or within a housing, eventually, the accumulation can clog between the belt and housing impeding belt movement.
Second, swarf can become entangled between a belt and a stationary conveyor component (e.g. the housing) acting as a harness impeding belt movement. In this case, an elongated piece of swarf, typically a long corkscrew shaped shaving, can become ensnared at opposite ends between the belt and another component restricting belt movement.
In addition to damaging belt and other conveyor components, clogging and other forms of belt restriction caused by swarf (and or parts, bar ends, tools, etc.) increase motor load and, at some point, can damage motor components if the load becomes excessive.
One solution to belt obstructions has been to equip conveyors with manually operable motors capable of both forward and reverse operation. In this case, when swarf conditions cause motor overloading, an operator can stop the belt, reverse the belt, clear the obstruction and again restart the belt. Removing an obstruction is referred to herein as “clearing”.
Unfortunately, this solution to the problem has a number of shortcomings. First, this solution requires an operator to assist what is otherwise an automatic system for removing swarf from work stations. While the operator only needs to act after a clog or entanglement is detected, practically the operator must always be present to identify clogs and entanglements.
Second, where the time required to clear a belt is appreciable, an entire machine line may have to be shut down during the clearing process, further increasing costs associated with the system.
Third, if the obstruction is not noticed immediately, clogged swarf may cause belt, housing and/or motor damage prior to an operator stopping the belt.
Fourth, if the obstruction is not noticed immediately, swarf may accumulate upstream of the clog and fall from the belt. In addition, excessive cooling agent may be flushed into the belt system generally causing a mess or overflowing onto the floor.
Fifth, where the obstruction occurs inside the housing, it may be difficult for an operator to identify the obstruction until swarf backs up to the mouth of the housing.
Another solution for removing swarf obstructions is to provide an automatic clutch on the motor which allows the shaft which drives the belt to slip when motor load becomes excessive. In this case, instead of damaging motor and conveyor components, a clutch allows the motor to operate with a safe load and the belt stops until an operator can perform a clearing process to remove the obstruction.
While this solution reduces the possibility of motor and conveyor component damage, it to is encumbered with shortcomings. For example, this solution still requires an operator to be present to clear every obstruction that occurs. In addition, when the belt is stopped due to overloading, either the entire machine line must be shut down or swarf will continue to accumulate on the belt. Shutting down the entire line is costly. However, swarf accumulation can eventually exceed belt receiving capacity with excess swarf falling off the belt onto a floor surface. This is especially dangerous when swarf is extremely hot as is often the case with metal shavings or the like.
Moreover, as swarf accumulates on a stationary belt during clearing, the accumulated swarf causes conditions which will likely lead to further obstruction once the belt is again running in the forward direction.
One solution to the swarf jamming problem is described in U.S. patent application Ser. No. 09/081,538 entitled “Method and Apparatus for Controlling Conveyor” filed on May 19, 1998. That application teaches a system wherein conveyor motor load is sensed and, when the load exceeds a predetermined load likely to correspond to a jam, the conveyor is stepped through a jam clearing process a specific number of times, the process and number of times calculated to likely clear the jam. For example, the clearing process may be to reverse the conveyor motor a given number of turns and then, once again, drive the motor in the forward direction. In the alternative the clearing process may be to reverse the conveyor until the conveyor has traveled in the reverse direction a specific distance and then, once again, drive the conveyor in the forward direction.
While this solution including counting the number of clearing processes is much better than prior solutions, under certain circumstances even this solution can be insufficient to protect the motor and conveyor components. For example, where each clearing process includes reversing the conveyor motor until a clearing process milestone is achieved prior to driving the motor in the forward direction, the milestone may never be reached if the jam also prohibits reverse conveyor travel. For example, where a clearing process requires 10 motor rotations prior to again driving the motor in the forward direction, if a jam impedes reverse conveyor travel, the 10 rotations are never achieved and the motor may either be damaged or destroyed. Similarly, if the milestone is a specific conveyor reverse travel distance, the reverse distance will never be achieved if reverse motion is impeded.
Moreover, even where a jam does not prohibit reverse motion, the jam may impede reverse motion such that reverse motion is slowed to the point where excessive load is placed on the motor.
In addition, even with a single machining process swarf characteristics may vary appreciably in ways that affect the optimum clearing protocol. For example, where swarf consists of relatively light weight pieces of metal, the torque required to drive the motor and conveyor in the reverse direction may be much smaller than the torque required to drive in reverse when swarf consists of relatively heavy metal pieces. Given a threshold total amount of motor work acceptable during a clearing process, the threshold is achieved with less clearing processes when the swarf includes heavy pieces and the load is large than with light weight pieces when the load is small. Thus, the optimum number of clearing processes where swarf pieces are light weight will often be greater than the optimum number when the pieces are large.
Furthermore, the likelihood of eliminating a jam via a clearing process is also related, in some respects, to swarf piece size. For example, On one hand where swarf pieces are relatively small jams that do occur will likely be relatively easy to eliminate as any jam will likely constitute a small swarf piece that can be dislodged relatively easily. On the other hand, where swarf pieces are relatively large jams that do occur will likely constitute swarf piece that are much larger and hence more difficult to move. With that said, it is likely that, given the same clearing process, it can be predicted that a small swarf jam would be easier to clear than a large swarf jam. For this reason the optimum number of clearing processes to be performed would also depend upon swarf size. A simple clearing process counting mechanism does not account for these differences.
Thus, a need exists for a system that will facilitate a clearing process when a conveyor jam occurs but that will protect the conveyor motor in the event that clearing process milestones cannot be achieved and that will cause an optimum clearing process independent of swarf characteristics.
BRIEF SUMMARY OF THE INVENTION
The present inventor has recognized that all of the problems with the prior art systems described above can be address by providing a clearing procedure that is time based instead of being based on a specific number of completed clearing processes. To this end, when a jam is detected due to excessive motor load, the present invention requires that a clearing protocol including a series of clearing processes commence and that a timer begin timing the duration of the clearing protocol. When the timer reaches a specific threshold value calculated to likely clear any jam, the system aborts the protocol independent of the number of separate processes that were completed.
Thus, even if a jam prohibits reverse conveyor motion the present invention protects the conveyor motor from damage. Similarly, even where a jam impedes reverse motion the inventive system will stop driving the motor in reverse prior to motor damage.
After a specific time is set for the timer, the system automatically adjusts the number of clearing processes as a function of swarf characteristics so that the number of processes varies and is at least closer to the optimum number corresponding to the specific swarf characteristics. This is because heavy swarf typically results in a greater load on the motor and hence slows the reverse and forward conveyor motion. In this case any given reverse and forward clearing process takes longer when swarf is heavy than when swarf is relatively light. Therefore, given a specific clearing protocol period, the number of clearing processes corresponding to light swarf is greater than the number corresponding to light swarf.
Similarly, where swarf size is small the overall weight corresponding to a jam will likely be much greater than where swarf size is large as swarf density on the conveyor would likely be greater. Thus, the great weight of small swarf pieces would slow the clearing processes and hence a smaller number of processes would occur in a given clearing protocol time period when compared to large swarf pieces. This is the desired effect. For example, as indicated above, where swarf pieces are small it is relatively more likely that a clearing process will eliminate a jam than where swarf pieces are large. Thus, where swarf pieces are small, the number of clearing processes expected to clear a jam also small. The number of clearing processes with the present invention is related to swarf size such that small swarf naturally results in a reduced number of clearing processes and large swarf results in a greater relative number of clearing processes.
These and other objects, advantages and aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a side elevational view of a swarf conveyor belt assembly and a control system according to the present invention;
FIG. 2 is an end elevational view of the conveyor of FIG. 1;
FIG. 3 is a cross-sectional view taken along the line 3 — 3 of FIG. 1;
FIG. 4 is a cross-sectional view taken along the line 4 — 4 of FIG. 1;
FIG. 5 is a schematic of the inverter of FIG. 1;
FIG. 6 is a flow chart illustrating an inventive method used by a controller to control the conveyor of FIG. 1;
FIG. 7 is a flow chart illustrating another inventive method according to the present invention; and
FIG. 8 is a block diagram illustrating the components of the controller of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
I. Hardware Configuration
Referring now to the drawings, where like reference characters represent corresponding elements throughout the several views, and more specifically referring to FIGS. 1 and 2, the present invention will be described in a context of an exemplary swarf conveyor system 10 . System 10 generally comprises five components or assemblies including a conveyor 12 , a motor 14 for driving the conveyor 12 , an inverter 16 for driving motor 14 , a parameter programming unit 18 and a computerized numerical controller 20 .
Referring to FIG. 4, conveyor 12 includes a belt-guiding track 22 , a track cover 24 and a conveyor belt 26 . Referring specifically to FIG. 1, track 22 defines a course of movement for belt 26 . To this end, track 22 includes a first horizontal section L 1 , a second horizontal section L 2 disposed generally above section L 1 , and an inclined section L 3 between horizontal sections L 1 and L 2 .
Referring to FIGS. 1, 3 and 4 , track 22 includes several different walls including a bottom horizontal wall 19 , a central horizontal wall 21 and two lateral vertical walls 23 and 25 . Walls 19 , 21 , 23 and 25 together define an upper channel 30 and a lower channel 32 below channel 30 along the entire length of track 22 .
Two low friction runners 36 and 38 are positioned on an upwardly facing surface 40 of wall 19 . Runners 36 , 38 are parallel, separated and extend along the entire length of track 22 . Similarly, a pair of low friction runners 42 , 44 are secured to an upwardly facing surface 46 of wall 34 in channel 30 . Runners 42 and 44 are also parallel, separated and extend along the entire length of track 22 .
Swarf guidance extensions 48 and 50 extend inwardly from facing surfaces of walls 23 and 25 above runners 42 and 44 . An upper surface 52 , 54 of each extension 48 , 50 respectively, slopes downwardly as it extends inwardly. Surfaces 52 and 54 help guide swarf onto belt 26 within channel 30 .
Referring to FIGS. 1 and 2, track 22 is supported by a leg 58 connected to section L 3 . Leg 58 includes two wheels collectively referred to by the numeral 60 that facilitate conveyor 12 movement. A rotating pulley-type hub 28 is located at a first end 22 a and a laterally extending motor housing (see FIG. 2) 56 is located at a second end 22 b of track 22 .
Track cover 24 (see FIGS. 1 and 4) is provided above channel 30 along sections L 2 and L 3 and along a section of L 1 adjacent L 3 . A door 62 is hinged to cover 24 at track end 22 b which covers end 22 b when closed but is openable by swarf exiting the track. A swarf collection bin 69 is illustrated in phantom.
Belt 26 can be of any design known in the art and therefore will not be explained here in detail. Suffice it to say that belt 26 is continuous and passes from channel 30 into channel 32 around a motor shaft at end 22 b and passes back from channel 32 into channel 30 around hub 28 at end 22 a. Belt 26 is sized so that it rests on, and is supported by, runners 36 , 38 , 42 and 44 .
Motor 14 is a typical three-phase squirrel cage induction motor, the characteristics of which should be understood by those of ordinary skill in the art and therefore will not be explained here in detail. However, it should be understood that motor 14 receives three-phase alternating voltage from inverter 16 which causes the motor to rotate in either a forward or reverse directions at either a high, a medium or low speed, depending on the frequency of the received alternating voltage. Motor 14 is located inside housing 56 and includes a shaft which extends from housing 56 into track 22 at end 22 b and is suitably linked to belt 26 to provide a rotating motivating force thereto. Therefore, when motor 14 operates in either the forward or reverse directions, the motor shaft causes belt 26 to move accordingly, conveying belt 26 in either forward or reverse directions.
Referring now to FIG. 5, inverter 16 receives three-phase AC line voltage from a utility on lines 64 , 66 and 68 at a utility frequency (e.g. 60 Hz) and modifies that frequency to provide three-phase alternating voltage at a controlled frequency on output lines 70 , 72 and 74 . Lines 70 , 72 and 74 supply motor 14 . Inverter also includes a brake output line 78 connected to motor 14 for stopping the motor 14 when required. A preferred inverter is the Mitsubishi Freqrol-A024 or the Freqrol-A044. Inverter 16 includes several input leads including forward start STF, reverse start STR, high speed HS, medium speed MS, stop select SS, and alarm reset RES leads. When a command signal to any of the leads (STF, STR, HS, MS, SS or RESP) is high, inverter 16 operates accordingly. For example, when a command signal to forward start lead STF is high, inverter 16 provides AC voltages on lines 70 , 72 and 74 driving motor 14 in the forward direction. Similarly when a command signal to reverse start lead STR is high, inverter 16 drives motor 14 in the reverse direction. When the signal at STF is high and neither the signal at high-speed lead HS nor at medium speed lead MS is high, inverter 16 drives motor 14 at a low speed. However, when either of the signals at HS or MS is high, inverter 16 drives motor 14 at the high or medium speeds, respectively. When the signal at stop select lead SS is high, inverter 16 uses line 78 to immediately stop motor 14 .
In addition to the three-phase voltages on line 70 , 72 and 74 and the brake output 78 , inverter 16 also includes at least one other output, a high load output on line 76 . As inverter 16 provides voltages on lines 70 , 72 and 74 , inverter 16 monitors the current drawn by motor 14 on one of the three lines 70 , 72 or 74 . For the purposes of this explanation it will be assumed that inverter 16 at least monitors a drawn current I f on line 70 . When the monitored current I f exceeds a threshold current level I th , a signal is provided on line 76 indicating that a high load has occurred. As well known in the motor controls art, current drawn by an induction motor increases as load on the motor increases. Therefore, when the load on motor 14 reaches a level which draws a current equal to the threshold current level I th , a signal is provided on line 76 .
In addition, inverter 16 can be provided with an alarm output 77 to indicate when monitored current I f exceeds threshold current I th .
Referring to FIGS. 1 and 5, parameter-programming unit 18 is connected to inverter 16 via a first bus 80 . Unit 18 includes a digital readout 82 and a keypad 84 which allow a user to program various inverter parameters via bus 80 . To this end, unit 18 can be used to set the threshold current level I th which is required prior to inverter 16 generating a signal on line 76 . In addition, unit 18 can be used to set a number of other parameters including high speed, medium speed and low speed frequencies, and can be used to manually run motor 14 in reverse, forward and at various speeds via inverter 16 .
Referring to FIG. 1 controller 20 includes a touch screen 88 and an abbreviated keypad 90 which allow an operator to control inverter 16 and monitor motor 14 operation. In addition, referring also to FIG. 8, controller 20 includes a programmable microprocessor 200 that controls inverter 16 during motor operation as a function of the output on line 76 . To this end, line 76 is received by controller 20 and a second bus 86 provides control signals from controller 20 to inverter leads STF, STR, HS, MS, SS and RESP. Thus, controller 20 can drive motor 14 via inverter 16 in the forward direction or the reverse direction at various speeds, can stop motor 14 and can reset an inverter alarm via the inputs. Processor 200 may include a timer 202 for timing the duration of a series of clearing processes as explained in more detail below.
Controller 20 can also be used to alter operating parameters such as the duration T r0 of the reverse rotation periods during a clearing process and the maximum number X m of clearing processes in a clearing method.
II. Control Method
Generally speaking, according to the inventive control method, with motor 14 operating in a forward direction so that conveyor 12 is moving forward, load on motor 14 will remain relatively constant and within an acceptable range during normal operation. However, when swarf obstructs belt 26 movement, motor load increases substantially. When load increases, the current drawn by motor 14 from inverter 16 also increases substantially. At some point, if the obstruction causes excessive loading, the drawn current exceeds the threshold current. Inverter 16 detects excessive load by comparing the monitored current I f drawing by motor 14 to the threshold current I th . When current I th is exceeded the maximum load is exceeded. At that point, inverter 16 generates a signal on line 76 which is provided to controller 20 . Then, to clear the obstruction, controller 20 sends a series of command signals via bus 86 to inverter 16 to stop motor 14 , reverse motor 14 for the predetermined reversal time period T r0 , stop motor 14 and restart motor 14 in the forward direction. This sequence of stopping, reversing, stopping and restarting in the forward direction will typically be sufficient to jostle an obstruction free.
If the obstruction persists, monitored motor drawn current I f will again quickly exceed the threshold current I th and the excessive load will again be identified. Once again, inverter 16 provides a signal via line 76 to controller 20 which in turn cycles through the clearing process. After a predetermined number X m of times through the clearing process, if the obstruction persists, controller 20 causes inverter 16 to stop motor 14 and sound an alarm via output 77 , either audio or visual or both, altering an operator that belt 26 has been halted.
Referring now to FIGS. 1, 5 and 6 , prior to conveyor 12 operation, controller 20 and unit 18 are used to set various operating parameters. Specifically, unit 18 is used to set the threshold current I th parameter while controller 20 is used to set the predetermined number X m of clearing processes which should be performed prior to stopping conveyor 12 and is used to set reverse time period T r0 . These parameters are set at process block 100 . Next, at block 102 controller 20 initializes a process number variable X and sets variable X equal to 0. Continuing, at process block 104 a counter T r is set equal to period T r0 and controller 20 provides a high command signal to the forward start lead STF of inverter 16 . When the STF command is received, inverter 16 provides output voltages on line 70 , 72 and 74 driving motor 14 and belt 26 in the forward direction.
At decision block 106 inverter 16 determines whether or not monitored current I f is equal to or exceeds the threshold current I th . To this end, inverter 16 monitors current I f through line 70 and compares that current I f to the threshold current I th . If monitored current I f is less than threshold current l th , the motor load is less than the maximum load and controller 20 control passes back up to process block 102 . However, when monitored current I f is greater than or equal to threshold current I th , control passes to process block 108 where variable X (i.e. number of clearing processes performed) is incremented by 1. Control then passes to decision block 110 where controller 20 determines whether or not variable X is equal to maximum number of clearing processes X m . Where variable X is equal to maximum number X m , the clearing process including stopping, reversing, stopping and restarting the belt in the forward direction has been completed X m times without successfully clearing the obstruction which is causing the excessive load. In this case, the clearing process will not likely be able to clear the obstruction and therefore, control passes to process block 112 where controller 20 sends a control signal via bus 86 to the stop select lead SS of inverter 16 . When inverter 16 receives the SS signal, inverter 16 stops motor 14 via brake output 78 thus causing conveyor belt 26 to stop. In addition, at block 112 , inverter 16 generates an alarm signal via output line 77 indicating that belt 26 has been halted.
Referring still to FIGS. 1, 5 and 6 , at decision block 110 , when variable X is less than maximum number X m , control passes to block 114 where the clearing process begins. To this end, at block 114 , controller 20 first provides a high control signal at lead SS causing inverter 16 to stop motor 14 and belt 26 . Then, controller 20 provides a high signal at reverse start lead STR which in turn causes motor 14 and belt 26 to move in the reverse direction. In addition, at block 114 controller 20 starts a timer which tracks the amount of time motor 14 is operating in the reverse direction. The timer counts down counter T r to zero. At decision block 116 controller 20 determines whether or not counter T r is equal to zero. Where counter T r is not equal to zero, control loops back to decision block 116 . When counter T r is equal to zero, control passes to block 118 where controller 20 again sends a high signal to inverter lead SS causing inverter 16 to stop motor 14 and belt 26 . Next, control again passes up to process block 104 where controller 20 resets counter T r to period T r0 and again provides a forward rotation start input signal STF to converter 16 . Again, when signal STF is received, inverter 16 drives motor 14 in the forward direction-causing belt 26 to move forward. At block 106 , if the motor load is less than the maximum load, the monitored current I f will be less than the threshold current level I th and control will again pass up block 102 .
Thus, a simple, inexpensive and reliable method and apparatus for implementing the method for automatically clearing swarf obstructions on a conveyor belt have been described.
Referring now to FIGS. 1, 8 , controller 20 can also be used to manage a swarf clearing procedure or process as a function of time as opposed to a function of the number of clearing attempts or cycles performed. To this end, referring also to FIG. 7, an exemplary inventive time based clearing method is illustrated as a flow chart beginning at process block 210 . At block 210 a clearing cycle is programmed selected or defined to be performed by processor 200 . The defining step can be performed via any type of interface (e.g., keypad 90 or touch screen 88 ). In addition, the predetermined duration for an ensuing clearing procedure or series of clearing cycles is defined at step 210 via the interface. To this end it is assumed that a system user that understands the process in which the swarf conveyor is used is available to provide the predetermined time. The skilled user bases the predetermined time on the likely duration of each swarf clearing cycle (i.e., the separate clearing efforts), the type of swarf (e.g., large or small, etc.) expected, the nature of a likely obstruction (i.e., easy or difficult to clear), etc.
After the process and time have been set a timed period counter Tt that is tracked by timer 202 (see FIG. 8) is set equal to zero at block 212 . At block 214 the inverter is powered to drive the conveyor belt in the forward direction,
At decision block 216 processor 200 determines whether or not monitored current I f is equal to or exceeds the threshold current I th . To this end, processor 200 monitors current I f through line 70 via the inverter 16 and compares that current I f to the threshold current I th . If monitored current I f is less than threshold current I th , the motor load is less than the maximum load and controller 20 control passes back up to process block 212 . However, when monitored current I f is greater than or equal to threshold current I th , control passes to decision block 218 .
At block 218 processor 200 enables timer 202 and timer 202 begins to time the duration of the clearing procedure that follows. After block 218 , at decision block 222 processor 200 compares the timed period Tt to the predetermined period T 1 . Where the timed period Tt is equal to or greater than the predetermined period T 1 the clearing procedure has already been performed for a period equal to the predetermined period and processor 200 turns the conveyor off. In addition, at this time processor 200 sounds an alarm indicating that a conveyor operator should manually check the conveyor to determine the cause of the obstruction and how to clear the obstruction. To this end, where the timed period is equal to the predetermined period control passes to block 224 .
Where the timed period Tt is less than the predetermined period T 1 , control passes to block 200 and the clearing procedure is enabled. When an obstruction has just occurred, enabling means commencing a first clearing cycle. For example, the defined clearing cycle may include stopping the motor, reversing the motor for a time or distance or for a number of rotations or until a specific reverse speed is obtained, etc., stopping the reverse action and then restarting the motor in the forward direction.
Next, control passes back up to decision block 216 where the measured current If is again compared to the threshold current and control continues to loop through steps 216 , 218 , 222 and 220 , possibly stopping at block 224 if an obstruction does not clear.
An example of how the time limited clearing procedure might operate is instructive. To this end, assume that an average clear cycle (e.g., stopping, reversing, stopping and again driving the conveyor forward) takes approximately 4 seconds and that a system user has programmed processor 200 to attempt to clear any obstructions for a predetermined 20 second period. In operation, referring still to FIGS. 7 and 8, with period Tt set equal to zero, the predetermined period T 1 set equal to 20 seconds and the motor operating in a forward direction, if the measured current If is less than the threshold current Ith, control continues to loop through blocks 212 , 214 and 216 . However, when the measured current If exceeds or is equal to the threshold current Ith, control passes to block 222 . Because period Tt is initially zero, at block 222 control passed to block 218 where clock 202 is enabled and begins to time period Tt. At block 220 the clearing process is commenced and control passes back up to block 216 .
The second time through blocks 216 , 222 and 218 , if the measured current If is less than the threshold current Ith control passes back to block 212 where time Tt is re-zeroed. However, assuming measured current If is equal to or greater than the threshold current Ith, at block 222 time Tt will be approximately 4 seconds after the first clearing cycle is completed and time period Tt will be less than the 20 second period T 1 . Thus, control will again pass to block 218 where clock 202 will remain enabled.
Assuming the obstruction remains uncleared by the clearing cycles, during the next four 4 second cycles as control passes through blocks 216 , 222 , 218 and 220 time period Tt will be less than predetermined period T 1 such that control does not pass back up to block 212 . During the clearing cycle following the next four (i.e., during the sixth overall sequential 4 second clearing cycle), time period Tt will exceed predetermined period T 1 and control will pass to block 224 where the conveyor is turned off and the alarm is sounded.
It should be understood that the methods and apparatuses described above are only exemplary and do not limit the scope of the invention, and that various modifications could be made by those skilled in the art that would fall under the scope of the invention. For example, while the method is described in the context of an inverter and an inverter controlled motor, clearly the inventive method could be implemented using some other motor drive type wherein motor load could be determined by some other means. For example, a clutch type motor could be used wherein, when the clutch disconnects the motor from a driving shaft due to excessive motor load, a sensor could detect the disconnection and start the clearing process above. In addition, while the conveyor described above includes a single motor, clearly the inventive method applies to other systems that require two or more conveyors. Moreover, while the invention is described above as one for use with a swarf conveyor, the invention is meant to cover all types of conveyors such as parts or material conveyors, conveyors including a belt and other types of non-belt conveyors which may become jammed. Furthermore, the invention is also meant to include control wherein various operating parameters could be modified. For example, when the belt is reversed, different speeds and durations might be specified and/or the system might be equipped to identify obstruction during a cleaning process (i.e. during belt/conveyor reversal).
To apprise the public of the scope of this invention, we make the following claims: | A clearing method for use with a conveyor belt driven by a reversible motor for essentially automatically eliminating swarf or other obstructions along the belt including an clearing process including sensing motor load and comparing sensed load to a maximum load, when the sensed load exceeds the maximum, performing a clearing process for a predetermined time period calculated to, given the clearly process, clear the obstruction. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 60/687,962 filed Jun. 7, 2005. The aforesaid provisional application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present disclosure generally relates to a bladder heater device. In particular, the present disclosure is directed to a bladder support heater device for both supporting and heating printed circuit boards (PCB) undergoing repairs.
[0003] Bottom side heating is typically an integral component to the circuit board repair process, particularly with regard to removal of leaded and balled components. The main function of bottom side heating is to reduce thermal bias, thereby allowing the circuit board to grow uniformly. Without bottom side heating, the local topside heat, which is applied to reflow a target component, would have negative effects on the circuit board as well as the repair process itself. The local heat would cause the PCB to expand in a small area thereby causing the PCB to buckle or “potato chip.” This may cause damage to the PCB by creating one or more non-planar areas on the surface of the PCB. The non-planar areas are damaging because they make it difficult to solder additional components to the PCB.
[0004] Known methods of bottom side heating include the following: local hot gas; area hot gas; infrared (IR); and combination IR/hot gas. Local hot gas heating generally has very limited use and is the least effective method as it may cause the same problems as local topside heating. Area hot gas heating may be effective at reducing the thermal bias, but it is difficult to control the thermal uniformity over the wide area of a heater array. IR heating can be uniform at the source. However, the absorption of the heat by the PCB is subject to emissivity of the PCB, i.e., darker areas tend to heat faster than lighter colored areas. IR is also the slowest form of heating.
[0005] In all bottom side heating cases, there is typically a need for bottom side circuit board support. As the PCB heats up, it tends to sag. This creates a non-planar site prohibiting proper contact with the replacement component or leads.
[0006] One known way to provide bottom side circuit board support is to strategically place tooling pins on the system work surface to support the PCB during the rework process. However, the proper placement of these pins, which is highly subject to operator error, is critical to a successful repair.
[0007] Another known way to provide bottom side circuit board support is to use fixed tooling to support the PCB. Although fixed tooling works well, it is costly to make and store.
[0008] Accordingly, the present disclosure contemplates a new and improved bladder support heater device which overcomes the above-referenced problems and others.
SUMMARY
[0009] In one aspect of the disclosure, a bladder support heater device includes the following: a control unit including a closed loop heating control, a resistive heating element, a heating tank containing a fluid, a pump, a pressure switch, and logic; and a flexible bladder joined with the control unit via a hose. The closed loop heating control, which is programmed according to the logic, causes the fluid to be heated by the resistive heating element and pumped to the flexible bladder until the pressure switch causes the pump to turn off.
[0010] In another aspect of the disclosure, a method of heating and supporting a circuit board, includes the following steps: positioning a flexible bladder between a bottom surface of the circuit board and a machine surface; and inflating the flexible bladder with a heated fluid to a predetermined pressure and a predetermined temperature.
[0011] One advantage of the bladder support heater device described herein resides in its use of conduction, which provides an efficient form of heating and also provides the most thermal uniformity.
[0012] Another advantage of employing a heated fluid in a bladder is that it does not require that an electricity-powered heater be positioned adjacent the bladder or PCB surfaces.
[0013] Yet another advantage of the present development it that it provides a substrate with both thermal and mechanical stability through a flexible conductive heating apparatus during a rework cycle. The device will conform to the bottom side of a substrate to provide uniform conductive heating during a repair operation while also providing under side substrate support.
[0014] Still a further advantage of the present device is that it may be maintained in a substantially two-dimensional form when not inflated, i.e., not in use, versus prior art designs that are always three-dimensional, thereby saving space.
[0015] Still further benefits and advantages of the present disclosure will become apparent to those skilled in the art upon a reading and understanding of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For the purpose of illustrating the invention, the drawings show a form of the invention that is presently preferred. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:
[0017] FIG. 1 is a schematic diagram of a bladder support heater device according to one embodiment of the present invention
[0018] FIG. 2 is a cross-sectional view of a bladder support heater device in a typical installation between a machine surface and a PCB, according to one embodiment of the present invention; and
[0019] FIG. 3 is a flow chart outlining a method in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring now to the drawings in which like reference numerals indicate like parts, and in particular to FIGS. 1 and 2 , there appears a thermally conductive bladder support heater device 10 , which heats the bottom side 14 of a PCB 12 while providing tooling free support of the PCB 12 . In one embodiment, the bladder support heater device 10 includes a control unit 20 and a flexible bladder 40 , which are joined together via a hose 42 . Fluid is heated in the control unit 20 and pumped through the hose 42 to the flexible bladder 40 , thereby both inflating and heating the flexible bladder 40 .
[0021] The control unit 20 includes a closed loop heating control 22 , a resistive heating element 24 , a heating tank or reservoir 26 containing a fluid, a pump 28 , a pressure switch 30 , and logic 32 which may be implemented in a microprocessor, microcontroller, controller, embedded controller, programmable logic device (PLD), field programmable gate array (FPGA) or field programmable object array (FPOA), or the like. Fluid is stored in the heating tank 26 . Upon activation of the control unit 20 and according to predetermined or preselected parameters, which are programmed into the logic 32 , the resistive heating element 24 is actuated to heat the fluid. The closed loop heating control 22 , which monitors the temperature of the fluid via sensors, is used to control the resistive heating element 24 to ensure the fluid is heated to a predetermined value. The pump 28 , which may be a gear pump or similar, is used to pump the heated fluid through the hose 42 to the flexible bladder. The pressure switch 30 deactivates the pump 28 when the pressure in the flexible bladder 40 reaches a predetermined or preselected value. Upon deactivation of the control unit 20 , the fluid in the flexible bladder 40 gravity drains back to the heating tank 26 in the control unit 20 , thereby deflating the flexible bladder 40 .
[0022] Operation of the resistive heating element 24 , the closed loop heating control 22 , the pump 28 , and the pressure switch 30 is interconnected with the programmed logic 32 , which includes programming of cycle durations and frequencies for each component. Parameters such as the stiffness of the PCB 12 , the anticipated load on the PCB 12 , the distance between the machine surface 44 and the bottom 14 of the PCB 12 , and the material characteristics of the flexible bladder 40 are all considered in developing the cycle durations and frequencies to be programmed into the logic device 32 .
[0023] The flexible bladder 40 may be manufactured from materials that are flexible, heat resistant, puncture resistant, and non-reactive, e.g., rubber-based materials. One possible material may be a synthetic rubber sold under the brand name VITON® by DuPont Performance Elastomers LLC of Wilmington, Del.
[0024] In one embodiment, the bladder 40 includes a central port 46 adapted to receive an external localized bottom heater (not shown) such as a hot gas bottom heater. An external localized bottom heater allows a higher heat source to impinge gas at the direct underside of the specific site to be repaired.
[0025] Another aspect of the present disclosure is a method of heating and supporting a circuit board, which includes the steps of positioning a flexible bladder between a bottom surface of the circuit board and a machine surface and inflating the flexible bladder with a heated fluid to a predetermined pressure and a predetermined temperature. As best illustrated in FIG. 2 , the unfilled, flexible bladder 40 is placed on the work surface 44 positioned under the substrate (e.g., PCB 12 in FIG. 2 ). At the start of the rework cycle, the control unit 20 pumps heated fluid up through the hose 42 .
[0026] In the depicted embodiment, the apparatus 10 includes the work surface or base 44 and a raised peripheral wall 48 defining a cavity or recess 50 . As the flexible bladder 40 fills, the gap between the bladder 40 and the substrate 12 is closed until the bladder 40 makes contact with the lower surface 14 of the substrate 12 , thereby providing conductive heat to the substrate 12 . The pressure switch 30 within the control unit 20 signals to stop pumping the heated fluid under preprogrammed control when a predetermined or preselected pressure is reached.
[0027] A flow chart in accordance with an exemplary embodiment appears in FIG. 3 . The temperature of the heating fluid is monitored at step 60 . At step 64 , it is determined whether a predetermined or preselected temperature has been reached. If the preselected temperature has not been reached at step 64 , the process returns to step 60 . Once the desired temperature is achieved at step 64 , the process proceeds to step 68 and the heated fluid is pumped to the bladder 40 . At step 72 , the pressure of the fluid is monitored. If a preselected or predetermined pressure has not been reached at step 76 , the process returns to step 68 . Once the desired pressure is reached, the pump 28 is deactivated at step 80 .
[0028] The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | An apparatus for heating a circuit substrate includes a source of heated fluid, a flexible bladder in fluid communication with said source of heated fluid, a pump for delivering said heated fluid to said flexible bladder, and a pressure switch for sensing a pressure in said flexible bladder deactivating said pump when the pressure reaches a preselected value. In a further aspect, a method of heating and supporting a circuit board is provided | 7 |
BACKGROUND OF THE INVENTION
The invention relates generally to a clamp for clamping a continuous yarn in a textile machine in which the yarn moves intermittently and axially. The invention is particularly directed to a yarn clamp for the weft yarn in an outside filling supply loom in which the weft yarn is advanced intermittently along its longitudinal axis from a weft yarn storage means to a weft yarn inserting means. In outside filling supply looms, the weft yarn is drawn from a supply package and stored in the weft storage means. At the time of weft insertion, the stored weft yarn is drawn from the storage means by the weft inserting means and inserted into the loom. In looms of this type, it is essential that the weft yarn is clamped between the weft storage means and the weft inserting means. Various types of clamping devices have been used for this purpose such as those shown in the following U.S. Pat. Nos. 3,575,217, Pfarrwaller issued Apr. 20, 1971; U.S. Pat. No. 3,865,149, Keldany issued Feb. 11, 1975; U.S. Pat. No. 3,916,935, Keldany issued Nov. 4, 1975; and U.S. Pat. No. 4,190,089 Cyvas issued Feb. 26, 1980.
In each of the above patents, the clamping means comprises a pair of plate-like elements, one of which is movable toward and away from the other. The weft yarn passes between these two plate-like elements and is clamped when the movable element moves against the fixed element.
A major problem arises in the use of the prior art weft yarn clamping means due to the fibrous nature of weft yarns. Loose fibers in the form of lint accumulates on the jaws of the clamp and prevents the clamp from gripping the weft yarn properly and periodically the accumulation of lint is drawn into the loom during a weft inserting sequence and this causes a defect in the cloth. These difficulties, experienced with the prior art clamping devices, have been obviated by the present invention.
It is, therefore, a principle object of the present invention to provide a yarn clamp in which lint build-up between the clamping elements is prevented.
Another object of the invention is the provision of a yarn clamp which is self-cleaning.
With these and other objects in view, as will be apparent to those skilled in the art, the invention resides in the combination of parts set forth in the specification and covered by the claims appended hereto.
SUMMARY OF THE INVENTION
The invention comprises a yarn clamp which uses a pair of rollers as the clamping elements. These rollers are mounted for rotation on axles supported by a frame. One of the axles is generally fixed in the frame whereas the other is supported by the frame for movement towards and away from the fixed axle, to move the roller mounted thereon into, and out of, contact with the other roller. The clamp is used in textile machines, such as looms or knitting machines, which requires yarn to be fed periodically. Actuating means, operating in timed relation with the textile machine, moves the movable roller into and out of engagement with the stationary roller so that the rollers are separated just prior to and during the feeding of the yarn and engaged between such feedings of the yarn to clamp it. Means are also provided for rotating the rollers and for wiping the annular clamping surfaces of the rollers so as to remove any lint that may be accumulated on such surfaces.
More specifically, the means for rotating the rollers comprise a pawl and ratchet mechanism that is operated by the actuating means, for imparting a partial rotation to each of the rollers during each movement of the movable roller away from the stationary roller.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms, as illustrated by the accompanying drawings, in which:
FIG. 1 is a front elevational view of the yarn clamp of the present invention and is located between the weft storage means and the weft inserting means of a loom;
FIG. 2 is a side elevational view of the yarn clamp, looking in the direction of arrow II in FIG. 1;
FIG. 3 is an enlarged plan view of the yarn clamp, showing the clamp in the closed position;
FIG. 4 is a plan view similar to FIG. 3, but showing the yarn clamp in the open position;
FIG. 5 is a vertical sectional view of the yarn clamp on an enlarged scale and taken on the line V--V of FIG. 3; and
FIG. 6 is a vertical sectional view of the yarn clamp on an enlarged scale and taken on the line VI--VI of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIGS. 1, 2, 3 and 4 which best show the general features of the invention, the yarn clamp, indicated generally by the reference numeral 10, is shown located between a weft yarn inserting means 12 and a weft yarn storage means 14 of an outside filling supply loom (not shown). The yarn clamp 10 comprises a first clamping roller 18 mounted for rotation about a first vertical axis 20 on a supporting frame 16. Roller 18 has a first annular clamping surface 19 which is concentric with the axis 20. A second clamping roller 22 is mounted for rotation about a second vertical axis 26 on a horizontal lever 24. Roller 22 has a second annular clamping surface 21 which is concentric with the axis 26. Lever 24 is pivotally mounted on supporting frame 16 by means of a pivot pin 28 (see FIG. 3) so that oscillation of the lever 24 about the pivot pin 28 causes the second clamping roller 22 to be moved toward and away from the first clamping roller 18. FIGS. 1, 2 and 3 show the clamping rollers in a closed position, whereby a weft yarn Y that extends between the weft yarn inserting means 12 and the weft yarn storage means 14 is clamped between the annular clamping surfaces 19 and 21 of the clamping rollers 18 and 22, respectively. FIG. 4 shows the unclamped or open position of the clamping rollers, whereby the clamping surfaces 19 and 21 are spaced from each other and the weft yarn Y is free to be drawn from the storage means 14 by the weft yarn inserting means 12.
The means for actuating the lever 24 to bring the second clamping roller 22 into and out of engagement with the first clamping roller 18 is a cam mechanism generally indicated by the reference numeral 30 (See FIGS. 1 and 2). Cam mechanism 30 comprises a cam 32 mounted for rotation with a drive shaft 34 which forms part of the loom driving mechanism. A follower roller 36 is rotatably mounted on the lower portion of a vertical lever 38. The upper portion of lever 38 is fixed to one end of a horizontal stub shaft 40 rotatably mounted in a forwardly-extending portion 42 of the frame 16. A two-part vertical lever, generally indicated by the reference numeral 44, is mounted on the opposite end of stub shaft 40 and comprises a lower portion 46 fixed to the stub shaft 40 and an upper portion 48 pivotally mounted on the lower portion 46 by means of a pivot pin 50. A compression spring 52 urges the upper portion 48 against the lower portion 46 so that lever 44 normally functions as a unitary lever. A link 54 connects the lever 44 to the lever 24. One end of the link 54 is pivotally attached to the upper portion 48 by means of a pivot pin 56 and the opposite end of link 54 is pivotally connected to the lever 24 by means of a pivot pin 58. The lever 44 is biased in the forward position by means of a compression spring 60 which maintains the follower roller 36 in engagement with the outer working surface 61 of the cam 32. Working surface 61 comprises a low portion 59 and a high portion 63.
When the follower 36 is engaged with the low portion 59 of the cam 32, lever 44 is rocked clockwise as viewed in FIG. 2, by the spring 60 so that the clamping roller 22 is moved away from the clamping roller 18 as shown in FIG. 4. When the cam follower roller 36 is engaged with the high portion 63 of the cam 32, vertical lever 44 is rocked counter-clockwise, as viewed in FIG. 2, against the bias of the spring 60 so that the clamping roller 22 is moved into engagement with the clamping roller 18, as shown in FIG. 3. The spring 60 is loosely mounted on a guide rod 62 that extends between the vertical lever 44 and the supporting frame 16. One end of the guide rod 62 is fixed to the vertical lever 44. The opposite end of guide rod 62 is guided for axial movement in a hole 64 in the supporting frame, as shown in FIG. 2. A pair of nuts 66 are threadingly mounted on the forward end of the guide rod 62 for adjusting the tension of the spring 60.
The upper end of the pivot pin 56 extends above the link 54 to a considerable degree so as to provide a means by which the upper portion 48 may be manually pivoted about pin 50 on the lower portion 46 of the two part lever 44 against the bias of the spring 52. In this way, the upper portion 48 may be pulled away from the lower portion 46 about pivot pin 50 to the dotted-line position as shown in FIG. 2. By moving upper portion 48 to the dotted-line position, the clamping roller 22 is moved out of engagement with the clamping roller 18. The amount of movement of the upper portion 48 away from the lower portion 46 is limited by a screw 68 which extends freely through the upper portion 48 and is threaded into the lower portion 46. Also, the screw 68 is used to adjust the biasing force of the spring 52.
Referring to FIGS. 3, 5, and 6, there is shown a pawl and ratchet mechanism generally indicated by the reference numeral 70 for providing incremental rotational movement to clamping rollers 18 and 22, respectively. Pawl and ratchet mechanism 70 comprises a first ratchet wheel 72 integrally formed with clamping roller 18 and a second ratchet wheel 74 integrally formed with clamping roller 22.
Referring particularly to FIGS. 3 and 5, clamping roller 18 sets on top of a first arm 76 and the ratchet wheel 72 extends downwardly into an annular cavity 75 in the first arm 76. Clamping roller 18 and arm 76 are mounted to the supporting frame 16 by means of a screw or axle 78. Screw 78 is screwed into the supporting frame 16. However, roller 18 and arm 76 are free to rotate relative to the screw or axle 78 and relative to each other. The vertical axis 20 extends through the center of the screw or axle 78. The annular periphery of the first ratchet wheel 72 is provided with a plurality of teeth 86 which are engaged by a pawl 88. Pawl 88 is mounted in a bore 90 in arm 76 for axial movement toward and away from the teeth 86 in a direction transversely of the vertical axis 20. Pawl 88 is urged into engagement with the teeth 86 by means of a compression spring 92. The tension of the spring 92 is adjusted by means of an adjusting screw 94.
Referring particularly to FIGS. 3 and 6, clamping roller 22 sets on top of a second arm 82 and the ratchet wheel 74 extends downwardly into an annular cavity 80 in arm 82. Clamping roller 22 and arm 82 are mounted to the lever 24 by means of a screw or axle 84. Screw or axle 84 is screwed into the lever 24. However, roller 22 and arm 82 are free to rotate relative to the screw or axle 84 and relative to each other. Vertical axis 26 extends through the center of the screw or axle 84. The annular periphery of the ratchet wheel 74 is provided with a plurality of teeth 96 which are engaged by a pawl 98. Pawl 98 is mounted in a bore 100 in arm 82 for sliding axial movement toward and away from the teeth 96 in a direction which is transverse to vertical axis 26. Pawl 98 is urged into engagement with teeth 96 by means of a compression spring 102. The tension of spring 102 is adjusted by means of an adjusting screw 104. As best illustrated in FIG. 3, the teeth of ratchet wheels 72 and 74 and pawls 88 and 98, respectively, are shaped so that relative movement of the pawl about the toothed periphery of the ratchet wheel in one direction rotates the ratchet wheel. Relative movement of the pawl in the opposite direction enables the pawl to be pushed away from the teeth of the ratchet wheel against the biasing force of its respective compression spring and slide past the teeth. Ratchet wheel 72 and its integral clamping roller 18 rotate only in a clockwise direction, as indicated by arrow 105 in FIG. 3, while the ratchet wheel 74 and its integral clamping roller 22 rotate only in a counterclockwise direction, as indicated by arrow 106 in FIG. 3.
The drive for the pawls 88 and 98 is best illustrated in FIG. 3. As pointed out hereinbefore, arm 76 and arm 82 are pivotally mounted about screws or axles 78 and 84, respectively. (See FIGS. 5 and 6 for details of the mounting) Arms 76 and 82 are free to revolve around screws 78 and 84. Arm 76 can revolve in a counterclockwise direction without effecting rotation of clamping roller 18 due to the inclination of ratchet teeth 86. However, when arm 76 moves in the clockwise direction as shown by arrow 105, roller 18 will also be moved due to the engagement of pawl 88 with teeth 86 of ratchet wheel 72.
Arm 82 is mounted to pivot about axle 84 and due to the inclination of teeth 96 on ratchet wheel 74, arm 82 can pivot in the clockwise direction relative to the roller 22 without effecting rotation of said roller. However, when arm 82 moves in the counterclockwise direction, roller 22 must rotate with it.
Arm 76 is connected to a first link 108 by means of a pivot pin 110 at a point spaced from vertical axis 20. The opposite end of link 108 is connected to screw 84 so that movement of roller 22 out of contact with the surface of roller 18 will cause arm 76 to pivot about axle or screw 78, thereby imparting a partial rotation to roller 18. As roller 22 is moved back into contact with the surface of roller 18 arm 76 is moved in a counterclockwise direction without rotating roller 18.
Arm 82 has pivotally attached to it a second link 112 at pivot point 114. The opposite end of link 112 is pivotally attached to frame 16 by a pivot pin 116 so that when roller 22 moves out of contact with the surface of roller 18, its movement will impart a counter-clockwise relative movement to arm 82 thereby imparting a partial rotation to roller 22. When roller 22 moves back into contact with the surface of roller 18 arm 82 will pivot about axle or screw 84 in a clockwise direction without rotating roller 22 due to the inclination of the teeth on ratchet 98. Thus it will be seen that whenever rollers 18 and 22 are moved out of contact with each other a partial rotation will be imparted to each of the rollers to cause them to rotate about their respective axis.
Referring particularly to FIGS. 2, 3 and 4, a wiper element 118 is loosely mounted between annular surface 19 of clamping roller 18 and a vertical bracket 120 of frame 16. Wiper element 118 has a concave surface 122 which is urged against annular surface 19 of the first clamping roller 18 by means of a locking screw 124. Locking screw 124 is threaded into the vertical bracket 120 and is of the type which is provided with a spring-loaded plunger that bears against wiper element 118 to urge the wiper element against clamping roller 18 with a slight biasing force. This slight biasing force is sufficient to enable the wiper element to wipe any lint that has accumulated on the annular surface of roller 18 as the roller is rotated past the wiper element 118. The biasing force provided by the locking screw 124 is also sufficient to enable the wiper element 118 to provide a braking force on the clamping roller 18. This braking force on the roller 18 insures that the pawl 88 will slide by the teeth 86 of the ratchet wheel 72 when the pawl 88 is moved in a counter-clockwise direction relative to the teeth. Without this braking force, there would be a tendency for the pawl 88 to rotate the ratchet wheel 72 in both directions for each oscillation of the pawl, particularly in view of the fact that the pawl is biased into engagement with the teeth 86 by the spring 92.
Roller 22 is also wiped and braked by a wiper element 126. Wiper element 126 is loosely positioned between the roller 22 and a vertical bracket 128 extending upwardly from the vertical lever 24. Wiper element 126 has a concave surface 130 that is urged into contact with the annular peripheral surface of the roller 22 by means of a biasing locking screw 132 which is similar to locking screw 124. The braking force applied by wiper elements 118 and 126 to rollers 18 and 22, respectively, insure that each of the rollers will be rotated in one direction only, although the direction is different for the two rollers as indicated by arrows 105 and 106.
The operation and advantages of the present invention will now be readily understood in view of the above description. When yarn clamp 10 of the present invention is applied to an outside filling supply loom, clamping rollers 18 and 22 are positioned between weft yarn inserting means 12 and weft yarn storage means 14, as shown in FIGS. 1 and 3 of the drawings. In this position, weft yarn Y extends from storage means 14, between annular surfaces 19 and 21 of rollers 18 and 22, respectively, to weft yarn inserting means 12. Drive shaft 34 is part of the loom driving mechanism and makes one rotation for each weft insertion by the weft yarn inserting means 12. Cam 32, thereby makes one rotation for each weft insertion by weft yarn inserting means 12. The timing of cam 32 is such that the oscillation of lever 24 by the follower mechanism causes clamping roller 22 to be moved toward and away from the first clamping roller 18 in timed relation with the weft yarn inserting sequence of the loom. During a weft yarn inserting sequence, which includes any intended axial movement of yarn Y from the weft yarn storage means 14, clamping roller 22 is moved away from the first clamping roller 18. After a weft yarn inserting sequence, clamping roller 22 is moved into engagement with clamping roller 18 so as to clamp weft yarn Y between annular surfaces 19 and 21. During each movement of clamping roller 22 away from clamping roller 18, both rollers are given a partial rotation of approximately 10° to 15° by the pawl and ratchet mechanism 70 and the connecting means 107. After several weft yarn insertions, the rollers 18 and 22 make a complete revolution so that the entire annular surface of each roller moves past its respective wiper element. Any lint that has accumulated on annular surfaces 19 and 21 of rollers 18 and 22, respectively, will be wiped away from these surfaces by the wipers 118 and 126. This insures that the annular surfaces 19 and 21 will be kept free of lint and that there is no possibility of a clump of lint being drawn into the loom by the weft inserting mechanism.
The yarn clamp 10 of the present invention is shown in association with a weft yarn inserting mechanism at one side of a loom. As shown in the drawings, the yarn clamp 10 is located at the right hand side of the loom when viewed from the front of the loom into which weft is inserted from right to left. In many looms, weft yarn is inserted from both sides of the loom. In such a case, a yarn clamp 10 would also be located at the left hand side of the loom and would be of opposite hand from that which is shown in the drawings. It is also contemplated that the yarn clamp of the present invention could be used in other types of machinery other than looms in which yarn or strand material is moved intermittently along its longitudinal axis and in which there is a need for clamping the yarn or strand material between periods of axial movement.
It is obvious that minor changes may be made in the form and construction of the invention without departing from the material spirit thereof. The invention is not to be confined to the exact form herein shown and described. | A yarn clamp for periodically clamping yarn on textile machines comprising a pair of clamping rollers supported on a frame for rotation about their axes. Means is provided for moving the clamping rollers into and out of contact with each other and for imparting a partial rotation to each of the rollers while they are out of contact. A wiping means is provided for wiping the surfaces of the clamping rollers when they rotate to avoid the accumulation of lint on the surfaces of the clamping rollers. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a one-way clutch that transmits the rotation of a drive member in only one direction to rotation of a driven member.
2. Description of Related Art
Ratchet-style clutches that transmit rotation in only one direction are known. FIGS. 7 and 8(a)-8(b) illustrate such a clutch. In FIGS. 7 and 8(a)-8(b), a drive clutch plate 102 and plate 105 are connected together through hole 102a and spindle 105a so that they can rotate relative to each other. A ratchet claw 103 is provided on a fixed spindle 102b of the drive clutch plate 102. A ratchet arm 103b of ratchet claw 103 contacts a fixed spindle 102c of the drive clutch plate 102. A ratchet claw tooth 103a of ratchet claw 103 engages the cam surface 105c of the secondary driven plate 105 to enable drive plate 102 to drive secondary driven plate 105 as shown in FIG. 8(a). The ratchet claw tooth 103a is pressed against a stepped portion 105(b) of cam surface 105c with a force determined by the resilient force created by the elastic deformation of the ratchet arm 103b. As shown in FIG. 8 (a), when the drive plate 102 rotates in the counter-clockwise direction (shown by arrow A) the stepped portion 105b of the cam surface 105c and the ratchet claw tooth 103a engage to transmit the rotation of the drive plate 102 to the secondary driven plate 105. As shown in FIG. 8 (b), when the drive plate 102 rotates in the clockwise direction (shown by arrow B) the ratchet claw 103 slides past the cam surface 105c, thus allowing the drive plate 102 to rotate without engaging the secondary driven plate 105.
With the clutch described above, friction is generated between the ratchet claw tooth 103a and the cam surface 105c because the ratchet claw tooth 103a of the ratchet claw 103 is pressed against the cam surface 105c by the resilient force of the ratchet arm 103b. Thus, even when the drive plate 102 is rotating freely as shown in FIG. 8(b), some torque is transmitted to the secondary driven plate 105. Simultaneously, a small torque load also appears in the drive plate 102. Hereafter, the torque load of the drive plate 102 during free rotation will be referred to as the free rotation load torque, and the torque transmitted to the secondary driven plate 105 will be referred to as the free rotation torque.
Especially when the clutch described above is used with small precision equipment such as cameras, comparatively large free rotation torque and free rotation load torque are generated when the ratchet claw tooth 103a rides over the stepped portion 105b because the bending length (length in the perimeter direction) of the arm 103b cannot be made sufficiently long in relation to the height of the stepped portion 105b. The pressure of the ratchet claw tooth 103a against the cam surface 105c is designated to be slightly larger than that necessary for proper operation to assure that the claw 103a will positively press against the cam surface 105c, regardless of variations in manufacture of the clutch. Manufacturing differences related to a larger design dimension will cause the pressure to be correspondingly larger than the design pressure.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a one-way clutch that will reduce the free rotation torque and free rotation load torque.
It is also an object of the present invention to reduce the size of the one-way clutch while achieving the torque reductions.
In order to achieve the above and other objects, embodiments of the present invention include a first engagement element that is part of a rotation transmitting element that is rotatably attached to a rotatable drive member. The first engagement element is forced toward a second engagement element that is attached to the inside center or to the outer perimeter of a rotatable driven member. When the rotatable drive member rotates in one direction, the rotatable drive member and the rotatable driven member engage so that the drive member rotatably drives the driven member. Rotation of the drive member in the other direction is not transmitted to the driven member. The rotation transmitting element is attached to the rotatable drive member in a manner that allows the rotation transmitting element to rotate freely relative to the rotatable drive member so that the first engagement element can separate from or connect to a second engagement element of the rotatable driven member.
In a first embodiment of the invention, the center of gravity of the rotation transmitting element is located so that the centrifugal force accompanying the rotation of the rotatable drive member in one direction will cause the rotation transmitting element to rotate in a direction that will cause the first and second engagement elements to engage, thereby connecting the rotatable drive member to the rotatable driven member for rotation together in the one direction. Centrifugal force drives the first engagement element toward the second engagement element. The force driving the first engagement element toward the second engagement element can be established by the position of the center of gravity and of the center of rotation of the rotation transmitting element. There is no need to consider the bending length of the rotation transmitting element because elastic force is not used to urge the first engagement element toward the second engagement element.
In second and third embodiments of the invention, in addition to the rotation transmitting element, an auxiliary element is attached to the rotatable drive member in a manner that allows the auxiliary element to pivot freely relative to the rotatable drive member. The rotation transmitting element rotates with the rotatable drive member in one direction causing the first engagement element to engage the second engagement element due to centrifugal force. The auxiliary element is pivotably attached to the rotatable drive member so that the center of gravity of the auxiliary element separates from the center of gravity of the rotation transmitting element when the drive-side rotating object rotates in the one direction.
The clutch is designed for the axes of the rotation spindles supporting the rotatable drive member and the rotatable driven member to be perpendicular to the direction of gravity, so that even when the centrifugal force that acts on the rotation transmitting element is counteracted by the force of gravity, the auxiliary element is caused to move by centrifugal force and the force of gravity applied to it so as to contact and force the first engagement element of the rotation transmitting element toward the second engagement element.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:
FIG. 1 is an oblique disassembled view that shows the construction of the first embodiment of a clutch in accordance with the present invention;
FIGS. 2(a)-2(c) are plan views of the FIG. 1 embodiment that show the interior mechanism of the clutch of the first embodiment;
FIG. 3 is an oblique disassembled view that shows the construction of the second embodiment of a clutch in accordance with the present invention;
FIGS. 4(a) and 4(b) are plan views of the FIG. 3 embodiment that show the interior mechanism of the clutch of the second embodiment;
FIG. 5 is an oblique disassembled view that shows the construction of the third embodiment of a clutch in accordance with the present invention;
FIGS. 6(a) and 6(b) are plan views of the FIG. 5 embodiment that show the interior mechanism of the clutch of the third embodiment of the present invention;
FIG. 7 is an oblique disassembled view that shows the construction of a conventional one-way clutch; and
FIGS. 8 (a) and 8(b) are plan views that show the interior mechanism of the clutch of FIG. 7.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
First Embodiment
The first embodiment of the present invention is described hereafter, with reference to FIGS. 1 and 2(a)-2(c).
As shown in FIG. 1, the clutch 1 includes a drive plate (or member) 2 and a driven plate (or member) 5 connected so as to rotate freely relative to each other by means of the hole 2a and the spindle 5a. A ratchet claw 3 is installed so as to rotate freely on a fixed spindle 2b of the drive plate 2. The ratchet claw 3 has a tooth portion 3a that can connect to the stepped portion 5b of the driven plate 5 and an arm 3b that extends from the center of rotation to the opposite side of the fixed spindle 2b from the tooth 3a. As shown in FIGS. 2(a)-2(c), the ratchet claw 3 is designed in form and mass distribution so that the centroid m is positioned on the arm 3b side away from the center of rotation (about fixed spindle 2b).
According to the construction described above, a moment develops through the centrifugal force F that accompanies the rotation of the drive plate 2 and acts on the ratchet claw 3. This moment rotates the ratchet claw 3 around the fixed spindle 2b in the counter-clockwise direction as shown in FIGS. 2(a)-2(c). The tooth 3a of the ratchet claw 3 is pressed against a central cam surface 5c of the driven plate 5. Thus, as shown in FIG. 2(a), when the drive plate 2 rotates in the counter-clockwise direction (shown by arrow A) the claw tooth 3a connects with a stepped portion 5b of the cam surface 5c, transmitting the rotation of the drive plate 2 to the driven plate 5. As shown in FIG. 2(b), when the drive plate 2 rotates in the clockwise direction (shown by arrow B) the claw tooth 3a slides past the cam surface 5c, the drive plate 2 freely rotating relative to the driven plate 5.
The pressure of the claw tooth 3a against the cam surface 5c varies according to the rotational speed of the drive plate 2 and the distance from the centroid of the ratchet claw 3 to the fixed spindle 2b. The location of centroid m varies according to the form and mass distribution of the claw tooth 3a and the arm 3b. The pressure decreases as the centroid m approaches the fixed spindle 2b, and the free rotation torque and the free rotation load torque also decrease. If the centroid m is made to approach the center of rotation of the ratchet claw 3, the movement of the centroid m when the claw tooth 3a rides over the stepped portion 5b decreases, and the fluctuations of the free rotation torque and of the free rotation load torque also decrease. Miniaturization of the clutch is achieved because there is no need to elongate the arm 3b in order to decrease the pressure of the claw tooth 3a. For example, if a manufacturing method with a high degree of accuracy is used, such as resin molding, there is little concern that the pressure of the claw tooth 3a will be too large due to manufacturing differences because the position of the centroid m varies little with manufacturing differences.
The clutch 1 of the first embodiment described above is designed for the axes of spindles of the drive plate 2 and of the driven plate 5 to be perpendicular to the direction of gravity. When, however, the rotational speed of the drive plate 2 is small, the centrifugal force F may be smaller than the force of gravity G when the ratchet claw 3 has moved to the top position as shown in FIG. 2(c). Thus the pressure of the claw tooth 3a may be lost. Therefore, it is preferable to use the clutch of the second embodiment, shown in FIGS. 3 and 4(a)-4(b).
Second Embodiment
In the second embodiment of the invention, shown in FIGS. 3 and 4(a)∝4(b), a drive plate 12 and a driven plate 15 of a clutch 11 are connected so as to be able to rotate freely relative to each other by means of a hole 12a and a spindle 15a. A ratchet claw 13 with a claw tooth 13a and an arm 13b is installed on a fixed spindle 12b of the drive plate 12 so as to rotate freely. An auxiliary element 17 is attached to a second fixed spindle 12c so as to also rotate freely. The auxiliary element 17 is attached so that its pointed end is inserted into the gap between a cam surface 13c molded into the inside of the pointed end of the ratchet claw 13 and the cam surface 15c of the driven plate 15. As shown in FIG. 4(a), the centroid ml of the ratchet claw 13 and the centroid m2 of the auxiliary element 17 have the center of rotation of the clutch 11 between them.
According to the construction described above, when the device is used with the spindle of the drive plate 12 and of the driven plate 15 perpendicular to the direction of gravity, the directions of the centrifugal force F2 and of the gravitational force G2 that act on the centroid m2 of the auxiliary element 17 nearly coincide when the ratchet claw 13 moves to the top side, as shown in FIG. 4(a). The centrifugal force F1 and the gravitational force F2 acting on the centroid ml cancel each other. The auxiliary element 17 is rotated clockwise about the fixed spindle 12c by a relatively large moment. Thus the cam surface 13c of the ratchet claw 13 connects with a pointed end of the auxiliary element 17 which pushes the ratchet claw toward the outside. A counter-clockwise moment is developed in the ratchet claw 13 about the fixed spindle 12b. Thus, even in the position shown in FIG. 4(a), the pressure of the claw tooth 13a on the cam surface 15c of the driven plate 15 is maintained.
As shown in FIG. 4(b), when the ratchet claw 13 has moved to the bottom side, the claw tooth 13a is pressed against the cam surface 15c by the centrifugal force and by gravity that act on the ratchet claw 13. If the force of gravity exceeds the centrifugal force on the auxiliary element 17, the auxiliary element 17 rotates in the counter-clockwise direction and its front edge touches the arm 13b of the ratchet claw 13. However, this does not lead to a conspicuous increase in the pressure of the ratchet tooth 13a on the cam surface 15c.
Third Embodiment
The third embodiment of the present invention is explained hereafter, with reference to FIGS. 5 and 6(a)-6(b). As shown, a drive plate 22 and a driven plate 25 of the clutch 21 of the present embodiment are joined by the hole 22a and the spindle 25a, which allow the plates to rotate freely. A ratchet claw 23 is installed onto a fixed spindle 22b of the drive plate 22 to rotate freely. An auxiliary element 27 is installed onto a second fixed spindle 22c of the drive plate 22 to rotate freely. The ratchet claw 23 has an arm 23b formed onto it extending to one side of the center of rotation of the drive plate 22. A claw tooth 23a is formed on the outside of the arm 23b. A cam surface 25c of the driven plate 25 is formed on the inside of an annular outer edge. A stepped portion 25b into which the claw tooth 23a may fit is formed into the cam surface 25c on the inside perimeter of the plate 25. The auxiliary element 27 is attached so that its pointed end is inserted between the inside perimeter of the ratchet arm 23b of the ratchet claw 23 and the larger diameter portion 25d of the spindle 25a of the driven plate 25.
With the described construction, when the ratchet claw 23 rotates in the counter-clockwise direction as shown in FIG. 6(a) through the centrifugal force accompanying the rotation of the drive plate 22, the claw tooth 23a is pushed against the cam surface 25c. Thus, when the drive plate 22 rotates in the clockwise direction (shown by arrow B in FIG. 6(a)) the claw tooth 23a connects with the stepped portion 25b, transmitting the rotation of the drive plate 22 to the driven plate 25. When the drive plate 22 rotates in the counter-clockwise direction (shown by arrow A in FIG. 6(a)) the claw tooth 23a slides past the cam surface 25c, allowing free rotation of the drive plate 22. If the device is used with the spindle of the drive plate 22 and of the driven plate 25 perpendicular to the direction of gravity, when the ratchet claw 23 has moved to the top as shown in FIG. 6(a), the ratchet claw 23 is forced in the counter-clockwise direction by the clockwise rotation of the auxiliary element 27 due to centrifugal force and the force of gravity, thus maintaining the pressure of the ratchet claw 23a on the cam surface 25c. In this example, when the ratchet claw 23 moves to the bottom side, as shown in FIG. 6(b), the auxiliary element 27 and the ratchet claw 23 separate. Therefore claw tooth 23a is pushed against the cam surface 25c by only the centrifugal force and gravitational force of the ratchet claw 23.
If the device is to be used with the spindle of the drive plate 22 and of the driven plate 25 oriented in the direction of gravity, or if the number of revolutions of the drive plate 22 is high and a centrifugal force sufficiently larger than the gravitational force is applied to the ratchet claw 23, the auxiliary element 27 may be omitted.
With the embodiments described above, drive plates 2, 12, and 22 comprise drive members, ratchet claws 3, 13, and 23 comprise rotation transmitting elements, claw teeth 3a, 13a and 23a comprise first engagement elements of the rotation transmission elements, driven plates 5, 15, and 25 comprise driven members, the cam surfaces 5c, 15c, and 25c along with stepped portions 5b, 15b, and 25b comprise second engagement elements of the driven members, and auxiliary elements 17 and 27 comprise auxiliary elements.
As described above, because the rotation in the disclosed embodiments of the present invention is transmitted through the connection of the first engagement element of the rotation transmitting element with the second engagement element through the centrifugal force that accompanies the rotation of the drive member, the first and second engagement elements can be pushed together by a smaller and more stable force than is used on a conventional clutch that uses an elastic force to force a first engagement element against a second engagement element. Thus the free rotation torque and the free rotation load torque that occur when the drive member rotates freely can be minimized. The rotation transmitting element can be made compact because no elastic force is used. Thus the clutch can be reduced in size.
With the invention of the second and third embodiments, because the rotation transmitting element is pushed by an auxiliary element, the first engagement element of the rotation transmitting element can be positively forced toward the second engagement element even when the centrifugal force and gravitational force of the rotation transmitting element cancel each other.
While this invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims. | A one-way clutch includes a first engagement element of a rotation transmitting element that is attached to a rotatable drive member. The first engagement element is forced toward a second engagement element that is attached to near the center or to the radially inner perimeter of an annular outer edge of a driven member. When the drive member rotates in one direction, the first and second engagement elements connect and the rotation of the rotatable drive member is transmitted to the rotatable driven member. The rotation transmitting element is connected to the drive member in a manner that allows it to rotate freely and so that the first engagement element may separate from or connect to the second engagement element. The rotation transmitting element is designed with its center of gravity located so that the rotation transmitting element will, through the centrifugal force accompanying the rotation of the rotatable drive member, pivot in the direction that will cause the first and second engagement elements to engage only upon rotation of the rotatable drive member in the one direction. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 35 USC 371 application of PCT/DE 02/00376, filed on Feb. 1, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The current invention relates to a method for measuring the injection quantity of injection systems, in particular for motor vehicles and in particular in production testing, in which a testing fluid is injected into a measuring chamber by an injection system and the injection-induced movement of a piston, which at least partially defines the measuring chamber, is detected by a detection device, which transmits a measurement signal.
2. Description of the Prior Art
A method of the above kind is known from the market. The method is applied by using a device, which is referred to as an injected fuel quantity indicator. This component is comprised of a housing in which a piston is guided. The inner chamber of the housing and the piston define a measuring chamber. This measuring chamber has an opening against which an injection system, for example an injector with an injection nozzle, can be placed in a pressure-tight manner. When the injection system injects fuel into the measuring chamber, a fluid contained in the measuring chamber is displaced. This causes the piston to move, which is detected by a distance sensor. The volume change of the measuring chamber and of the fluid contained therein and therefore the quantity of fuel injected can be calculated from the distance traveled by the piston.
In the known injected fuel quantity indicator, a device comprised of a measuring plunger and an inductive distance measuring system is used to measure the movement of the piston. The measuring plunger is embodied as a probe or is connected to the piston. When the piston moves, this also causes the measuring plunger to move and finally, the movement of the measuring plunger is detected and a corresponding signal is sent to an evaluation unit.
The known method already operates with a very high degree of precision with regard to the detected movement of the measuring plunger. However, the mass of the injected testing fluid calculated from this movement and the volume of injected fuel likewise calculated from it fall somewhat below the path measurement in terms of the precision. This problem is more intense the smaller the movement of the piston is, i.e. the smaller the injected testing fluid quantity is. But it is precisely these small quantities of testing fluid that current and future injection nozzles must be able to reliably inject.
The object of the current invention, therefore, is to modify a method of the type mentioned at the beginning so that it permits a more precise determination of the mass of the injected testing fluid and of the volume of testing fluid injected.
This object is attained in that the pressure of the testing fluid is detected in the measuring chamber and the measurement signal is processed taking into account the pressure detected.
SUMMARY OF THE INVENTION
Detecting and measuring pressure changes results in the fact that with an injection of testing fluid, the actually injected fluid mass can be determined with greater precision. The invention is in fact based on the recognition that the mass of a particular volume depends on the density prevailing in this volume. However, the density inside a volume also depends on the pressure prevailing in the volume.
Because the pressure, which prevails in the testing fluid contained in the measuring chamber, is detected according to the invention, the properties of the testing fluid in the measuring chamber can be precisely determined and consequently, the corresponding injected mass can also be calculated precisely from the measured volume. By taking into account the pressure actually prevailing in the measuring chamber, it is also possible to convert the injected volume measured at a particular pressure into a particular comparison value (e.g. 1 bar). In this manner, it is very easily possible to compare different injections and different injection systems to one another since these measured injection quantities are based on the same ambient conditions.
The method according to the invention thus makes the determination of the mass of testing fluid injected into the measuring chamber more precise and also permits the calculation of a volume based on particular ambient conditions, which in turn permits a better comparison of different injection systems.
In a first modification, the invention proposes that the temperature of the testing fluid be detected in the measuring chamber and that the measurement signal be processed taking into account the temperature of the testing fluid. This modification assures that the properties of the testing fluid contained in the measuring chamber depend not only on the pressure but also on the temperature of the testing fluid in the measuring chamber. This further increases the precision and comparability of testing values.
Alternatively, the invention also proposes that taking into account the measured pressure and possibly the measured temperature, the density of the testing fluid in the measuring chamber is determined and based on this, a comparison volume at a particular comparison pressure and possibly at a particular comparison temperature is determined. This is a simple and very precise method for determining a parameter, which can be used to precisely compare the quality of different injection systems.
In another modification of the method according to the invention discloses that the progression of the pressure during an injection is detected and the measurement signal is processed taking into account the detected progression of the pressure. This allows the method to take into account the fact that the pressure in the measuring chamber can change during an injection.
The invention also proposes that when the pressure of the testing fluid in the measuring chamber exceeds a limit, an error message is generated. It is relatively important for the precision of the measurement that the pressure of the testing fluid in the measuring chamber lie with a particular range of values. An excessive pressure in the measuring chamber, like an insufficient pressure, can lead to a distortion of the measurement result. This fact is taken into account by this modification.
It is particularly preferable that when the pressure of the testing fluid in the measuring chamber exceeds a limit, a safety device is activated, which reduces the pressure of the testing fluid in the measuring chamber. For example, it is possible that the movement of the piston might become blocked. In this instance, the pressure in the measuring chamber during an injection could reach a level that is critical for the measuring device. This can be detected by the pressure measurement and appropriate countermeasures can be initiated.
The current invention also relates to a computer program, which is suitable for executing the above method, when it is run on a computer. It is particularly preferable if the computer program is stored in a memory, in particular a flash memory.
In addition, the invention relates to a device for measuring the injection quantity of injection systems, in particular for motor vehicles, and in particular in production testing, having a measuring chamber into which a testing fluid can be injected by an injection system, having a piston, which at least partially defines a measuring chamber, and having a detection device, which detects a movement of the piston and generates a corresponding measurement signal.
In order to increase precision in the detection of the injected fluid mass, and also to permit a better comparison of the injection quantities and injection volumes measured in different injections, the invention proposes that the device include a detection device for the pressure of the testing fluid in the measuring chamber as well as a processing unit in which the measurement signal is processed, taking into account the pressure detected.
It is particularly preferable if the processing unit of the device is provided with a computer program as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention will be explained in detail below in conjunction with the accompanying drawings,in which:
FIG. 1 shows a section through an exemplary embodiment of a device for measuring the injection quantity of injection nozzles; and
FIG. 2 shows a flowchart of a method for operating the device from FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , a device for measuring the injection quantity of injection systems is labeled as a whole with the reference numeral 10 . It includes a centrally disposed body 12 , which is secured to a sleeve 14 . This sleeve is in turn supported on a base plate 16 . The device 10 is fixed by means of the base plate 16 .
An essentially central stepped bore 18 is let into the central body 12 . A cylindrical insert 20 is inserted into the upper section of the stepped bore 18 and is supported by means of a collar 22 against the top of the central body 12 . A head 24 is placed onto the insert 20 in a pressure-tight fashion, which likewise has a stepped bore 26 let into it, which in the assembled state shown in FIG. 1 , extends coaxial to the stepped bore 18 . An adapter 28 is inserted from above into the stepped bore 26 and is sealed in relation to the stepped bore 26 by means of O-rings 30 . An injection system, in this instance an injector 32 , is inserted with its injection nozzle 33 into the adapter 28 . The injector 32 is in turn connected to a high pressure testing fluid supply (not shown). An injection damper 34 is inserted into the lower region of the stepped bore 26 in the head 24 .
The insert 20 also contains a bore 38 , which in the installation position shown in FIG. 1 , extends coaxial to the stepped bore 18 and to the stepped bore 26 . A piston 40 is guided so that it can slide in the bore 38 . A helical spring 42 , which is supported against a transducer receptacle 44 , pushes the piston 40 upward. A measuring chamber 45 is defined by the top end of the piston 40 , the lower unthreaded region of the injection damper 34 , and the lower region of the stepped bore 26 . The piston 40 is embodied as a closed, hollow body.
The measuring chamber 45 formed between the piston 40 and the head 24 is filled with a testing fluid (unnumbered). The pressure of this testing fluid in the measuring chamber 45 is measured by a pressure sensor 50 , which is disposed outside the intersecting plane of FIG. 1 and is therefore only depicted symbolically in the drawing. The pressure sensor 50 is inserted into the measuring chamber 45 through an oblique through bore (not shown). A temperature sensor 46 detects the temperature of the testing fluid in the measuring chamber 45 . The pressure sensor 50 and the temperature sensor 46 are connected to a control and processing unit 52 , whose output is connected to a magnetic drain valve 53 , through which the testing fluid can be drained from the measuring chamber 45 . To the left of the central body 12 , there is also a constant pressure valve 54 , which, even at very different gas pressures underneath the piston 40 , provides for a drainage rate from the measuring chamber 45 that is virtually independent of the gas pressure underneath the piston 40 when the electromagnetically actuated drain valve 53 is open.
The transducer receptacle 44 likewise contains a stepped bore 56 , which in the installation position shown in FIG. 1 , is likewise coaxial to the other stepped bores 18 , 26 , and 38 . A spring retainer 58 with a cylindrical shoulder 60 is mounted onto the underside of the transducer receptacle 44 . The shoulder 60 engages in the stepped bore 56 . The spring retainer 58 and its shoulder 60 also have a central stepped bore 62 , which is open toward the bottom.
A shoulder of the stepped bore 62 in the spring retainer 58 supports a helical spring 64 , which pushes a sensor retainer 66 upward against a collar of the transducer receptacle 44 that protrudes radially inward. The sensor retainer 66 is tubular or sleeve-shaped and its upper region has an eddy current sensor 68 screwed into it so that the top end of this sensor is a short distance under the bottom end of the piston 40 . A connecting line 70 of the eddy current sensor 68 is routed outward through the tubular sensor retainer 66 and the spring retainer 58 and is connected to the control and processing unit 52 .
In the event of a malfunction, for example due to an insufficient emptying of the measuring chamber 45 between two injections or two injection cycles, if the piston 40 moves too far downward, then it comes to rest with its bottom end in contact with the top end of the eddy current sensor 68 . Because the sensor retainer 66 is supported by the helical spring 64 , the piston 40 , together with the eddy current sensor 68 and the sensor retainer 66 , can move further downward—in this instance counter to the initial spring stress of the helical spring 64 . A downward motion of the piston 40 is possible provided that the testing fluid can flow out of the measuring chamber 45 through a circumferential groove (unnumbered) in the stepped bore 38 of the insert 20 . This prevents damage to the device 10 in the event of a malfunction.
The device 10 , which is depicted in FIG. 1 and is for measuring the injection quantity of an injection nozzle 28 , operates according to the following method (see FIG. 2 ):
Testing fluid (not shown) is supplied by means of the high pressure testing fluid supply to the injection system 32 and its injection nozzle 33 and, by means of the injection damper 34 , is injected into the measuring chamber 45 that is likewise filled with testing fluid. The injection damper 34 prevents the injection jets from directly striking the top end of the piston 40 . A direct impact of the injection jets against the piston 40 could set the piston into oscillations, which do not correspond to the actual course of the injection. The injection of testing fluid into the measuring chamber 45 increases the testing fluid volume in the measuring chamber 45 . The additional volume traveling into the measuring chamber 45 moves the piston 40 downward, counter to the force of the helical spring 42 and the gas pressure underneath the piston 40 . This changes the distance between the bottom end of the piston 40 and the eddy current sensor 68 .
This change in the distance between the eddy current sensor 68 and the bottom end of the piston 40 results in a change in the complex input impedance on the input side of the winding of the eddy current sensor 68 . This change is metrologically evaluated in the control and processing unit 52 and is used to determine a distance sm (block 72 in FIG. 2 ) that the piston 40 has traveled.
Based on the measured distance sm—after the start of the calculation in block 71 , a volume Vm is determined in block 74 . This corresponds to the volume by which the measuring chamber 45 has increased due to the movement of the piston 40 . This volume is calculated from the measured distance sm and the cross sectional area of the piston 40 , which is waiting in block 76 and has been called up from a memory 78 .
In block 80 , this volume Vm, which is also referred to as the “displacement volume”, is used to calculate the injected mass mi of testing fluid. This is done by multiplying the displacement volume Vm by the density of the testing fluid. However, the density of the testing fluid in the measuring chamber 45 on the one hand, depends on the temperature T (block 82 ) and on the other hand, depends on the pressure p (block 84 ), which prevail in the testing fluid in the measuring chamber 45 . These are detected by the pressure sensor 50 and the temperature sensor 46 and, based on the detected values, in block 80 , first the density prevailing in the testing fluid in the measuring chamber 45 is determined at the detected pressure p and the detected temperature T, and based on this density, the injected mass mi is determined.
Based on the actually injected mass mi of testing fluid, which has been injected into the measuring chamber 45 , in block 86 , a comparison or norm volume Vnorm is calculated based on a determined pressure pnorm and a determined temperature tnorm (block 88 ). This comparison or norm volume Vnorm is particularly well-suited for comparing different injections and for comparing different injection systems 32 . The method depicted in FIG. 2 ends at block 92 .
The device shown in FIG. 1 and the method shown in FIG. 2 can considerably improve the precision in the calculation of a volume injected into the measuring chamber 45 under defined norm conditions (norm temperature and norm pressure) and in the calculation of the actually injected testing fluid mass. This increase in precision has an especially significant effect, particularly on the measurement of small injection quantities.
In an exemplary embodiment that is not shown, the pressure which prevails in the testing fluid in the measuring chamber and is detected by the pressure sensor is also used for malfunction and safety monitoring of the device. If the pressure of the testing fluid in the measuring chamber lies beyond a defined limit, then it can be assumed that there is a malfunction in the system so that an error message is generated. For example with a jam med piston, a very rapid increase in the pressure in the measuring chamber can occur, which can cause damage to the device. In this instance, when the pressure of the testing fluid in the measuring chamber exceeds a limit, the magnetic drain valve 53 is triggered by the control and processing unit so that the valve opens and testing fluid is drained from the measuring chamber and the pressure in the measuring chamber is reduced. This reliably prevents damage to the device for example due to a jamming of the piston.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | In a method for measuring the injection quantity of injection systems, in particular for motor vehicles and in particular in production testing, an injection system injects a testing fluid into a measuring chamber. A detection device detects a movement of a piston, which at least partially defines the measuring chamber. This detection device generates a corresponding measurement signal. In order to increase the precision of the calculation of the injected testing fluid mass, the invention proposes that the pressure of the testing fluid in the measuring chamber be detected and that the measurement signal be processed taking into account the detected pressure. | 5 |
The present invention deals with the production of composite materials having a matrix of aluminum alloy which is reinforced with discontinuous fibers or particulates made of dissimilar materials.
BACKGROUND OF THE INVENTION
It has been recognized in the art that the properties of aluminum matrix alloys could be improved in one or more important respects by dispersing throughout the matrix a dissimilar material having little or no solubility in the metal matrix. For example, graphite dispersed in aluminum improves the wear resistance thereof. Graphite, normally speaking, is insoluble in and immiscible with an aluminum melt and would be rejected from such a melt. The problem is solved in accordance with U.S. Pat. No. 3,885,959 by coating the surface with nickel, a metal which is wetted readily by molten aluminum thereby permitting ready dispersal of graphite particles in the aluminum matrix. Other dispersed solid particulate materials can improve the stiffness of modulus or other mechanical properties such as strength, etc. of composite materials having a matrix of aluminum or aluminum alloys. Dispersed silicon carbide is an example of a material which can improve the physical properties of aluminum or aluminum alloys. Other materials when dispersed in fibrous form can improve the strength of aluminum. U.S. Pat. No. 4,012,204 describes the production of fibrous compositions infiltrated with an aluminum lithium alloy. Articles such as
(1) D. Webster, "Effect of Lithium on the Mechanical Properties and Micro-structure of SiC whisker Reinforced Aluminum Alloys," Metall. Trans. A, Vol. 13A, 1982, pp. 1511-1519; and
(2) R. A. Page and G. R. Leverant, "Relationship of Fatigue and Fracture to Microstructure and Processing in Al 2 O 3 Fiber Reinforced Metal Matrix Composites," Fifth International Conference on Composite Materials, TMS-AIME, Proceedings, 1986, pp. 867-886.
also deal with the problem.
In the production of composite materials having a metal matrix, three production methods have been recognized as follows:
(1) Solid-state or semi-solid-state consolidation;
(2) Pressure infiltration or squeeze casting; and
(3) Casting.
Of the above-mentioned three methods, the casting method is the simplest but has been investigated the least. The casting method involves merely the mixing of molten matrix alloy and the reinforcing material at temperatures above the liquidus temperature of the matrix alloy. Once mixed, the molten alloy containing the suggested reinforcing material is solidified by casting in a mold or in the melting crucible.
The casting method has a cost advantage compared to the other methods mentioned and is adaptable to the production of large ingots. The problem with the casting method has been that difficulties have been encountered in wetting the reinforcing material with the molten matrix metal or alloy. Unless wetting of the reinforcing material is effected, rejection from the melt occurs.
SUMMARY OF THE INVENTION
In accordance with the invention, non-oxide reinforcing materials from the group consisting of silicon carbide fibers, silicon carbide particles, PAN (Polyacrylonitrile) and pitch-based carbon fibers may be dispersed in a molten bath of aluminum alloy which contains about 0.2% to about 1%, by weight, of lithium and mixing the solid discontinuous phase material with the aluminum alloy bath for a time sufficient to provide substantially complete dispersion of the solid material throughout the bath and then solidifying the bath while maintaining the dispersion.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the invention, the aluminum alloy bath to form the matrix of the final composition material may contain in addition to the requisite 0.2% to about 1%, by weight, of lithium, up to about 4% copper, up to about 4% silicon, up to about 4% magnesium, up to about 2% zinc; up to about 1% tin, up to about 2% iron, and the balance essentially aluminum.
The lithium present in the molten aluminum alloy bath aids in wetting the reinforcing material. For this purpose, a lithium content less than 1% is sufficient although lithium contents lower than about 0.2% by wt. of the bath are insufficient. The lithium content is kept below about 1% since the vapor pressure of lithium at the temperatures of the molten aluminum alloy is high resulting in rapid loss of lithium. In addition, excessive lithium contents in the bath produce difficulties in melting practice and introduce potential corrosion problems.
Particulate materials used as reinforcing materials in accordance with the invention will generally have an average particle size less than about 100 microns; e.g. about 5 to about 70 microns. Fibers introduced as dispersions may have an average diameter of about 8 to about 20 microns and an average length of about 200 to about 1000 microns.
The aluminum alloy matrix material may also contain elements such as copper and/or magnesium and/or silicon which contribute strengthening to the matrix. Titanium carbide fibers or particles can also be introduced in amounts up to 5% by volume, as titanium carbide surfaces are wetted by molten aluminum.
In producing the composite materials of the invention, the aluminum base matrix alloy is melted in a crucible which may, for example, be made of graphite and an appropriate amount of lithium either as a metallic lithium or as a master alloy containing up to about 10% lithium, may be introduced into the molten matrix alloy. The desired reinforcing material is then added in an amount up to about 30%, e.g. about 20% by volume, and mixed mechanically as by stirring. No pretreatment of the reinforcing material is necessary. The mixture of the molten metal alloy and particulate or fibrous reinforcing material is solidified either by casting into a mold or by cooling in the melting crucible. Continuous casting of the mixture may also be resorted to. The process can be carried out in a normal atmosphere. The solidified ingot may be further processed by extrusion, press-forging at a temperature at which the matrix alloy is partially melted, or by other forming processes or combinations thereof.
Examples will now be given.
A number of charges weighing from 450 to 640 grams of aluminum alloy of the type shown in the Table were melted in a graphite crucible surrounded by a vertical tubular furnace. Two to four grams of lithium were added to the molten metal and mixed therewith by stirring. Various reinforcing materials in various amounts as shown in the Table were added to the molten alloy and mixed by stirring using a screw-type motorized stirrer having four blades made of molybdenum. In each case, the crucible was removed from the furnace and cooled by forced air.
Details of the various experiments are given in the following Table. Of the heats shown in the Table, heats G8, G10, G20 and G22 were successfully extruded at a reduction ratio of about 10 to 1. Heat G20 was hot-pressed after extrusion at 630° C. (1165° F.), a temperature in the liquid-solid two-phase region for the alloy. Hot-pressing is a desirable production technique for forming the final desired product and also eliminates minor defects in the composite.
TABLE__________________________________________________________________________Heat Matrix Al Alloy Reinforcing Material Li AdditionNo. Type Grams Type Grams Wt % Vol % Grams Wt % Result of Mixing__________________________________________________________________________G-2 6061 650 Carbon Fiber VMD (65) (9.1) (11.9) 0 0 Did not wet. Mixing stopped when about 15 grams carbon fibers were put in the crucible.G-3 6061 650 Carbon Fiber VMD 65 9.1 11.9 2 0.28 Mixed well.G-6 6061 600 SiC Particulate M 120 16.6 14.4 2 0.43 Slight difficulties in mix- ing, but eventually mixed.G-7 6061 625 SiC Particulate M 65 9.4 8.0 3 0.43 Mixed adequately.G-8 6061 650 Carbon Fiber VMD 65 9.1 11.8 3 0.42 Mixed well.G-9 6061 650 SiC Particulate I 65 9.0 7.7 4 0.56 Mixed well.G-10 6061 650 SiC Particulate I 85 11.5 9.8 4 0.54 Mixed adequately.G-13 6061 650 SiC Whiskers 65 9.4 8.0 4 0.58 Mixed well.G-16 6061 505 SiC Particulate PH 102 16.8 14.5 2 0.33 Mixed well.G-20 6063 600 SiC Particulate PH 130 17.8 15.4 2 0.27 Mixed well.G-21 6061 450 SiC Particulate N 120 19.2 16.8 0 0 4.8% TiC and 3.2% Si were added. Did not wet.G-22 6061 490 SiC Particulate N 80 13.7 11.8 2 0.34 1.7% TiC was added. Mixed well.__________________________________________________________________________ Reinforcing Materials: Carbon Fiber VMD: Pitchbased chopped carbon fibers. SiC Particulate M: About 1000 mesh. SiC Particulate I: About 800 mesh. SiC Particulate PH: 200 meshminus, 320 meshplus single crystal particulates. SiC Particulate N: 400 mesh.
Composites produced in accordance with the invention have improved hardness as compared to the properties of the aluminum alloy matrix without the dispersed dissimilar phase.
For example, Heats No. G-20 and G-22 from the Table had a Vickers hardness of about 118 and 100 HV10, respectively, after extrusion and T4 heat treatment, whereas the base alloy showed 58 HV10 after the same treatments. It is also expected that the composites produced with the invention have higher strength, stiffness, and wear resistance than the base alloy.
It will of course be appreciated that fibrous materials distributed throughout a metal matrix by mixing will be randomly dispersed but will nevertheless strengthen the matrix as long as the fiber is wetted by the molten matrix metal and is firmly bonded thereto in the solid state.
Composite materials produced in accordance with the invention such as Alloy 6061 matrix material strengthened with about 3% to about 30%, by volume, of silicon carbide particles are useful in applications such as automotive connecting rods, piston pins, cums and gears.
Although the present invention has been described in conjunction with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and appended claims. | Reinforced composite aluminum-matrix articles containing a non-oxide reinforcing material, such as silicon carbide fibers or particles, are produced by a casting process wherein a small amount of lithium less than about 1%, by weight, is included in a melt of aluminum matrix alloy to facilitate wetting of the reinforcing material and ready dispersal thereof in the aluminum matrix alloy. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording apparatus such as a printer, a copying machine, a word processor, a personal computer, a facsimile and the like. More particularly, it relates to a recording apparatus in which a recording sheet is pinched between and conveyed by a pinch roller and a convey roller and, after recording, the recording sheet is pinched between and discharged by a discharge roller and spur wheels.
2. Related Background Art
An example of conventional techniques with reference will be explained to FIG. 13, a pinch roller 5 is always urged against a recording sheet 3 or a convey roller 4 . Further, a discharge roller 11 is selected to have a convey amount slightly greater than that of the convey roller 4 so that tension is applied to the recording sheet 3 to eliminate looseness of the recording sheet and permit the recording under a good condition. After the recording sheet 3 leaves the pinch roller 5 , the recording sheet is discharged mainly by a conveying force of the discharge roller 11 .
However, the above-mentioned conventional technique has the following disadvantages.
(1) When a trail end of the recording sheet 3 leaves the pinch roller 5 , as shown in FIG. 4, the recording sheet is subjected to a force F directed toward a downstream direction and a downward direction, so that, since a convey distance of the recording sheet 3 is increased and conveying accuracy is worsened, recording accuracy at a rear end portion of the recording sheet 3 is worsened.
(2) After the trail end of the recording sheet 3 leaves the pinch roller 5 , since the recording sheet is conveyed mainly by the discharge roller 11 and spur wheels 12 which are rotated faster than the convey roller 4 , a convey distance of the recording sheet 3 per one line space is increased to worsen the conveying accuracy, thereby worsening the recording accuracy at the rear end portion of the recording sheet 3 .
SUMMARY OF THE INVENTION
To eliminate the above-mentioned conventional drawbacks, the present invention provides a (first) recording apparatus comprising a recording portion for effecting the recording on a recording sheet, a convey means for conveying the recording sheet to the recording portion by pinching the recording sheet between a pinch roller and a convey roller, and a discharge means for discharging the recording sheet by pinching the recording sheet between a spur wheel and a discharge roller. It further comprises an urging means for urging the pinch roller against the recording sheet, an urging force controlling means for controlling an urging force of the urging means, and a detecting means for detecting the fact that a trail end of the recording sheet is conveyed up to a predetermined position disposed upstream of a position where the trail end of the recording sheet leaves the pinch roller, wherein the urging force controlling means reduces the urging force of the urging means on the basis of a detection result from the detecting means.
The present invention further provides a recording apparatus comprising a (second) recording portion for effecting the recording on a recording sheet, a convey means for conveying the recording sheet to the recording portion by pinching the recording sheet between a pinch roller and a convey roller, and a discharge means for discharging the recording sheet by pinching the recording sheet between a spur wheel and discharge roller. It further comprises an urging means for urging the pinch roller against the recording sheet, an urging force controlling means for controlling an urging force of the urging means, and a detecting means for detecting the fact that a trail end of the recording sheet is conveyed up to a predetermined position disposed upstream of a position where the trail end of the recording sheet leaves the pinch roller, wherein the urging force controlling means releases the urging force of the urging means on the basis of a detection result from the detecting means.
The present invention also provides a (third) recording apparatus comprising a recording portion for effecting the recording on a recording sheet, a convey means for conveying the recording sheet to the recording portion by pinching the recording sheet between a pinch roller and a convey roller, and a discharge means for discharging the recording sheet by pinching the recording sheet between a spur wheel and a discharge roller. It further comprises a rotation controlling means for controlling rotations of the convey roller and the discharge roller, and a detecting means for detecting the fact that a trail end of the recording sheet is conveyed up to a predetermined position disposed upstream of a position where the trail end of the recording sheet leaves the pinch roller, wherein the rotation controlling means reduces convey amounts of the convey roller and the discharge roller corresponding to one line space.
The present invention further provides a (fourth) recording apparatus comprising a recording portion for effecting the recording on a recording sheet, a convey means for conveying the recording sheet to the recording portion by pinching the recording sheet between a pinch roller and a convey roller, and a discharge means for discharging the recording sheet by pinching the recording sheet between a spur wheel and a discharge roller. It further comprises a rotation controlling means for controlling rotation of the discharge roller, and a detecting means for detecting the fact that a trail end of the recording sheet is conveyed up to a predetermined position disposed upstream of a position where the trail end of the recording sheet leaves the pinch roller, wherein the rotation controlling means reduces a convey amount of the discharge roller corresponding to one line space.
The first or second recording apparatus may further include a rotation controlling means for controlling rotation of the convey roller and the discharge roller so that the rotation controlling means reduces convey amounts of the convey roller and the discharge roller corresponding to one line space. Alternatively, the first or second recording apparatus may further include a rotation controlling means for controlling rotation of the discharge roller so that the rotation controlling means reduces convey amount of the discharge roller corresponding to one line space.
In the third recording apparatus, the rotation controlling means may set the convey amount of the discharge roller to become the same as a convey amount of the convey roller before detected by the detecting means. In the fourth recording apparatus, the rotation controlling means may set the convey amount of the discharge roller to become the same as a convey amount of the convey roller before detected by the detecting means.
When the first or second recording apparatus includes the rotation controlling means for controlling rotation of the convey roller and the discharge roller, the rotation controlling means may set the convey amount of the discharge roller to become the same as a convey amount of the convey roller before detected by the detecting means. When the first or second recording apparatus includes the rotation controlling means for controlling rotation of the discharge roller, the rotation controlling means may set the convey amount of the discharge roller to become the same as a convey amount of the convey roller before detected by the detecting means.
In any of the first to fourth recording apparatuses, the detection means may comprise a sensor disposed in the vicinity of the convey roller, and a rotation amount measuring means for measuring a rotation amount of the convey roller. In any of the first to fourth recording apparatuses, the recording portion may be of ink jet recording type in which the recording is effected by discharging ink in response to a signal.
In any of the first to fourth recording apparatuses, the recording portion may be of ink jet recording type in which the recording is effected by discharging ink by growth of a bubble formed by heating the ink to exceed the film-boiling temperature generated by energizing an electrical/thermal converter in response to a signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory view showing a portion of a recording apparatus according to a first embodiment of the present invention in a condition that a sensor lever abuts against a recording sheet;
FIG. 2 is an explanatory view showing a condition that a trail end of the recording sheet has reached a pinch roller from a position shown in FIG. 1;
FIG. 3 is an explanatory view showing a condition that the pinch roller has been shifted upwardly from a position shown in FIG. 1;
FIG. 4 is an explanatory view for explaining a force acting on the recording sheet from the pinch roller;
FIG. 5 is a block diagram showing a control portion of a recording apparatus according to first and second embodiments of the present invention;
FIG. 6 is a block diagram showing a control portion of a recording apparatus according to a third embodiment of the present invention;
FIG. 7 is a block diagram showing a control portion of a recording apparatus according to a fourth embodiment of the present invention;
FIG. 8 is an explanatory view showing a concrete example of a drive system of the recording apparatus according to the second embodiment of the present invention;
FIG. 9 is an explanatory view showing a concrete example of a drive system of the recording apparatus according to the third embodiment of the present invention;
FIG. 10 is an explanatory view showing a concrete example of a drive system of the recording apparatus according to the fourth embodiment of the present invention;
FIGS. 11A, 11 B, 11 C, 11 D, 11 E and 11 F; and FIGS. 12A, 12 B and 12 C are explanatory views showing operating conditions of the recording apparatus according to the above-mentioned embodiments; and
FIG. 13 is an explanatory view showing a conventional recording apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 3 are sectional views (showing a side of a convey path for a recording sheet) for explaining an ink jet recording apparatus according to a first embodiment of the present invention. In FIGS. 1 to 3 , the arrow A indicates a conveying direction for the recording sheet. The recording sheet is conveyed from a condition shown in FIG. 1 to a condition shown in FIG. 3 .
In FIG. 1, a pinch roller 5 is supported by a pinch roller holder 5 a which is pivotally mounted on a pinch roller holder shaft 5 b and is biased by a compression spring 5 c so that the pinch roller is urged against a convey roller 4 . The convey roller 4 cooperates with the pinch roller 5 to convey the recording sheet toward the conveying direction (shown by the arrow A). The convey roller 4 is driven by a convey motor (not shown) to convey the recording sheet 3 by a predetermined amount. A stepping motor is used as the convey motor. A sheet end detecting PE sensor lever 1 for the detecting presence/absence of the recording sheet 3 is disposed upstream of the convey roller 4 and the pinch roller 5 in the recording sheet conveying direction.
A carriage 8 provided in a recording portion 6 is supported by a guide shaft 9 for reciprocal movement in a direction perpendicular to the conveying direction A for the recording sheet 3 . Further, a recording head (recording means) 7 is mounted on the carriage 8 to record on the recording sheet 3 conveyed onto a platen 10 by the convey roller 4 and the pinch roller 5 . The recording means may be of ink jet recording type in which the recording is effected by discharging ink from the recording head. That is to say, the recording head 7 includes fine liquid discharge openings (orifices), liquid passages, energy acting portions provided in the respective liquid passages, and energy generating means for generating bubble forming energy to be applied to the liquid in the energy acting portions.
Regarding such energy generating means, there are recording systems using electrical/thermal converters such as piezo-electric elements, recording systems using energy generating means in which a liquid droplet is discharged by heating the liquid by means of electromagnetic wave such as laser, recording systems using energy generating means in which liquid is discharged by heating the liquid by means of an electrical/thermal converter such as a heat generating element including a heat generating resistance body, and the like.
In the recording head used in the ink jet recording system among the recording systems, since liquid discharge openings (orifices) for discharging recording liquid droplets can be arranged with high density, the recording can be effected with high resolving power. Further, the recording heads using electrical/thermal converters as the energy generating means can easily be made compact, can effectively utilize advantages of IC techniques and/or micro-working techniques in which progress and reliability have been remarkably increased in a recent semi-conductor field, can easily be mounted with high density and can be made cheaper.
The recording head 7 can be moved so that a distance between a front surface 7 a of the recording head and a recording surface 3 a of the recording sheet 3 can be maintained properly in correspondence to a thickness of the recording sheet 3 . Spur wheel(s) 12 are urged against a discharge roller 11 by spring(s) (not shown) to serve as a pinch roller for the discharge roller. The spur wheel(s) 12 cooperate(s) with the discharge roller 11 to discharge the recording sheet 3 onto a discharge tray (not shown) without smudging the recording surface 3 a of the recording sheet 3 .
FIG. 5 is a block diagram showing a control portion of the ink jet recording apparatus. An MPU 104 for controlling the entire apparatus has a control time governing timer 105 . A ROM 106 serves to store control program of the MPU and the like, and a RAM 107 serves as a work area of the MPU 104 and serves to store information such as a speed of the carriage 8 and the like. An EEPROM 108 serves to protect the information even after a power source is turned OFF. A discharge heater driver 109 serves to drive a discharge heater for causing the recording head to discharge ink in response to recording information, and a carriage motor driver 110 serves to drive a carriage motor 111 for shifting the carriage 8 through a timing belt and pulleys (not shown). A convey motor driver 112 serves to control the driving of a convey motor 113 for driving the convey roller 4 .
A PE sensor 2 for detecting the presence/absence of the recording sheet 3 and tip and trail ends of the recording sheet is disposed upstream of the convey roller 4 . A recovery system motor driver 114 serves to control the driving of a discharge recovery treating apparatus such as an ink suction device (not shown) for restoring the recording head to a record permitting condition or for maintaining the recording head in the record permitting condition.
A sensor 116 serves to detect an operating position of a cam (not shown) of the discharge recovery treating apparatus. A solenoid driver 117 serves to control the driving of a solenoid 19 for controlling the urging of the pinch roller. An interface portion 103 connects the recording apparatus to a host computer so that the information can be communicated between the recording apparatus and the host computer through the interface portion. An electronic equipment 101 such as a computer, a word processor and the like connected to the recording apparatus through the interface portion 103 , and a printer driver 102 serves to set various conditions regarding the recording apparatus and sends commands to the recording apparatus in accordance with the set conditions.
Next, a recording operation on the recording sheet 3 will be explained. One-line recording is performed on a predetermined position of the recording sheet 3 by the recording apparatus and then the recording sheet 3 is conveyed by an amount corresponding to one line space. Such one-line recording and conveyance of the recording sheet are alternately repeated. When the recording sheet 3 leaves the PE sensor lever 1 , the trail end of the recording sheet is detected. As a result, the recording sheet 3 is conveyed by a predetermined distance L (FIG. 2) from a position where the PE sensor lever 1 was contacted with the recording sheet 3 to a position where the pinch roller 5 is contacted with the trail end of the recording sheet 3 . In this case, since the stepping motor is used, the number of steps corresponding to the distance L is judged by a CPU. Consequently, the fact that the recording sheet has been conveyed up to a predetermined position situated upstream of a position where the recording sheet leaves the pinch roller. Preferably, the predetermined position can be appropriately selected within a range between a separation position where the recording sheet has just left the pinch roller and a position situated upstream of the separation position and spaced apart from the separation position by a distance corresponding to one line space.
That is to say, the MPU (control means) detects the fact that the trail end of the recording sheet 3 has passed through the PE sensor lever 1 , by utilizing the PE sensor 2 and the PE sensor lever 1 . After the trail end of the recording sheet 3 was detected by the PE sensor 2 , when the stepping motor (convey motor 113 ) was rotated by the number of steps required for the convey roller to convey the recording sheet 3 by the predetermined distance L, the solenoid 19 is turned ON by the MPU.
When the solenoid 19 is energized, a connection portion 20 between the pinch roller holder 5 a and the solenoid is pulled toward the solenoid 19 , so that the pinch roller holder is rotated upwardly around the pinch roller holder shaft 5 b , thereby shifting the pinch roller 5 upwardly to separate the pinch roller from the recording sheet 3 (FIG. 3 ). As a result, the trail end of the recording sheet 3 is not subjected to a force (as shown in FIG. 4) toward a downstream direction. Thereafter, the recording sheet 3 is conveyed by the discharge roller 11 and the spur wheel(s) 12 to be discharged onto the discharge tray (not shown). In this way, a series of the recording operation is completed.
Thus, an increase in the convey distance of the recording sheet 3 due to the application of the force F can be prevented, and the convey accuracy of trail end of the recording sheet passing through the pinch roller can be prevented from being worsened.
In the above explanation, while an example that the urging (pressurizing) of the pinch roller 5 is released in order to release the downstream force F acting on the trail end of the recording sheet 3 was explained, when an urging force of the pinch roller 5 acting on the convey roller 4 is relatively small or when the recording sheet 3 is thin, the urging force of the pinch roller may be reduced or weakened, in place of complete release of the urging force of the pinch roller. In this case, the shift amount of the pinch roller 2 obtained by the solenoid 19 and the connection portion 20 may be selected to an amount that the pinch roller does not separate from the upper surface of the recording sheet.
(Second Embodiment)
Next, an embodiment in which a trail end of a recording sheet 3 is conveyed toward a downstream side by a pinch roller and then the recording sheet is conveyed by a discharge roller 11 and spur wheel(s) 12 will be explained.
In FIG. 8 (explanatory view for explaining an arrangement in which a convey roller and a discharge roller are driven by a common drive source), a driving force from a motor gear 13 a is transmitted to a convey roller gear 15 through a two-stage gear 14 a and then is transmitted to a discharge roller gear 16 through a two-stage gear 14 b . A total speed reduction gear ratio from the convey motor to the convey roller gear 15 is selected to 1:15 and a total speed reduction gear ratio from the convey motor to the discharge roller gear 16 is selected to 2:29.
FIG. 11A shows a relation between time lapse (when the trail end of the recording sheet 3 is situated upstream of the pinch roller 5 ), and a convey amount condition of the recording sheet 3 by means of the convey roller 4 , a convey amount condition of the recording sheet 3 by means of the discharge roller 11 , a recording condition of the recording head, a detection condition of the PE sensor and a pressurizing condition of the pinch roller. In the illustrated embodiment, a convey amount Vb of the discharge roller is selected to become greater than a convey amount Va of the convey roller by 2 to 3%, so that the recording sheet 3 can be conveyed without looseness. Further, the recording operation is performed while the recording sheet 3 is not being conveyed. The PE sensor is in a condition that it does not detect the trail end of the recording sheet and the pinch roller is in the pressurizing condition.
In the recording operation regarding the recording sheet 3 , the trail end of the recording sheet 3 is detected when the recording sheet 3 leaves the PE sensor lever 1 , and the recording sheet 3 is conveyed by the predetermined distance L.
Now, the convey amount corresponding to one line space which was previously set is changed to a new amount. In the illustrated embodiment, before the trail end of the recording sheet 3 is contacted with the pinch roller 5 , a convey amount of 48 steps per one line space is set in the convey motor 112 , and, thereafter, the convey amount is changed to 47 steps per one line space. Such a driving condition is shown in FIG. 11 B. In this condition, since the convey amount of the convey motor 113 corresponding to one line space is changed, the convey amount of the convey roller 4 is changed or reduced from Va to Va1 and the convey amount of the discharge roller 11 is changed or reduced from Vb to Vb1. Thus, even when the recording sheet is conveyed by the discharge roller 11 and the spur wheel(s) 12 , since the recording sheet is conveyed by the predetermined distance without increasing the convey distance per one line space more than that before the trail end of the recording sheet is detected, the convey accuracy of the trail end of the recording sheet 3 can be prevented from being worsened.
The changed convey amount Vb1 of the discharge roller 11 is not limited to a specific value but may be determined in accordance with material of the recording sheet 3 and/or discharging ability of the discharge roller 11 . An example that the changed convey amount of the discharge roller is set to be equal to the convey amount of the convey roller 4 before the trail end of the recording sheet 3 is detected by the PE sensor 2 is shown in FIG. 11 C. In this case, even when the recording sheet is conveyed by the discharge roller 11 and the spur wheels 12 , the recording sheet 3 is conveyed without changing the convey distance per one line space between before and after the trail end of the recording sheet 3 is detected by the PE sensor 2 . With this arrangement, the convey accuracy of the trail end of the recording sheet can be improved.
In the above explanation, while an example that the convey amount of the convey motor is changed after the trail end of the recording sheet 3 is passed through the pinch roller 5 was explained, such an example can be combined with the aforementioned embodiment. Such a combination is shown in FIGS. 11D and 11E. In this case, in addition to the advantage obtained by such an example, the increase in the convey distance of the recording sheet due to the downstream force F of the pinch roller 5 acting on the trail end of the recording sheet 3 can be prevented and further reduction of the convey accuracy can be prevented. Further, when this embodiment is combined with the first embodiment, although the predetermined position can be appropriately selected within the range between the separation position where the recording sheet has just left the pinch roller and the position situated upstream of the separation position and spaced apart from the separation position by the distance corresponding to one line space, the predetermined position may be situated upstream of such a range.
(Third Embodiment)
Next, a further embodiment regarding constructions of convey and discharge rollers will be explained. In FIG. 9 showing an arrangement in which a convey roller and a discharge roller are driven by respective drive sources, a driving force of the convey roller 4 is transmitted from a motor gear 13 a to a convey roller gear 15 through a two-stage gear 14 a and a driving force of the discharge roller 11 is transmitted from a motor gear 13 b to a discharge roller gear 16 through a two-stage gear 14 b . A total speed reduction gear ratio from the convey motor to the convey roller gear 15 is selected to 1:15 and a total speed reduction gear ratio from the discharge motor to the discharge roller gear 16 is selected to 2:29.
FIG. 6 is a block diagram showing a control portion of an ink jet recording apparatus according to this embodiment. In this control portion, a convey motor driver 118 for controlling the driving of the discharge motor 119 for driving the discharge roller 11 is added, in comparison with the control portion shown in FIG. 5 .
In the recording operation regarding the recording sheet 3 , the trail end of the recording sheet 3 is detected when the recording sheet 3 leaves the PE sensor lever 1 , and the recording sheet 3 is conveyed by the predetermined distance L. Now, the convey amount corresponding to one line space which was previously set is changed from Vb to Vb1 smaller than Vb.
With this arrangement, even when the recording sheet is conveyed by the discharge roller 11 and the spur wheels 12 , since the recording sheet 3 is conveyed without changing the convey amount per one line space between before and after the trail end of the recording sheet 3 is detected by the PE sensor 2 , the convey accuracy of the trail end of the recording sheet can be prevented from being worsened. Incidentally, FIG. 11F shows a driving condition in this case.
The changed convey amount Vb1 of the discharge roller 11 is not limited to a specific value but may be determined in accordance with material of the recording sheet 3 and/or discharging ability of the discharge roller 11 . An example that the changed convey amount of the discharge roller is set to be equal to the convey amount of the convey roller 4 before the trail end of the recording sheet 3 is detected by the PE sensor 2 is shown in FIG. 12 A. In this case, even when the recording sheet is conveyed by the discharge roller 11 and the spur wheels 12 , the recording sheet 3 is conveyed without changing the convey distance per one line space between before and after the trail end of the recording sheet 3 is detected by the PE sensor 2 . With this arrangement, the convey accuracy of the trail end of the recording sheet can be improved.
The third embodiment can be combined with the first embodiment. In such a combination, driving conditions shown in FIGS. 12B and 12C are used. In this case, in addition to the above-mentioned advantage, the increase in the convey distance of the recording sheet due to the downstream force F of the pinch roller 5 acting on the trail end of the recording sheet 3 can be prevented. Further, when this embodiment is combined with the first embodiment, although the predetermined position can be appropriately selected within the range between the separation position where the recording sheet has just left the pinch roller and the position situated upstream of the separation position and spaced apart from the separation position by the distance corresponding to one line space, the predetermined position may be situated upstream of such a range.
(Fourth Embodiment)
Next, a still further embodiment regarding constructions of convey and discharge rollers will be explained.
FIG. 10 is an explanatory view showing a concrete arrangement of a drive system in which a convey roller and a discharge roller are driven by a common drive source and a clutch gear is interposed between a convey roller 4 and a discharge roller 11 . A driving force from a motor gear 13 a is transmitted to a convey roller gear 15 through a two-stage gear 14 a and then is transmitted to a discharge roller gear 16 through a two-stage gear 14 b . Further, the two-stage gear 14 b is rotatably supported by a two-stage gear guide 18 a and a two-stage gear guide shaft 18 b so that the two-stage gear can be shifted upwardly by a solenoid (not shown). A clutch gear 17 a has an input associated with the convey roller gear 15 and an output associated with the discharge roller gear 16 . When the two-stage gear 14 b is interposed between the convey roller gear and the discharge roller gear as shown, since the discharge roller gear is rotated faster than the convey roller gear, there is no connection between the input and the output of the clutch gear 17 a . A total speed reduction gear ratio from the convey motor to the convey roller gear 15 is selected to 1:15 and a total speed reduction gear ratio from the discharge motor to the discharge roller gear 16 is selected to 2:29.
FIG. 7 is a block diagram showing a control portion of an ink jet recording apparatus according to this embodiment. In this control portion, a two-stage gear guide drive solenoid driver 120 for driving a two-stage gear guide drive solenoid 121 is added, in comparison with the control portion shown in FIG. 5 .
In the recording operation regarding the recording sheet 3 , the trail end of the recording sheet 3 is detected when the recording sheet 3 leaves the PE sensor lever 1 , and the recording sheet 3 is conveyed by the predetermined distance L. Now, the two-stage gear 14 b is shifted upwardly to disconnect the discharge roller gear 16 from the convey roller gear 15 . In this case, the driving force is transmitted to the convey roller gear 15 through the two-stage gear 14 a and then is transmitted to the discharge roller gear 16 through the input and the output of the clutch gear 17 a . Since the speed reduction ratio from the convey motor to the convey roller gear 15 is 1:15 and the speed reduction ratio from the convey motor to the discharge roller gear 16 also becomes 1:15, the convey amount of the discharge roller 11 becomes the same as that of the convey roller 4 . Thus, even when the recording sheet is conveyed by the discharge roller 11 and the spur wheels 12 , since the recording sheet 3 is conveyed without changing the convey amount per one line space between before and after the trail end of the recording sheet 3 is detected by the PE sensor 2 , the convey accuracy of the trail end of the recording sheet can be prevented from being worsened. Incidentally, FIG. 12A shows a driving condition in this case.
Further, the fourth embodiment can be combined with the first embodiment. In such a combination, a driving condition shown in FIG. 12C is used. In this case, in addition to the above-mentioned advantage, the increase in the convey distance of the recording sheet due to the downstream force F of the pinch roller 5 acting on the trail end of the recording sheet 3 can be prevented.
Further, when this embodiment is combined with the first embodiment, although the predetermined position can be appropriately selected within the range between the separation position where the recording sheet has just left the pinch roller and the position situated upstream of the separation position and spaced apart from the separation position by the distance corresponding to one line space, the predetermined position may be situated upstream of such a range.
Incidentally, in the present invention, the values set in the above-mentioned various embodiments are not limited to the aforementioned ones but may be appropriately selected. Further, the recording means of the recording apparatus is not limited to the ink jet recording system but may be of other recording type.
As mentioned above, the present invention relates to the recording apparatus in which the recording sheet is conveyed to the recording portion by a pinch roller and a convey roller while being pinched between these rollers, and after recording the recording sheet is pinched between and discharged by the discharge roller and the spur wheels, when the trail end of the recording sheet is conveyed to the predetermined position situated upstream of the position where the trail end of the recording sheet leaves the pinch roller. In such recording apparatus, by releasing or reducing the urging force or pressurizing force of the pinch roller or by reducing the convey amounts of the convey roller and the discharge roller or the convey amount of the discharge roller, the conveying accuracy of the trail end of the recording sheet can be prevented from being worsened, thereby improving the accuracy of the record position. | A recording apparatus includes a recording section, a convey section, and a discharge section. The invention further includes an urging device for urging a pinch roller against a recording sheet, an urging force controller for controlling an urging force of the urging device, and a detector for detecting that a trail end of the recording sheet is conveyed to a predetermined position disposed upstream of a position where the trail end of the recording sheet leaves the pinch roller. The urging force controller reduces or releases the urging force of the urging device on the basis of a detection result from the detector, thereby eliminating the force of the pinch roller acting on the trail end of the recording sheet. The apparatus prevents the conveying accuracy of the recording sheet from being adversely affected. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The invention described and claimed hereinbelow is also described in German Patent Applications EP 07117056.7 filed on Sep. 24, 2007. This European Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
[0002] The present invention relates to rotary tools and in particular to interfaces for attaching different sorts of working members, such as driver bits or sockets, to the shaft of a rotary tool.
[0003] Patent Application No. 10-155574 discloses a hybrid interface that allows one to secure either a driver bit or a socket to rotary tool output shaft. The output shaft is configured to include a hexagonal cavity for receiving a driver bit along with means, such as a ball and sleeve arrangement, for attaching or releasing the bit. The distal end of the output shaft has a square-shaped periphery, and so it is also able to accommodate a typical socket. One embodiment is configured to cooperate with a pin and an O-ring to secure sockets according to a standard used in Japanese markets. A second embodiment employs a spring-loaded protrusion mounted to a hole on the periphery of the output shaft to secure sockets configured with an inner annular groove which is typical of the standard used in North American and European markets.
[0004] JP Patent Application No. 2004-190714 discloses a socket attachment interface intended to simplify the attachment of sockets according to the Japanese standard. A detachable spring member is secured with a screw to the end face of the output shaft of a rotary tool and includes one or more protrusions that cooperate with one or more through-holes in the socket.
[0005] Accordingly, it is an object of the present invention to provide a rotary tool which is a further improvement of existing rotary tools.
SUMMARY OF THE INVENTION
[0006] The present invention provides a hybrid tool attachment interface that incorporates advantages from both of the above-described designs and which can accommodate a driver bit as well as a variety of sockets. The design is simple to manufacture and assemble and does not require additional tools for mounting or removing bits or sockets.
[0007] The inventive rotary tool comprises an output shaft having an axis of rotation, a distal neck portion which has at least three neck faces that do not interest the axis of rotation and a generally U-shaped spring element having a base portion and two leg portions, wherein the spring element straddles the distal neck portion.
[0008] The U-shaped spring element is securely attached to the output shaft without any separate fastening means and has the advantage that features that can be used to secure multiple types of working members can be embodied in an inexpensively constructed part that is furthermore easily detachable should it be subject to wear or damage and need to be replaced.
[0009] The design has the advantage that the output shaft is provided with an elongate cavity coaxial with its axis of rotation, so that it can optionally receive a driver bit, thereby providing additional functionality for the user, who can select from either a driver bit or a socket without needing to use a separate adaptor.
[0010] The output shaft is further provided with means for securing a driver bit within the elongate cavity. Preferably these means comprise a slidably-mounted sleeve which is biased by a spring and which cooperates with balls which act as locking members when a driver bit with a circumferential groove is inserted. In this way, the user can easily remove or attach a driver bit of this type without any separate tools.
[0011] The spring element of the inventive rotary tool has two tip portions, each of which is contiguous with one of the two leg portions. These two tip portions together with the base portion and the two leg portions embrace the distal neck portion to retain the spring element. Hence the force of the spring and its geometry allow the spring plate to surround and fasten itself to the neck region of the output shaft without the need for separate fastening means. Since it is detachable, the user may optionally remove the spring element for replacement or use with certain tool types.
[0012] Each of the two leg portions contacts one of the neck faces of the distal neck portion and this serves to grip around the output shaft to retain the spring element. Preferably the leg portions contact the neck faces within recessed regions of the neck faces. This has the advantage that the spring plate can lie flush with the rest of the distal neck portion to provide an overall generally flat profile for insertion of a socket.
[0013] Adjoining the recessed faces of the distal neck portion are elevated portions that serve as stop surfaces. These stop surfaces provide the advantage that the spring plate is prohibited from moving axially along the axis of rotation when a socket is inserted onto or removed from the distal neck portion.
[0014] One of the means by which the spring plate retains a socket is by having at least one spring-elastic protrusion on a leg portion. Preferably two such protrusions are present on two leg portions. The protrusions can advantageously mate with either an internal groove or a radial cavity within a socket.
[0015] When a socket is inserted, it will generally deflect the spring-elastic protrusion as well as the portions of the spring plate, preferably arms, that surround the protrusion. Therefore it is advantageous to provide cavities extending from each neck face to the elongate cavity to receive each spring-elastic protrusion when they are deflected. It is preferable if there are multiple aspects to the cavity, an internal cylindrical aspect that can be used to mate with a pin inserted through the shaft and the socket, as well as a larger, and preferably conically shaped cavity portion. The larger, conically-shaped portion can accommodate the protrusion and the flexible arms surrounding the protrusion even when the protrusion is maximally deflected.
[0016] To allow the same attachment interface to accommodate sockets according to a Japanese standard wherein a pin and O-ring are used to secure the socket, the base portion of the spring element is provided with an opening. The opening is positioned generally coaxially with the cavity in the output shaft so they may cooperate to form an insertion pathway for the pin that is used to secure the socket.
[0017] Since protrusions for retaining a socket as well as a pathway for traversing the output shaft with a pin are provided at the same time, the inventive rotary tool can securely attach working members via at least three different means. First, a driver bit can be inserted and retained in the elongate cavity. Second, a socket with an internal groove can be retained via the spring-elastic protrusions. Third, a socket with a radial cavity can be retained not only via the spring-elastic protrusions, but also via cooperation with a pin which traverses an opening in the spring plate and a cavity in the output shaft, so that it can be secured by an O-ring extending around the perimeter of the socket.
[0018] The novel features which are considered as characteristic for the present 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
[0019] FIG. 1 is a schematic drawing of a side view of a rotary tool according to the present invention, wherein features that are located within the tool housing are indicated with dashed lines.
[0020] FIG. 2 is a side view of the preferred embodiment of an attachment interface for a rotary tool.
[0021] FIG. 3 is a section view of the attachment interface of FIG. 2 taken along section line A-A.
[0022] FIG. 4 is an exploded perspective view of an attachment interface.
[0023] FIG. 5 is a detail section view of FIG. 3 .
[0024] FIG. 6 is a section view of the attachment interface with a socket according to a Japanese standard mounted thereon.
[0025] FIG. 7 is a section view of the attachment interface with a socket originally intended for mounting according to a Japanese standard mounted thereon.
[0026] FIG. 8 is a section view of the attachment interface with a socket according to a standard used in North America and Europe mounted thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] An example of a rotary tool according to the present invention is illustrated in FIG. 1 . While the illustrated embodiment is a power tool, and specifically a cordless impact driver, the invention may be advantageously used with a variety of rotary tools irrespective of whether they are powered or whether they include an impact driving function. Within housing 10 of rotary power tool 12 are a motor 14 and its associated motor shaft 16 . A transmission 18 converts the rotation of the motor shaft 16 into increased output torque, but correspondingly reduced speed rotation of the driveshaft 20 .
[0028] The driveshaft 20 is coupled to a hammer 22 which is in turn coupled to an output shaft 24 . The driveshaft 20 , hammer 22 and output shaft 24 are configured to transmit repetitive bursts of output torque via a hammer and anvil arrangement as is well known to those skilled in the art. An example of such an impact driver is shown in US 2006/0237205-A1, which is hereby incorporated by reference. The tool is provided with a handle 26 and a trigger 28 so that it may be conveniently operated by a user. The power source is a DC battery 30 in this exemplary cordless tool, but an AC power source is a standard alternative.
[0029] FIGS. 2-4 show various views of a tool attachment interface for a rotary tool. The output shaft 24 has a proximal neck portion 32 , a distal neck portion 34 , an end face 36 , and an axis of rotation 38 . An elongate cavity 40 in the output shaft 24 is centered around the axis of rotation 38 . The cavity is preferably polygonally shaped so that it can accommodate a complementary polygonally-shaped driver bit (not shown).
[0030] As means for securing a driver bit, a sleeve 44 , a compression spring 46 , and a retaining ring 48 , are mounted around the proximal neck portion 32 of the output shaft 24 . All of these elements are secured to the proximal neck portion 32 once a C-ring 50 is inserted into annular groove 52 . The force from the spring 46 positions the sleeve 44 such that balls 54 mounted in radial cavities 56 are urged partially into the elongate cavity 40 to act as locking members to act on a hexagonal driver bit with an annular groove (e.g., according to the DIN 3126-E6.3 standard) so that it can be securely attached and released from the output shaft 24 .
[0031] The radial cavities 56 are sized with a variable diameter, such that the balls 54 may travel within the radial cavities 56 but can only protrude partially into elongate cavity 40 . A user can urge the sleeve 44 against the spring force, so that the balls have space enough to exit entirely from the elongate cavity 40 . Rather than ball pairs 54 , a single ball, an elongate pin, or a blade may alternatively be used as locking members.
[0032] Besides these preferred means for retaining a driver bit, many prior art alternatives are also compatible, so long as they can coexist with the socket-retaining means that will be further described. The essential features are that the output shaft 24 is configured with an elongate cavity 40 , and the means for securing the driver bit are located within or around the proximal neck portion 32 of the output shaft 24 . For example, one or more screws mounted perpendicular to the axis of rotation could also be used to secure the driver bit.
[0033] Alternatively, a magnetic part incorporated into the proximal neck portion 32 could be used to attract and retain the driver bit. Furthermore different methods of adjustment are possible. Instead of being biased by the spring 46 , the sleeve 44 could instead be threaded to the proximal neck portion 32 , so that its position is adjusted via rotation in order to correspondingly position the one or more locking members.
[0034] To accommodate sockets that have a square-shaped female interface, the distal neck portion 34 of the output shaft 24 is preferably square-shaped in a cross-section taken perpendicular to the axis of rotation 38 . Detailed features of the distal neck portion 34 are shown in FIGS. 4 and 5 . Each of its four neck faces 60 is configured with a neck cavity 62 that traverses the space between the neck face 60 and the elongate cavity 40 and comprises a cylindrical portion 64 and a conical portion 66 . The surface of each neck face 60 is partially recessed. Each of four recessed faces 70 are linked by similarly recessed bevel faces 69 at the four corners of the distal neck portion 34 . Front 67 and rear 68 elevated portions are found on either side of the recessed faces 70 and bevel faces 69 .
[0035] Without any further elements attached, the distal neck portion 34 is sufficient to permit a user to mount and secure a Japanese-type socket 71 to the output shaft 24 using a metal pin 72 and a rubber O-ring 74 as retaining means as is customary for this standard (see FIG. 6 ). To do so, a socket 71 is mounted onto the output shaft 24 such that each inner face 76 of the socket makes contact with elevated portions 68 of each neck face 60 . Then a pin 72 is inserted through radial cavities 78 in the socket and through two neck cavities 62 of the output shaft 24 . Finally, an O-ring 74 is mounted around an annular groove 80 of the socket 71 to trap the pin 72 .
[0036] Note that a given socket 71 can be mounted in any of four possible orientations relative to the output shaft 24 , resulting in the mounting pin 72 traversing the socket 71 in one of two possible orientations. In every case, there is no interference from the driver bit mounting means and therefore the two distinct mounting interfaces may coexist on the same output shaft 24 .
[0037] So that the output shaft 24 can also accommodate different types of sockets, and so that they may be retained without separate fastening members, a spring plate 82 comprising a base portion 84 , two leg portions 86 , two corner portions 88 , and two leg tip portions 89 is preferably mounted to the distal neck portion 34 of the output shaft 24 . Each of the two corner portions 88 link the base portion 84 with a leg portion 86 . Each of the two leg tip portions 89 extend from the end of the leg portion, that is, they extend from the part of the leg portion 86 opposite the part of the leg portion 86 that interfaces with the base portion 84 .
[0038] The spring plate 82 is best visualized in the exploded view of FIG. 4 . It is fastened to the output shaft 24 without any separate fastening means and does not require the use of tools for attaching or detaching. The cross section of the mounted spring plate 82 taken perpendicular to the axis of rotation 38 (not shown) is substantially U-shaped, as defined by the base portion 84 and the two leg portions 86 .
[0039] The thickness of the spring plate 82 corresponds very closely to the dimensions of the distal neck portion 34 , so that when the spring plate 82 is mounted, each of its portions contacts a recessed face 70 or a bevel face 69 , so that it is substantially but not necessarily exactly flush with the surface of the front 67 and rear 68 elevated portions of each neck face 60 (see FIG. 5 ). These elevated portions 67 , 68 provide a stop surface to counter the axial force acting on the spring plate 82 when a socket is inserted or removed.
[0040] The two corner portions 88 and the two leg tip portions 89 of the spring plate 82 are complementary to the bevel faces 69 of the distal neck portion 34 . As each neck face 60 of the distal neck portion 34 is structurally equivalent, the spring plate 82 can be mounted in any of four possible orientations. The spring plate 82 exerts a spring force which tends to grip the distal neck portion 34 via its two leg tip portions 69 . It can be manually removed by overcoming this spring force. The distal neck portion 34 may alternatively have an asymmetrical design, for example with only two neck cavities 62 . In this case, the spring plate 82 is preferably inserted in particular orientations.
[0041] While the spring force itself comprises sufficient attachment means for retaining the spring plate 82 , alternatives are possible. If the spring plate 82 were provided with an opening on one of its faces that corresponded to a cavity on the distal neck portion 34 , the parts could be secured with a screw or the like. A suitable screw head would be flat and its head preferably somewhat recessed within the spring plate 82 so as not to interfere with the insertion of a socket. In addition, such a screw should not be long enough to enter the elongate cavity 40 so as to interfere with the mounting of a driver bit.
[0042] At the center of each leg portion 86 of the spring plate 82 there is a spring-elastic protrusion 90 . Four openings 92 surround the protrusion, thereby establishing four flexible arms 94 . Although not absolutely essential features of the spring plate, these openings 92 and arms 94 reduce the force necessary to deflect a protrusion 90 below the surface of the leg portion 86 . As will be seen below, this may potentially happen during the insertion of a socket onto the attachment interface. Therefore, a leg portion 86 with two, three, five, six or even more openings can be used towards this same goal and present reasonable alternatives. The spring plate 82 is preferably manufactured through stamping of sheet metal and these openings 92 and arms 94 can be readily introduced during this process.
[0043] When it is deflected, each protrusion 90 exerts a radial force generally perpendicular to the axis of rotation 38 . When a socket 71 is inserted, its inner face 76 deflects each protrusion 90 while the socket 71 slides into its mounting position, at which time the protrusion 90 acts on a cavity 78 or groove 100 in the socket 71 . When the spring plate 82 is mounted to the output shaft 24 , the position of each protrusion 90 and flexible arm 94 corresponds roughly to the position of the cylindrical portion 64 and conical portion 66 of the neck cavity 62 respectively. This structure provides sufficient space for the protrusion 90 and flexible arms 94 to be deflected in the general direction of the axis of rotation 38 against its inherent spring force.
[0044] The base portion 84 of the spring plate 82 has an opening 96 roughly comparable in diameter to that of the cylindrical portion 64 of a neck cavity 62 . Since the opening 96 is positioned coaxially with the neck cavity, a pin 72 can be inserted through these features so that a socket 71 can be mounted using a pin 72 and O-ring 74 even when the spring plate 82 is mounted to the output shaft 24 . In this configuration, the inner faces 76 of the socket 71 constantly deflect the protrusions 90 , but this is permissible since there is adequate space in the neck cavity 92 to accommodate the protrusions 90 as described above. Alternatively and preferably, the same socket 71 could be removed, rotated ninety degrees, and inserted past the spring force of the protrusions 90 , so that each protrusion 90 engages with a radial cavity 78 in the socket 71 as shown in FIG. 7 . A socket 98 with an internal annular groove 100 is also retained by this attachment interface as shown in FIG. 8 .
[0045] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
[0046] While the invention has been illustrated and described as embodied in a rotary tool with multiple tool attachment interfaces, 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.
[0047] 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. | A rotary tool has an output shaft having an axis of rotation and a distal neck portion which has at least three neck faces that do not intersect the axis of rotation, and a substantially U-shaped spring element having a base portion and two leg portions, wherein the spring element straddles the distal neck portion. | 1 |
BACKGROUND OF THE INVENTION
This invention generally relates to saw chain sharpening devices and more particularly this invention relates to saw chain sharpening devices where the saw chain being sharpened is mounted on the cutting bar and the operator of a chain saw is at the job site which is frequently in the woods. This device provides for precise and accurate file sharpening of the saw chain by providing precisely aligned file guide bushings which allows the operator of the chain saw to accurately sharpen the saw chain without taking the chain saw to a shop. It is important to note that there are several devices on the market that are within the art of saw chain sharpening. A number of these devices have been patented and are described in U.S. Pat. Nos. 2,440,633; 3,005,362; 3,027,784; 3,055,238; 3,322,000; 3,670,600. The devices defined and claimed in the U.S. Pat. Nos. 3,005,362; 3,670,600; 3,905,118 and 3,322,000 are particularly designed for use in the woods and for use by the chain saw operator. Some of the prior art devices designed for use in the woods have been constructed to simply rest on the cutting bar or on the saw links or otherwise and are not secured to the chain saw. Because the device is not secured to the saw assembly, the saw teeth consequently are not filed consistently with regard to the angle across the cutting edge of the saw tooth and are not consistently filed in a direction which is about 10° to 11° inclined to the horizontal to the vertically directed cutting bar. Those devices designed to provide sufficient accuracy so that the saw chain is properly filed are either very difficult to use by the operator and require special set-up procedures, procedures all of which are difficult and cumbersome, especially in the woods. Also most of the devices which provide for accurate sharpening are expensive and simply not economically feasible for use by the chain saw operator. Because of the cost of these devices, it would be more realistic for the chain saw operator to simply hand file the saw without using anything other than a file. Such filing may result in a saw chain useable until it can be put in the shop for proper sharpening. There are other devices which are less expensive and which are designed for use in the field by the chain saw operator. Although these devices may be low in cost, they generally do not provide the accuracy and the control of the file resulting in a saw chain improperly filed. In summary, saw chain sharpening devices that are currently available and useable in the woods by the chain saw operator are either expensive, cumbersome and difficult to use or they are low cost but fail to provide the control and the positioning of the file in order to properly file the saw chain according to the manufacturer's specifications. Accordingly, it is an object of this invention to provide a saw chain sharpening device which is simple to use and with no adjustments to be made by the chain saw operator. Another object of this invention is to provide a low cost, highly reliable and long lasting device which is useable by the chain saw operator at the work place. A still further object of the invention is to provide a device which is not only simple to use by physically small, light weight and portable. Yet another object of the invention is to provide a device which when straddle mounted on the chain saw and affixed to the cutting bar provides a file guide means for very accurately controlling the file angle relative to the saw chain tooth being filed. Yet another object of the invention is to provide a device having hardened steel bushings diammetrically opposed and having at least one pair of these bushings angularly positioned relative to the cutting bar and the saw chain so that the operator can file sharpen the saw chain to the manufacturer's specifications. The at least one pair of bushings being diammetrically opposed on an axis which is about 30° from an axis which would be normal to the saw chain travel direction that direction being along the cutting bar from the motor end toward the tip end on the top edge of the bar. Further objects and uses of the invention will become apparent after reading the following detailed specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a chain saw having the device of this invention mounted thereon.
FIG. 2 is a view of a saw tooth of a saw chain.
FIG. 3 is a top view of the saw chain sharpening device straddle mounted over the saw chain and clamped onto the cutting bar.
FIG. 4 is a side view of the saw chain sharpening device viewing in a direction along the cutting bar toward either the cutting bar engine end or cutting bar tip end.
FIG. 5 is a bottom view of the device of this invention.
FIG. 6 is a top view of the saw chain sharpening device showing a bushing exploded out of the device.
FIG. 7 is a view taken on section lines 7--7 of FIG. 4.
FIG. 8 is a perspective view of the gauge tab.
FIG. 9 is similar to the embodiment shown in FIG. 5 but showing two clamping screws.
FIG. 10 is a view of the device with one pair of diammetrically opposed file guide means.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the saw chain sharpening device 18 is straddle mounted over the saw chain 14, the saw chain 14 being properly mounted on the cutting bar 16 of the chain saw 10. In the particular embodiment of the device depicted by the drawing figures, the device 18 is attached to the cutting bar 16 by means of a clamping screw 32 and by means of a cutting bar contact surface 28 both of which which are secured against the cutting bar 16. The combination of the surface against the cutting bar 28 and the screw device 32 that is used to tighten the sharpening device 18 on the cutting bar 16 causes the sharpening device 18 to be removably attached to the cutting bar 16. Further, it allows the operator to mount the saw chain sharpening device 18 on the bar 16 in any position convenient from the engine end 8 of the cutting bar 16 to the tip end 9 of the cutting bar 16. The saw chain sharpening device 18 is positioned vertically, that is in a direction going from above the cutting bar to below the cutting bar, by means of a top registration surface 24 on the top of the cavity inside of the saw chain sharpening device 18. The saw chain sharpening device 18 is positioned by the operator to not rest on the top surface 13 of the saw teeth 12 but to be just clear of the top surface 13 of the teeth 12, the clearance which can be set by inserting a piece of paper or any such material such as a book match cover to allow this clearance. This clearance is defined as the space formed between the top surface 13 of the teeth 12 and the top registration surface 24. The purpose of this clearance is, to allow the saw chain 14 to freely pass through the saw chain sharpening device 18 and particularly through the saw chain passage way 26. After the operator securely attaches the saw chain sharpening device 18 to the cutting bar 16 in proper vertical position, he then inserts a round file through the guide means 36 in walls 22 of the saw chain sharpening device 18. The bushings 38, which are the guide means for the file, allow for the file to be slideably guided across the cutting surface 11 of the saw tooth 12. When the file is inserted through the guide means 36, the saw chain 14 is carefully drawn toward the tip end 9 of the cutting bar 16 until it touches the file. When the operator has drawn the saw chain 14 toward the tip end 9 of the cutting bar 16 until the file is engaged against one of the saw teeth 12, the operator then pushes the file forward through the file guide bushings 38. While pushing the file forward the operator should rotate the file. This practice is very important and results in a sharper filed tooth. While pushing and rotating the file, modest pressure is caused between the tooth 12 and the file by applying a slight pull of the saw chain 14 toward the tip end 9 of the bar 16. The pull is released when the file is pulled back after the push stroke of the file. This process is repeated until the tooth is properly filed. The file is then drawn back through the saw chain sharpening device 18 so that it is clear of the saw chain 14. The saw chain 14 is then drawn back toward the tip end 9 of the cutting bar 16 until the next like tooth 12, in other words, right hand or left hand tooth is again within the saw chain sharpening device. (There are so called right hand and left hand teeth alternately affixed to the chain to form the saw chain). The file is then reinserted through the two aligned file guide holes 36 or bushings 38 and the saw chain 14 is then pulled toward the tip end 9 of the cutting bar 16 until it again engages with the file. The operator then, as he previously did for the prior tooth, continues to draw the file back and forth until the tooth 12 is properly sharpened all the while maintaining a slight degree of pull on the chain 14 toward the tip end 9 of the cutting bar 16 on the forward stroke and releasing the pull on the back stroke. This process is continued until all the like direction teeth, in other words, right hand or left hand teeth have been sharpened. If the saw chain sharpening device 54 is one as depicted in FIG. 10 having only one pair of diammetrically opposed alignment holes 56 for the file, the device must be removed from the cutting bar, rotated 180° and remounted on the cutting bar. The file guide alignment holes 56 will then be in proper angular position relative to the cutting bar 16 to file the other direction teeth. The process is again repeated as was done before, that is applying the filing technique as previously described. A very important feature of the invention is that the operator is not able to alter the angular position of the file in any way. The file position is rigidly maintained because the file passes directly through a pair of hardened bushings 38 or file guide alignment holes 36 positioned in the device 18 according to the manufacturer's specifications. The result being that the saw chain being filed must be filed at exactly that angle. There is no adjustment by the operator. There is no way the operator filing the saw chain 14 can file it in any way other than at the prescribed angle. The very unique combination of this invention provides for some beneficial and unexpected results. Saw chain 14 should be filed at an angle of about 30° with a perpendicular to the saw chain 14 and saw chain bar 16. The positioning of the file guides 36 on the frame 19 provides this angle. In addition however, an effective angle of about 10° to about 11° above a horizontal and in the direction in which the file is pushed is also desired. While this angle of about 10° to about 11° is not designed into the device 18, because of the uniqueness of the design, this angle results and is a consequence of a "roll-over" of the saw chain 14 which is caused by the filing action on the push stroke. All that is required is that the saw chain 14 be tightened onto this cutting bar 16 (using the tension adjustment on the saw chain 10) so that it freely moves on the bar 16 without significant slack or looseness. This overall result is completely unexpected and unobvious. It should be noted that in prior art devices the saw chain is, by design, rigidly positioned while filing. In addition, prior art devices basically do not provide a device where the operator can rotate the file on the push stroke--a procedure very necessary in order to obtain a finely sharpened edge on the tooth. The file rotation is not only essential to obtaining a sharp edge on the saw tooth 12 but the rotation also results in an even wear of the sharpening file. This invention 18 allows for such rotation and yet provides a means for controlling the critical angles while filing the saw chain 14.
Having described how the device of this invention is used, the device itself and in particular, the preferred embodiment of the device itself will now be described.
The frame means of the preferred embodiment is a cylindrical member 19 and is essentially made from a cylindrical rod having a length sufficiently long so as to be able to be mountable on the cutting bar 16 over the top of the saw chain 14.
The cylindrical rod has a hole drilled from a top surface 21, the top surface 21 being that surface which will be uppermost from the top surface 13 of the saw teeth 12 when the device is mounted on the saw chain 14 and cutting bar 16. The hole is drilled partially through the cylindrical rod thereby creating a cylindrical cavity inside the rod, the cylindrical cavity having interior walls and a bottom, thus creating a lower wall 20 of the inner cavity of the cylindrical rod. A slot 29 is cut through the lower wall 20 of the cavity. The cylindrical member 19 having a cavity therein now can be described as having cylindrical walls 22 with a wall thickness equal to approximately the difference between the outer radius of the rod and the radius of the cavity within the rod and further, it also will have a bottom surface or a lower wall 20 with a slot 29 cut therethrough across the full outer diameter or twice the outer radius of the cylindrical member 19. One wall of this slot 29, the cutting bar contacting surface 28, will be the wall against the cutting bar 16 of the chain saw 10 when the device 18 is mounted on the cutting bar 16. The cutting bar contacting surface 28 is positioned so that when the device 18 is mounted on the cutting bar 16, the centerline 15 of the cutting bar will correspond to the centerline 17 of the cylindrical rod. The width of the slot 29 is of sufficient width to allow the sharpening device 18 to be able to be straddle mounted over top of the saw chain 14 down onto the cutting bar 16. A hole 30 is drilled and threaded which is positioned so as to be central to the slot 29 in the lower wall 20 of the cylindrical member 19 and in opposition to the cutting bar contacting surface 28. The axis of the threaded hole 30 being on a radial line of the cylindrical member 19 and perpendicular to the slot 29. The combination of the cutting bar contact surface 28 opposite the threaded hole 30 and the clamping screw 32 mounted in the threaded hole 30 serves as the clamping means which secures the saw chain sharpening device 18 onto the cutting bar 16. A saw chain passage way 26 is cut in the cylinder walls 22 of the cylindrical member 19 on a radial line that is parallel to the slot 29 and about perpendicular to the threaded hole 30 and positioned above the slot 29 and above the lower wall 20 having a configuration so as to allow the saw chain 14 to pass through the cylinder walls 22 without touching them. The top registration surface 24 of the saw chain passage way 26 is positioned relative to the slot 29 so that when the saw chain sharpening device 18 is straddle mounted on the cutting bar 16 and over the saw chain 14, the top registration surface 24 of the saw chain passage way 26 will essentially rest on the top surface 13 of the saw teeth 12. In practice, a shim would be placed over the saw teeth 12 so that when the saw chain sharpening device 18 is mounted over the saw chain 14, the shim provides a clearance for the saw chain teeth 12 to pass through the saw chain passage way 26 without engaging or touching this top registration surface 24. Two pair of diammetrically opposed holes 36 are drilled in the cylinder walls 22 on radial lines called axes of alignment 34 which are angularly disposed about 60° from the radial line for the saw chain passage way 26 which radial line is the same as the cutting bar centerline 15. The two axes 34A and 34B of the two pair of diammetrically opposed holes 36A and 36B will intersect on a plane which plane is parallel to the cutting bar contacting surface 28 opposite the threaded hole 30 in the slot 29 and coincident with a plane containing the cutting bar centerline 15. Further, each axis 34A and 34B of the diammetrically opposed holes 36A and 36B would have an angle 35 between them of about 60° and the two axes 34A and 34B would lie in a plane said plane being horizontal and approximately perpendicular to the plane coincident with the cutting bar centerline 15. If the two pair of diammetrically opposed hole 36A and 36B are themselves to be used as the file guide means, the interior walls of each of these four holes would be radiused throughout the length of the holes to allow the round file to easily insert through the holes 36 without engaging either the front or rear edges of the holes 36. In the preferred embodiment where the file guide means are hardened steel bushings 38, the holes 36 drilled in the cylinder walls 22 are of a diameter about equal to the outer diameter of the hardened bushings 38. The inner diameter 39 of the bushings 38 are to accommodate the proper file diameter for the saw chain 14 being sharpened. In the embodiment using the hardened steel bushings 38, the bushings 38 are press mounted in the file guide holes 36 that are drilled in the cylinder walls 22. The inner diameter 39 of the bushings 38 varies throughout the length of the bushing 38, the diameter being larger at each end and smallest toward the center of the bushing 38. This variation appears as a radius of curvature in the axial direction 34A and 34B of the bushing 38 and allows the file to slide more easily through the bushings 38. An additional feature of the saw chain sharpening device 18 is an adjustable gauge 40 for filing each tooth 12. The adjustable gauge 40 is mounted on the cylindrical member 19 near the lower wall 20 of the cylindrical member 19 on a chord which would be essentially parallel to the cutting bar contacting surface 28 and on the side of the cylindrical member 19 opposite the threaded hole 30 and clamping screw 32. The adjustable gauge 40 comprises a tab like device 44 which is positioned on a thumb screw 42 and held by a compression spring 46 so that the operator who is in the process of filing a saw chain 14 can adjust the position of the tab 44 so that it will contact either a forward or a leading edge of the tooth or the trailing edge of a tooth not being sharpened. After filing the tooth which is in the process of being sharpened by a predetermined amount, either the tooth just prior sharpened or the next tooth to be sharpened (depending on the operator) will come into contact with the tab 44 on the file gauge 40. At the time contact is made with the other tooth, the tooth being sharpened has been filed by about an equal amount to the prior tooth that was sharpened. In this way the adjustable gauge 40 provides a means for filing each tooth on the saw chain 14 by approximately the same amount. The saw chain sharpener 18 can be fabricated using any material which has sufficient strength so that the sharpener will stay in proper position on the chain saw. The material also should be easily machineable. Materials such as stainless steel, steel, aluminum, teflon, or nylon are examples of material which can be used to fabricate the sharpener 18. The materials listed are for illustration only and the list is not necessarily complete.
Having described the invention, it will be apparent to those skilled in the art that various modifications may be made thereto without departing from the spirit and scope of this invention as defined in the appended claims. | A device for sharpening saw chains while the saw chain is mounted on a chain saw cutting bar. The saw chain sharpening device is designed for use by a chain saw operator at the job site. The device comprises a frame configured to be straddle mounted over the saw chain and removeably clamped to the cutting bar. The frame has mounted thereon at least one pair of diammetrically opposed bushings having an inside diameter to accept a saw file and to permit the file to be slideably moved and axially aligned with the axis of alignment positioned relative to the saw chain so that the saw tooth being filed will be filed at the proper angle. The file guide bushings also provide precise control of the saw file position relative to the saw tooth being sharpened. | 1 |
CROSS-REFERENCE
This application is a continuation-in-part of my copending application entitled "FLOATING CHIP DISPENSER" filed on Feb. 22, 1979 as U.S. Ser. No. 14,118, which in turn is a continuation-in-part of my earlier copending application entitled "A METHOD AND COMPOSITION FOR THE LONG TERM CONTROLLED RELEASE OF A NON-PERSISTENT ORGANOTIN PESTICIDE FROM AN INERT MONOLITHIC THERMOPLASTIC DISPENSER" filed on Jan. 22, 1979 as U.S. Ser. No. 5,174, which in turn is a continuation-in-part of an application bearing the same title which was filed on June 19, 1978 as U.S. Ser. No. 916,570, now U.S. Pat. No. 4,166,111.
BACKGROUND OF THE INVENTION
The present invention relates to the incorporation of the soluble or sparingly soluble compounds of various elements recognized as essential to plant health and growth in a modified thermoplastic dispensing pellet, powder, granule, or other convenient dispensing form. Such compounds are salts or oxides of well recognized trace elements vital to plant nutrition. Said salts or oxides upon contact with water release zinc, iron, copper, boron, manganese, molybdenum, magnesium, cobalt and selenium in an ionic form as a water solution. Said plants, through natural processes, absorb the trace nutrient during uptake of the nutrient enriched water. Release, being largely moisture dependent, is self-regulatory. During the growing season, wherein soil moisture is readily available, trace nutrient release is continuous and uniform. When moisture is not present, the plants generally do not grow and said nutrients are not released, thus avoiding loss of nutrient.
Heretofore, agronomists and nutritionists have recognized the vital and essential function of various elements needed in minute quantities by growing plants. Such elements have been termed "trace nutrients." Their functions vary, some being essential to the photosynthetic process or being a critical component in various enzyme systems. In general, the complete lack of a given trace element precludes plant growth. For instance, Western Australia would not support agricultural field crops prior to the introduction of zinc into the soil. In most instances where trace nutrients are utilized, the normal soil content is too low for proper nutrition and plants cultivated in said soils are generally more susceptible to disease, show poor growth characteristics and consequently crop yields are low.
It is common practice to supplement trace element poor soils by adding the needful material directly or as an additive in bulk nutrient applications containing those substances classified as "fertilizers", i.e., nitrogen, potassium and phosphorus. Most agricultural commodities require trace element soil supplement for optimum growth and thus maximum yield. Such agricultural commodities include field crops such as wheat, alfalfa, potatoes, clover, tobacco, pineapple, soy beans, sugar, beets, cotton, corn, barley, oats, rice, and the like; citrus fruits; nuts, such as pecans peanuts, coffee, cocoa, walnut, almond; fruits such as apples, pears, cherries, plums, peaches; vegetables, such as beans, peas, cauliflower, carrots, lettuce, tomatoes, cabbage, and the like; and, forestry commodities such as pine trees, and pasture grasses. In the latter case, elements essential to animal growth such as zinc, iron, copper and selenium are ingested by domestic animals consuming said pasture grasses as forage. Lack of trace amounts of critical elements in the cow, sheep, goat and swine lead to deficiency diseases and thus decreased output of meat, milk and wool.
It is probable that lack of application of trace nutrients in U.S. agricultural activities could lead to substantial declines in food production. It is also likely that proper use of trace elements in soils lacking adequate quantities of said materials, such as in vast reaches of Africa, would lead to a dramatic increase in agricultural productivity.
Heretofore, in a typical utilization system, relatively high dosages of trace nutrients are added periodically to the soil. A number of disadvantages, ameliorated by this invention, occur. Said nutrients are of necessity water soluble salts or oxides else the treated plant cannot absorb them. Being water soluble, a large proportion of material applied, perhaps 80 percent or more, is lost from the root zone via natural processes such as percolation in the vertical direction to earth strata below the effective range of the root structure or washed beyond said root range through the movement of ground waters in the horizontal direction. In addition, the type of soil plays a profound role in the trace nutrient contact and ingestion processes. Alkaline soils and/or clay type soils generally complex the added nutrient chemical thus creating insoluble ligands of no value to the nutrient deficient plant. The rate of soil intervention in the nutrition process varies with pH and type, but is an extremely important negative factor.
Relatively massive amounts of the trace elements must thus be applied to overcome natural loss processes and mechanisms. This leads to two distinct and severe disadvantages. In general, treatment must be afforded before such growing season and sometimes followed by one or more retreatments during that season. It is unusual for one treatment to last over any great length of time and consequently, effort is expended and chemicals are purchased repeatedly by the agriculturist at frequent intervals with a concommitant economic factor increasing the cost of foodstuff production. Probably of even greater significance is that massive treatment early in the season leads to luxurious consumption (i.e., consumption beyond real plant needs) early in the growing season with rapidly depleting chemical availability during the middle and late growing season. It is generally recognized that the uniform availability of the trace nutrient in appropriate day-by-day quantities optimizes yield.
The use of controlled-release trace nutrients of the present invention will overcome the luxury consumption, inadequate consumption cycle thus giving greater crop yield, will reduce the total amount of trace nutrient needed, and will also greatly extend between treatment times, from one to two, three, or more years, possibly five or ten years, depending on agricultural practices and natural circumstances (crop rotation and so on).
It is well known that biocidal materials can be incorporated in a polymeric matrix and caused to release at a rate efficacious with pest destruction. U.S. Pat. No. 3,417,181 teaches that organotin toxicants can be dissolved in an elastomer-type matrix and caused to release through a diffusion-dissolution mechanism when exposed to water. The crux of this seminal invention was keyed to the necessity of the agent being soluble in the polymer. Similarly, U.S. Pat. Nos. 3,590,119; 3,426,473; 3,851,053; and 3,639,583 extend the scope of the art to embrace new formulations encompassing different elastomers, specific release regulants that effect the diffusion path length and the like, but again the key concept is the necessity of agent solubility in the elastomer. Agents incorporated are organic pesticides and the generic matrix type is elastomers such as natural rubber, styrene-butadiene rubber, and the like. In contrast, U.S. Pat. No. 4,012,221 teaches that inorganic copper salts capable of being released into water are incorporated in a moderately crosslinked elastomer in which the copper salts are insoluble.
It is well known to the compounding art that agents not soluble within a polymeric matrix will not move at an efficacious rate through said matrix to said matrix surface and thus enter the ambient environment.
Almost all organic pesticidal agents lack solubility in thermoplastic matrixes. Similarly, inorganic pesticidal agents are likewise insoluble in known thermoplastic or thermosetting polymers.
One method of causing an insoluble organic agent to emit from a plastic dispensing unit is to use a third phase material that is (1) soluble in some extent in said plastic and (2) will carry said organic agent in solution or serve as a migratory pathway for said agent to reach the surface of said dispenser. It is, of course, recognized that the incorporated agent must reach the plastic/external environment interface to have any effect on organisms inhibiting the external environment. U.S. Pat. Nos. 2,956,073 and 3,116,201 describe the use of plasticizers as carrier elements. In an improvement on such patents, U.S. Pat. Nos. 3,705,938 and 3,864,468 teach that surface loss from a plasticized matrix is subject to control through the use of a regulating membrane at said surface.
The controlled-release art has been generally confined to the incorporation and release of insecticides, bactericides, molluscicides and other toxic materials of an organic nature from an elastomer, wherein solubility is essential or a plastic, wherein an additive carrier material is critical. Microencapsulation processes wherein an inner core of the toxic agent is surrounded by a polymeric matrix is well known to the pest control art. In general, release is effected by the rupture of the enveloping membrane and/or the passage of water through the porous membrane structure, said water path serving as a means of egress for said pesticide which reaches in this manner the external environment.
Little work has been hitherto performed in the development of efficacious long lasting fertilizing systems. U.S. Pat. No. 3,748,115 teaches that plant nutrients can be bound in a matrix of synthetic rubber, waxes, asphalt, and the like. In this work, four critical elements of the invention are set forth. The fertilizer, emphasizing bulk materials and not trace nutrient, must be uniformly dispensed in a hydrophobic binding element. The dispensing unit must be cylindrical in shape. Said cylinder must be partially coated with a water-insoluble, water-permeable exterior membrane. A portion of the cylinder must be non-coated with said membrane. U.S. Patent 3,520,651 extends this art to teach that more than one nutrient can be incorporated in similar dispensing commodities.
In contrast, the subject invention is related to trace nutrient elements, the binding matrix need not be hydrophobic, the dispenser can take any shape although the granule or pellet is preferred, and no exterior membrane is utilized.
Of course, fertilizing materials have long been compounded with various binders to facilitate dispersal and, in some cases, to prolong availability by slowing the rate of solution in water through precluding immediate nutrient element contact with water. U.S. Pat. No. 3,336,129 teaches that the use of small amounts of water insoluble copolymers and terpolymers of ethers, substituted ethers, ethylene oxide and the like will serve as carriers for fertilizing materials, said copolymers and terpolymers must be crosslinked. Materials are comprised of polymer+fertilizer+water+soil components and the plant is grown within this medium.
Also, fertilizers such as urea can be coated in a granular form as taught in U.S. Pat. No. 3,336,155 thus retarding solution in ground waters. U.S. Pat. No. 3,276,857 teaches that a fertilizer can be encapsulated with asphalt or various waxes and thus emission into the environment is slowed.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide for the slow release of plant trace nutrients.
It is another object of the present invention to provide for the slow release of trace nutrients, as above, wherein said trace nutrients are contained in a polymer matrix.
It is a further object of the present invention to provide for the slow release of trace nutrients, as above, wherein said trace nutrients include zinc, iron, copper, boron, manganese, molybdenum, magnesium, cobalt, and selenium.
It is an additional object of the present invention to provide for the slow release of trace nutrients, as above, wherein said trace nutrients, when applied to soil and through water dissolution, is readily available to various plants such as crops, citrus fruits, nuts, vegetables, pasture grasses, trees, and the like through natural processes such as absorption of the trace nutrient during uptake of the nutrient-enriched water.
It is still another object of the present invention to provide for the slow release of trace nutrients, as above, wherein said polymer matrix is made from a copolymer of ethylene-vinyl acetate, a copolymer of ethylene-propylene, a low density polyethylene, and combinations thereof.
It is a still further object of the present invention to provide for the slow release of trace nutrients, as above, wherein said polymer matrix is made from a copolymer of ethylene-vinyl acetate, a copolymer of ethylene-propylene, and combinations thereof.
It is yet another object of the present invention to provide for the slow release of trace nutrients, as above, wherein said polymer matrix contains a porosigen compound.
It is yet another object of the present invention to provide for the slow release of trace nutrients, as above, wherein said porosigen desirably is soluble or sparingly soluble in water such that said trace nutrient is released over a time period from a few months to a few years.
These and other objects of the present invention will become apparent from the specification.
In general, a slow release trace nutrient composition, comprises: 100 parts of a polymer matrix; said polymer matrix made from a compound selected from the class consisting of an ethylenevinyl acetate copolymer, an ethylene-propylene copolymer, a low density polyethylene, and combinations thereof; the amount by weight of said ethylene constituent in said ethylene-vinyl acetate copolymer ranging from about 60 percent to about 95 percent, the weight average molecular weight of said ethylenevinyl acetate copolymer ranging from about 40,000 to about 400,000; the amount by weight of said ethylene constituent in said ethylene-propylene copolymer ranging from about 30 percent to about 75 percent, the weight average molecular weight of said ethylene-propylene copolymer ranging from about 50,000 to about 250,000; said low density polyethylene having a density of from about 0.90 to about 0.94 grams per cc and a weight average molecular weight of from about 100,000 to about 400,000; and a plant trace nutrient contained in said polymer matrix, the amount of said trace nutrient being such that said trace nutrient is slowly released when said polymer matrix is in contact with an aqueous environment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the concepts of the present invention, trace nutrients are slowly and controllably released to soil to improve plant growth and yield over an extended period of time. This result is obtained by incorporating the trace nutrient into a polymer matrix. Additionally, the matrix can contain soluble or sparingly soluble porosigen compounds therein.
In my prior copending continuing applications, my invention related to the sustained release of various pesticides, from a polymer matrix, against such aquatic pests such as mosquito larva, the aquatic larva form of parasites, molluscan hosts of trematode parasites, and the like. The pesticide such as an organotin compound, and the like, could be contained in a polymer matrix which either sank or floated. The exact nature of the various pesticides and porosigens contained within the polymer matrix, as well as the concepts of the inventions therein, are set forth in my previous continuing applications which are hereby fully incorporated by reference.
Now it has been found that trace nutrients can slowly be released when contacted by an aquatic environment or moisture, such as rain or moisture in the soil, often times by only the copolymer matrix when the trace nutrient itself is a porosigen, and most always released when using the porosigen compounds set forth below. A polymer matrix binder of the present invention is an ethylene-vinyl acetate copolymer. Such a copolymer is readily available in commerce and the amount by weight of the ethylene units, based upon the total weight of the copolymer, ranges from about 60 percent to about 95 percent with a range of from about 80 percent to about 93 percent being preferred. The weight average molecular weight of the copolymer generally ranges from about 40,000 to about 400,000 and preferably from about 75,000 to about 300,000. Desirably, the copolymer has an ASTM Test #D1238 melt flow index of from about 6 to about 12 and preferably from about 7 to about 11 and a Vicat softening point of from about 70° C. to about 95° C. Since, apparently, the ethylene repeating units in the copolymer act as a regulator with regard to pore size, higher amounts of the ethylene constituent will result in slower release times.
Additionally, another polymer matrix or binding agent of the present invention which can be utilized alone or in combination with said ethylene-vinyl acetate copolymer, that is from 1 percent to 99 percent and preferably from about 35 percent to about 60 percent is an ethylene-propylene copolymer having a weight average molecular weight of from about 50,000 to about 250,000 with a preferred range of from about 100,000 to about 200,000. The percent by weight of the ethylene units can generally vary from about 30 percent to about 75 percent, and preferably from about 45 to about 75 percent by weight, based upon the total weight of the copolymer. The melt flow index of the ethylene-propylene copolymer can generally range from about 15 to about 45, and preferably from about 20 to about 32 according to ASTM Test #D1238 at 190°, 21600 gm,gm/10 minutes.
Additionally, it has been found that low density polyethylene can be used by itself as a polymer matrix. Preferably, the polyethylene matrix has been found useful to provide a long release deviation when blended with the ethylene-vinyl acetate copolymer or the ethylene-propylene copolymer, or combinations thereof. By low density polyethylene, it is meant a polyethylene having a density of from about 0.90 to 0.94 g/cc and a weight average molecular weight of from about 100,000 to about 400,000. The melt flow index of the low density polyethylene may be similar to said ethylene-vinyl acetate copolymer, that is from about 5 to about 14, and preferably from about 7 to about 11, as in Microthene MN 718 (manufactured by U.S.I. Chemicals). Melt flow=8.5 g/10 minutes according to ASTM Test #D1238. Although generally a lower release rate is obtained, the melt flow index of the low density polyethylene may be low, that is from about 1.0 to about 5.0 as when Microthene MN 703 is utilized (a low density polyethylene manufactured by USI Chemicals) having a melt index of 1.2 g/10 minutes according to ASTM Test #D1238. Similarly, a low density polyethylene having a high melt flow index such as from about 11 to 25 may be utilized and results in a greater release rate. Thus, depending upon the rate of release, various amounts of low density polyethylene may be utilized, as from 1 percent to 99.9 percent. Generally, to obtain desirable release rates, the amount of homopolyethylene utilized may range from about 30 percent to about 75 percent and, preferably, from about 40 percent to about 60 percent by weight based upon the total weight of the polymer matrix blend, that is the weight of the ethylene-vinyl acetate copolymer and/or the weight of the ethylene-propylene copolymer with the low density polyethylene.
The various trace elements utilized are generally in the form of salts or oxides, which are readily available, desirably low in cost, and are not highly deliquescent. It is noted that the term "salts" includes the various hydrates thereof, that is the mono-, the di-, the tri-, the tetra-, the penta-, the hexa-, the hepta-, etc. Should the salt not exist in a non-hydrate form, the most common forms are meant. With regard to zinc-containing compounds which may be utilized as trace nutrients, they include the following: zinc sulfate, zinc chloride, zinc carbonate, zinc oxide, zinc phosphate, zinc chlorate, zinc nitrate, the various existing hydrates thereof, and the like. Typical copper trace nutrient compounds include copper sulfate, copper carbonate, copper oxide, copper oxychloride, copper nitrate, copper phosphate; various copper complexes such as tetramines, diamines; the various existing hydrates thereof, and the like. Typical iron trace nutrient compounds include iron chloride, iron sulfate, iron oxide, the various existing hydrates thereof, and the like. Typical manganese trace nutrient compounds include manganese oxide, manganese sulfate, manganese chloride, manganese nitrate; the various existing hydrates thereof, and the like. Typical boron trace nutrient compounds include boric acid, sodium biborate; the various existing hydrates thereof, and the like. Typical molybdenum trace nutrient compounds include molybdenum oxide, sodium molybdate, potassium molybdate, the various existing hydrates thereof, and the like. Typical cobalt trace nutrient compounds include cobalt sulfate, cobalt chlorate, cobalt nitrate; the various existing hydrates thereof, and the like. Typical selenium trace nutrient compounds include sodium selenate, selenium dioxide, selenium trioxide, selenium oxychloride, selenium disulfide, selenium sulfur oxide, and the like. Typical magnesium compounds include magnesium carbonate, magnesium sulfate, magnesium nitrate, magnesium acetate, magnesium oxide, magnesium chloride, magnesium ammonium chloride, magnesium phosphate, magnesium sulfite; the various existing hydrates thereof, and the like.
Desirably, the amount of trace nutrient released by the polymer matrix is such to make the plant grow or to supplement the environment. That is, the soil is supplemented such that the plant's intake is supplemented, preferably to an extent of its normal amount of the particular trace nutrient required. Naturally, the exact amount will vary depending upon several factors such as the lack of the specific trace nutrient in the soil, the various types of soil, the intake requirement of a particular trace nutrient for a specific plant or crop. Thus, the actual amount will vary from site to site, depending upon soil characteristics and the plant species involved. Accordingly, the exact demands for a particular trace nutrient of the present invention will naturally and inherently vary greatly. In order to achieve a desirable amount of trace nutrient required for a particular or specific soil and type of plant, several methods may be utilized. For example, a much larger amount of the polymer matrixes containing the particular trace nutrient or nutrients may be released, i.e., a larger number of pounds per acre. Another method is simply to utilize a formulation having a higher release rate of a particular trace nutrient. Still another method is to use a formulation having a higher amount of trace nutrient content therein. Yet another method relates to utilizing larger particles, that is, granules or chips. Additionally, other variations may also be utilized. As an approximate rule of thumb, the formulation can contain from about 1 percent to about 60 percent by weight of a particular trace nutrient ion, based upon the total weight of the formulation. A desirable amount is from about 2 percent to about 50 percent, with a more desirable amount being from about 4 percent to about 40 percent. The amount of trace nutrient compound which usually exists as a salt or oxide ranges from about 10 to about 160 parts by weight based upon 100 parts by weight of the polymer, desirably from about 25 to about 125 parts, and preferably from about 50 to about 100 parts by weight.
Generally, a particular soil is usually deficient in one or two trace nutrients. However, in some instances, it may require a few or even several trace nutrients. According to the present invention, a plurality of trace nutrients can be contained within a particular polymer matrix in various amounts suitable to meet the demands of the particular crop or plant desired. Thus, a so-called "one-shot approach" may be utilized instead of applying several applications of polymer matrixes, each containing a different trace nutrient.
Release of the trace nutrient is generally confined to the soil environment. However, the plants allowed to assimilate the trace nutrients will not grow unless the soil contains some degree of moisture. Thus, moisture is utilized as a transporting material in dispensing the trace nutrient. Therefore, it is essential that the formed polymer matrix be amenable to water egress and ingress. Thus, the porosity of the polymer matrix becomes important to the slow release process. It is generally believed that the enhancement of microporosity (free volume) as well as macroporosity of the polymer matrix is important to the present invention. Porosity can be imparted by various chemical compounds termed porosity enhancing agents or "porosigens." However, depending upon the type of polymer utilized as well as the type of compound utilized as a trace nutrient which, itself, often times serves as a porosity agent, it is thus not always necessary to utilize such an agent. For example, trace nutrient compounds such as a chloride, copper sulfate, iron sulfate, iron chloride, manganese sulfate, manganese oxide, manganese chloride, boric acid, sodium biborate, sodium molybdate, cobalt sulfate and sodium selenate can be utilized without the aid of a porosigen. Of course, a co-porosigen of a low water solubility would increase the rate released and a co-porosigen having a higher water solubility would increase the rate even more.
Generally, the amount of trace nutrient and the optional porosigen is such that release occurs over a period in excess of one month to a couple, a few, and even several years. Although largely dependent upon soil conditions and plant intake required, an amount of porosigen is utilized such that the daily release rate of the trace nutrient varies from about 0.001 to about 4 percent by weight per day based upon the total weight of the trace ion available in a particular matrix. A desired daily release rate is from about 0.001 or, more desirably, 0.01 percent to about 3 percent of the total amount of trace nutrient ion available, and more desirably from about 0.90 percent to about 1.6 percent per day, and preferably from about 0.30 percent to about 1.1 percent per day.
As noted above, the type of porosigen will vary depending upon the desired release rate sought. Should a relatively low increase rate be sought over the release rate level effected by only the polymer and the trace nutrient, a number of moderate or low solubility compounds can be utilized as a porosity-inducing agent. By moderate solubility, it is meant that the solubility is approximately 0.1 grams or less per 100 grams of water, whereas by a low solubility compound, it is meant that it has a solubility of approximately 0.01 grams or less per 100 grams of water.
Generally, any compound which is inert with respect to the polymer matrix and the trace nutrient can be utilized, as a porosigen. By inert, it is meant that the porosigen does not chemically react with the polymer or the trace nutrient. Additionally, the porosigen is also not damaging or harmful to the environment in terms of toxicity. Thus, the porosigen can be any compound which is set forth in the Handbook of Chemistry and Physics, 1977-78 Edition, published by the Chemical Rubber Co., which is hereby fully incorporated by reference, and meets the above requirements with regard to solubility and non-harmful to the environment.
A suitable class of an inert porosigen compound includes the inorganic salts or the hydrates thereof, or oxides. The cation of such a salt may generally be any of the alkaline metals and preferably any of the non-toxic alkaline earth metals, Column 1A and 2A, respectively, of the Periodic Table. Additionally, various other metals may be utilized such as iron, nickel, zinc, tin, silver and the like. The anion portion of the salt may generally be any negative charge entity, as the various carbonates, the various bicarbonates, the various nitrates, nitrites, or nitrides, the various sulfates, sulfites, or sulfides, the various phosphates, phosphites, or phosphides, including the ortho, pyro, hypo, variations thereof, and the like. Generally, the sulfates, sulfites and sulfides are preferred as anions, with carbonates being highly preferred. Moreover, as noted above, the anion may be an oxide of the metal. Specific examples of coleachants include magnesium carbonate, magnesium sulfide, magnesium phosphide, magnesium oxide, calcium carbonate, calcium bicarbonate, calcium nitride, calcium oxide, calcium phosphate, calcium phosphite, calcium sulfide, calcium sulfite, iron carbonate, iron sulfate, iron sulfide, iron sulfite, nickel carbonate, nickel sulfide, zinc carbonate, zinc oxide, zinc sulfide, zinc sulfite, tin sulfide, tin oxide, silver carbonate, silver oxide, silver sulfide, silver sulfite, sodium bicarbonate lithium phosphate, beryllium oxide, strontium carbonate, strontium sulfate, and strontium sulfite. Additionally, silicon dioxide may also be utilized. Magnesium carbonate, strontium carbonate, ammonium carbonate, and barium carbonate are preferred, with calcium carbonate being highly preferred.
When it is desirable to use a porosigen compound having a soluble porosigen, that is a solubility greater than 0.1 grams per 100 grams of water, generally any inert and non-environmental harmful compound can be utilized which has a solubility of from about 0.1 to about 1.0 gram and desirably from about 1.0 to about 100 grams per 100 grams of water. Examples of such soluble compounds are set forth in the Handbook of Chemistry and Physics, 1977-78 Edition, published by the Chemical Rubber Company which is hereby fully incorporated by reference. Specific examples include sodium carbonate and sodium bicarbonate.
Generally, the halogen salts of the alkalin metals and the alkalin earth metals, Column 1A and 2A, respectively, of the Periodic Table, as well as of nickel, iron, zinc, tin and silver, which have a solubility of at least 0.1 grams/100 grams of water, and preferably the chloride salts thereof can also be utilized. The Handbook of Chemistry and Physics, 1977-78 Edition, Supra. is hereby fully incorporated as to such specific compounds since the list is rather extensive. Additionally, ammonia as a cation constitutes another class of salts with specific examples being ammonium bromide, ammonium carbonate, ammonium bicarbonate, ammonium chlorate, ammonium chlorite, ammonium chloride, ammonium fluoride, ammonium sulfate, and the like. Additionally, sodium silicate can also be used. Of this group, sodium bicarbonate, sodium carbonate, silicon dioxide, sodium silicate, and ammonium sulfate are preferred. Moreover, inert liquids compatible with and dispersible in the polymer matrix such as the lower and glycerol glycols may be utilized, especially ethylene glycol.
Generally, suitable amounts of a porosigen range from 0.1 to 70 parts by weight based upon 100 parts by weight of polymer matrix, desirably from about 1.0 parts to about 30 parts, and preferably from about 2.0 parts to about 12 parts.
The slow release trace nutrient composition or formulation can contain, in addition to the above-mentioned components, various well known and conventional additives to enhance dispersion, add color, aid in processing, or to alter density. For example, zinc stearate may be utilized as a dispersant in suitable amounts as from 0.2 parts to about 5 or 10 parts by weight per 100 parts by weight of polymer with about 1 or 2 parts being preferred.
The composition can also contain suitable amounts of an attractant-porosigen such as from about 2 to about 25 parts of soy oil or lecithin when it is desired that a particular type of animal eat the nutrient, e.g., cattle, with 4 to 16 parts being desirable. Additionally, various amounts, i.e., 1 to 30 or 2 to 12 parts of carbon black may be utilized as a regulant.
In order to form a suitable thermoplastic dispenser which releases suitable amounts of the trace nutrient, it is desirable that the particle sizes of the various components be relatively small. For example, it is desirable that the various trace nutrients have a Tyler mesh size of roughly 100 or greater (i.e., a particle size smaller than 100 mesh) and preferably smaller than 200 mesh. Accordingly, a particle size range for the porosigen is generally the same. The particle size of the ethylene-vinyl acetate copolymer, the polyethylene, and the ethylene-vinyl acetate copolymer is roughly about 50 to 200 Tyler mesh. Since the composition is made by heating and melting the polymer, the polymer size prior to formation of the matrix is not very important.
The slow release trace nutrient composition is prepared by mixing the trace nutrient with the copolymer and/or the low density polyethylene either alone or with the porosigen in suitable proportions as indicated above in any conventional mixing apparatus along with various additives such as colorants, dispersants, and the like. The mixture is then coalesced by heating at least above the softening point and preferably above the melting point of the polymer and partitioned for use in any suitable size or shape, for example, chip, pellet, etc. Thus, the mixture may be added to a conventional extruder where it is molded at from about 120° C. to about 220° C. in a suitable form such as a ribbon which can be cut into pellets, etc.
Before numerous examples are presented to disclose various embodiments and best mode of the invention, a few general rules are noted with regard to determining the effect of any formulation with regard to release of a trace nutrient. In general, the incorporation of a porosigen agent will cause the release of more trace nutrient on a daily basis. Conversely, the incorporation of a low density polyethylene will moderate or reduce the daily release, especially if the polyethylene has a low melt flow index (for example, 5.0 or less). If the trace nutrient is fairly soluble in water, for example, 1.0 or greater, or if a very low release rate is desired and the polymer is either the ethylene-propylene copolymer or the ethylene-vinyl acetate copolymer, a porosigen is not required. Additionally, the ethylene-vinyl acetate copolymer gives better release than the ethylene-propylene copolymer. As well appreciated by one skilled in the art, many factors can effect the results such as the actual particle or chip size of the polymer matrix, surface area of the polymer matrix or chip, and the like, so that the general rules are just that, general rules.
The invention will be better understood by reference to the following examples.
Typical formulations for the controlled release of zinc ions are set forth hereinbelow.
EXAMPLE I--ZINC SULFATE FORMULATIONS
Several formulations of zinc sulfate in various plastic matrices and without porosigen additives are depicted in the following table:
TABLE I__________________________________________________________________________ FORMULATION (PARTS)INGREDIENT 1-A 1-B 1-C 1-D 1-E 1-F 1-G 1-H 1-I 1-J 1-K__________________________________________________________________________EVA 763.sup.1 50 40 50 50 50 50 100 -- -- 50 50LDPE 718.sup.2 40 50 40 40 40 40 -- 100 -- 40 40LDPE 703.sup.3 -- -- -- -- -- -- -- -- 100 -- --Zinc Stearate.sup.4 2 2 2 2 2 2 2 -- 2 2 2Zinc Sulfate.sup.5 80 80 80 80 60 80 80 80 80 80 80Am. Sulfate.sup.6 -- -- 5 10 5 5 5 5 5 -- --Ethylene Glycol.sup.7 -- -- -- -- -- 2 -- -- -- -- --Sodium Bicarbonate.sup.8 -- -- -- -- -- -- -- -- -- 5 10__________________________________________________________________________ .sup.1 Ethylene vinylacetate copolymer (U.S. Industrial Chemical Co. code MU763, Melt Index 9.0) .sup.2 Low density polyethylene (U.S. Industrial Chem. Co. code MN718, Melt Index 8.5) .sup.3 Low Density polyethylene (U.S. Industrial Chem. Co. code MN703, Melt Index 1.2) .sup.4 Zinc stearate used as a .sup.5 Zinc sulfate monohydrate, 200 mesh, Sherwin Williams Co., 361S (ZnSO.sub.4 . H.sub.2 O) .sup.6 Ammonium sulfate (porosigen) .sup.7 Ethylene glycol (porosigen) .sup.8 Sodium Bicarbonate (porosigen)
The materials in Table I were immersed in mineral free distilled water. Said water was analyzed at periodic intervals for zinc ion in accordance with the standard diphenylthiocarbazone method (ASTM 25.077).
After each zinc determination, immersion water was discarded and zinc free water added to the test containers in order to forstall the development of solution equilibrium. Analyses were performed at 1, 2, 7, 14, 21 and 30-day intervals and once monthly thereafter for 4 to 12 months.
Steady state conditions typified by a continuous emission rate were achieved, usually by the seventh day past immersion. After initial addition to water, a preliminary high emission is observed as the zinc sulfate molecules on or very close to the surface are dissolved by and lost into the surrounding waters.
The following steady state emission rates were determined:
______________________________________ EMISSION RATEFORMULATIONS % AGENT LOSS PER DAY______________________________________1-A 0.041-B 0.081-C 0.831-D 0.381-E 0.341-F 0.761-G 0.371-H 0.01-I 0.131-J 0.371-K 1.2______________________________________
Several salient features underlying the uniqueness of this invention can be noted. (1) Other factors being constant, comparison of 1-G using ethylene-vinyl acetate alone as the matrix element (0.37 percent per day emission) with formulation 1-H using low density polyethylene (melt index 8.5) as the sole matrix element (0.0 percent per day emission) and formulation 1-I using only low density polyethylene (melt index 1.2) indicates that polyethylene alone provides a lower and, in an agricultural context, inferior loss rate.
It is evident that the use of a porosity-enhancing agent such as ammonium sulfate and sodium bicarbonate, among others, greatly increases emission rate.
Ethylene glycol in conjunction with ammonium sulfate greatly enhances porosity growth and hence increased emission. In contrast, ethylene glycol alone provides only a small degree of porosity enhancement.
Under the test conditions used, specifically the fact that immersion water was of slightly acidic pH, the use of sodium bicarbonate as the porosigen provided considerably higher emission rates. Compare formulation 1-J having approximately 3 percent porosigen (0.37 percent per day emission) with 1-K having approximately 6 percent porosigen (1.2 percent per day emission).
EXAMPLE II--ZINC OXIDE FORMULATIONS
The low water solubility of zinc oxide results in much lower omission rates as compared with the highly water soluble zinc sulfate material of the previous example.
A few formulations are depicted below:
TABLE II______________________________________ FORMULATION (parts)Ingredient 2-A 2-B 2-C 2-D 2-E______________________________________EVA 763 50 50 50 100 50LDPE 718 40 40 40 -- --LDPE 703 -- -- -- -- 40Zinc Stearate 2 2 2 2 2Zinc Oxide 80 80 80 80 80Ammonium Sulfate -- 5 -- -- 5Sodium Bicarbonate -- -- 5 -- --______________________________________
Periodic zinc analysis using the procedure previously described provided the following results:
______________________________________ EMISSION RATEFORMULATION % AGENT LOSS PER DAY______________________________________2-A 0.005 percent2-B 0.014 percent2-C 0.017 percent2-D 0.017 percent2-E 0.018 percent______________________________________
Comparing 2-A (no porosigen) to 2-B (3 percent ammonium sulfate) again indicates the enhancement of porosity, and hence emission, observed by the use of such additives. Also comparing 2-D (using ethylene-vinyl acetate copolymer alone) having a 0.017 percent per day emission with 2-A, wherein ethylene-vinyl acetate copolymer is modified with polyethylene, indicates the moderating effect of said polyethylene. Importantly, it is observed that when ethylene-vinyl acetate copolymer (melt index 9.0) is modified with polyethylene of melt index 8.5 (MN 718), emission is present.
EXAMPLE III--ZINC CHLORIDE FORMULATIONS
Several formulations using highly water soluble zinc chloride salt (432 g/100 g H 2 O compared to 100 g/100 g H 2 O zinc sulfate soluble) were similarly prepared and evaluated for zinc emission rate. Formulations and emission rates are shown below.
TABLE III______________________________________ FORMULATION (parts)Ingredient 3-A 3-B 3-C______________________________________EVA 100 -- --MN 718 -- 100 --MN 703 -- -- 100Zinc Stearate 2 2 2Zinc Chloride 80 80 80Ammonium Sulfate 5 -- --Emission Rate %loss per day 2.1% 0.18% 0.90%______________________________________
In this instance, the extreme water solubility of zinc chloride is such that it, in essence, acts as its own porosigen, porosity growth arising as the zinc ion is rapidly dissolved into the surrounding water. Although the highest emission is is from ethylene-vinyl acetate copolymer as expected, polyethylene will also bind and emit, though at a much reduced rate.
EXAMPLE IV--ZINC CARBONATE FORMULATIONS
Under practical use conditions, the very low emission observed with zinc oxide materials and the high rates expected with zinc chloride may not be optimal in many instances. Likewise, zinc sulfate having considerable water solubility may not be acceptable in an agricultural situation of high rainfall and/or prolonged heavy ground moisture, rice paddy for instance. Thus, a relatively low solubility of controlled-release zinc carbonate might be of greater utility. Formulations and emission rates are depicted in the following table:
TABLE IV______________________________________ FORMULATION (Parts)Ingredient 4-A 4-B 4-C 4-D 4-E______________________________________MU 763 50 50 50 100 100MU 718 40 40 40 -- --Zinc Stearate 2 2 2 -- 2Zinc Carbonate 50 80 80 80 80Ethylene Glycol 25 -- -- -- --Sodium Bicarbonate -- -- -- -- --Ammonium Sulfate -- -- 5 -- --Emission Rate% Loss per day 0.0% 0.014% 0.038% 0.029% 0.040%______________________________________
It is observed that even large amounts of ethylene glycol without another porosigen also present does not enhance porosity. Comparing 4-D using MU 763 only as the binding matrix without a porosigen to essentially the same material with about 3 percent ammonium sulfate (4-C), the porosity enhancement in the latter case leads to a higher emission rate.
BIOASSAY EVALUATION
Due to the high variability of composition and nature of soils, and the lack of a standard soil type, the tests described herein as typifying the invention have been performed in water since standardization is possible. It is recognized that (1) the end use of the formulations of this invention are in application to soil for (2) the increase in the yield of specific agricultural commodities. In this respect, a fast emission zinc sulfate formulation and a slow emission zinc carbonate formulation were evaluated in zinc poor soil as a means of ascertaining merit therein. Soy bean plants were grown in seven inch diameter pots in the laboratory, said pots each containing 1,300 grams of soil. Two hundred milliliters of water were added once daily. Results are shown below:
______________________________________GROWTH RATE OF SOY BEANS IN ZINC POORSOIL TREATED WITH CONTROLLEDRELEASE ZINC FORMULATIONS AVERAGE POSTCOM- POT GERMINATION ZINC CONTENTPOUND DOSAGE STEM GROWTH (Leachate)______________________________________1-D.sup.1 1 g 2.75 cm/day 0.0015 ppm/day 0.5 g 1.94 cm/day 0.0011 ppm/day 0.2 g 1.40 cm/day 0.0007 ppm/day 0.1 g 1.14 cm/day 0.0002 ppm/dayControl 0.0 g 1.09 cm/day 0.00008 ppm/day4-E.sup.2 1 g 3.13 cm/day 0.0003 ppm/day 0.5 g 2.20 cm/day 0.0004 ppm/day 0.2 g 2.14 cm/day 0.0002 ppm/day 0.1 g 1.95 cm/day 0.0002 ppm/dayControl 0.0 g 1.07 cm/day 0.00008 ppm/day______________________________________
As can be observed in examining the bioassay data, a definite enhancement in soy bean growth is present due to the use of controlled release zinc formulations. It is further noted that in this instance the zinc carbonate material gave better growth characteristics in that less of the emitted agent was lost through leaching. To further illustrate the importance of the distinction between fast and slow emission formulations, zinc analysis was performed on plant tissue and soil after 56 days of growth. Results are shown below:
______________________________________FORMU- Zn++ Zn++ Zn++LATION DOSAGE (Soil) (Leaf) (Root)______________________________________1-D.sup.1 1.0 g 0.075 ppm 0.03 ppm 0.10 ppm 0.5 g 0.060 ppm 0.05 ppm 0.09 ppm 0.2 g 0.050 ppm 0.03 ppm 0.08 ppm 0.1 g 0.050 ppm 0.04 ppm 0.07 ppmControl 0.0 0.00 0.05 ppm 0.04 ppm4-E.sup.2 1.0 g 0.01 ppm 0.08 ppm 0.05 ppm 0.5 g 0.01 ppm 0.05 ppm 0.03 ppm 0.2 g 0.04 ppm 0.08 ppm 0.02 ppm 0.1 g 0.02 ppm 0.08 ppm 0.01 ppmControl 0.0 0.005 ppm 0.05 ppm 0.01 ppm______________________________________ .sup.1 43 percent zinc sulfate and 6 percent porosigen; rapid release. .sup.2 44 percent zinc carbonate and no porosigen providing a very slow release.
Whereas the higher emission rate of 1-D leads to a greater soil concentration at any given instant than that seen with 4-E; the leaf content is greater and hence plant growth, in the latter instance. Under differing moisture conditions, the values might well reverse.
EXAMPLE V-COPPER EMISSION
Several copper salts and oxides were incorporated in plastic matrices and the release rates measured in demineralized water using the procedure previously described. The bicinchoninate method of determining copper ion content was used.
COPPER SULFATE MONOHYDRATE MATERIALS (CuSo 4 .H 2 O)
A number of formulations containing copper sulfate monohydrate were prepared in accordance with the following recipes. Unlike zinc formulations, it was discovered that an ethylene-propylene thermoplastic (Vistalon 702, melt index 27, product of Exxon Chemical Co.), when modified by a low density polyethylene, provided a superior release rate.
TABLE V__________________________________________________________________________ FormulationIngredient 5-A 5-B 5-C 5-D 5-E 5-F 5-G 5-H 5-I__________________________________________________________________________EPM 702 100 -- -- -- -- 50 100 -- 50LDPE 718 -- 100 40 -- -- 50 -- 100 50LDPE -- -- -- -- 50 --EVA 763 -- -- 50 100 50 --Zinc Stearate 2 2 2 2 2 2 2 2 2Copper SulfateMonohydrate 80 80 80 80 80 80 80 80 100Ammonium Sulfate 5 5 -- 5 -- -- -- -- 5__________________________________________________________________________
Copper release rate in water was found to be as follows:
______________________________________ Release RateFormulation % copper ion/day Remarks______________________________________5-A 0.19% EMP 702, with (NH.sub.4).sub.2 SO.sub.4 additive as a porosi- gen5-B 0.19% LDPE 718, with (NH.sub.4).sub.2 SO.sub.4 additive as a porosigen5-C 0.026% EVA 736/LDPE 718, no porosigen5-D 0.15% EVA 763 with (NH.sub.4).sub.2 SO.sub.4 additive as a porosigen5-E 0.37% EVA 763/LDPE 703, no porosigen5-F 0.28% EPM 702/LDPE 718, no porosigen5-G 0.002% EPM 702, no porosigen5-H 0.0021% LDPE 718, no porosigen5-I 0.31% EPM 702/LDPE 718 with (NH.sub.4).sub.2 SO.sub.4 additives as the porosigen______________________________________
It is evident that the addition of a porosity enhancing agent, ammonium sulfate, greatly increases the loss rate of copper ion. When a LDPE is used, whose melt index varies greatly from that of EVA, enhanced release is obtained, for example, EVA 763 of a melt index 9.0 modified with LDPE 718 of melt index 8.5, as with compound 5-C displays a very slow copper ion emission, whereas EVA 763 of melt index 9.0 modified with LDPE 703 of melt index 1.2, as with compound 5-E has a much higher emission rate.
EXAMPLE VI--COPPER CARBONATE EMITTING FORMULATIONS
Formulations were prepared containing very low solubility copper carbonate as the copper ion source. Recipes are shown below:
TABLE VI______________________________________ FormulationIngredient 6-A 6-B 6-C 6-D______________________________________EPM 702 50 100 -- --LDPE 718 50 -- -- --LDPE 703 -- -- -- --EVA 763 -- -- 100 50Zinc Stearate 2 2 2 2Copper Carbonate 80 80 80 80Ammonium Sulfate -- -- -- --______________________________________Measured loss rates over a 120-day periodare shown below with other pertinent information: Loss Rate % MeltFormulation Cu++/day Matrix Indices Porosigen______________________________________6-A 0.0021% EPM 702/ 27/8.5 none LDPE 7186-B 0.0033% EPM 702 27 none6-C 0.0042% EVA 763 9.0 none6-D 0.0017% EVA 763/ 9.0/1.2 none LDPE 703______________________________________
It is again noted that the use of a low density polyethylene modifier lowers the copper emission rate.
EXAMPLE VII--COPPER OXYCHLORIDE FORMULATIONS
Several controlled-release copper formulations were prepared utilizing Cu 2 (OH) 3 Cl as the copper source. It was discovered that the principles previously enumerated similarly held for this material incorporated in thermoplastics. Note the following recipe comparison.
TABLE VII______________________________________Ingredient 7-A 7-B______________________________________LDPE 718 (M.I. = 8.5) 50 --EPM 702 (M.I. = 27) 50 100Zinc Stearate 2 2Cu.sub.2 (OH).sub.3 Cl 80 80Ammonium Sulfate 5 5Loss Rate % Cu.sup.++ /day 0.021% 0.0057%______________________________________
It is again observed that emission rate is enhanced when LDPE is used to modify the EPM matrix.
EXAMPLE VIII--CUPROUS OXIDE FORMULATIONS
Cuprous oxide having extremely low water solubility was incorporated in thermoplastic matrices and loss rate measured as depicted below.
TABLE VIII__________________________________________________________________________INGREDIENT 8-A 8-B 8-C 8-D 8-E 8-F 8-G__________________________________________________________________________LDPE 718 50 50 -- -- 100 100 --EPM 702 50 50 100 100 -- -- --LDPE 703 -- -- -- -- -- -- 50EVA 763 -- -- -- -- -- -- 50Zinc Stearate 2 2 2 2 2 2 2Cuprous Oxide 80 80 80 80 80 80 80(NH.sub.4).sub.2 SO.sub.4 -- 5 -- 5 5 -- 5Loss Rate % Cu/day 0.0028 0.0031 0.0023 0.0027 0.0037 0.0027 0.0010__________________________________________________________________________ Although emmission rates are quite low again, it is observed that saidrate is enhanced through the use of a porosigen.__________________________________________________________________________
It is duly noted that emission rate of copper ion from the aforementioned formulations is temperature dependent. When soil conditions are cold and plant growth absent, the wasteful emission of copper is drastically reduced, while as the growing season progresses with warming weather, copper release increases to fully satisfy, when appropriate dosages are used, the needs of the crops. The following data taken as water emission rate at several temperatures exemplifies this phenomenon.
______________________________________RELEASE OF Cu++ FROM 5-I(Accumulative % Release, average of replicates)Time (days) 90° F. 72° 40° F.______________________________________1 6.4% 5.5% 4.6%5 14.0% 7.5% 6.3%10 14.9% 9.9% 6.35%20 17.5% 12.5% 6.65%31 26.9% 13.2% 7.1%45 31.4% 15.5% 7.55%60 32.4% 18.6% 7.6%87 38.7% 23.8% 7.7%118 41.75% -- 8.1%158 45.6% -- 8.4%______________________________________
EXAMPLE IX--IRON EMISSION
Various water soluble or sparingly water iron salts or oxides can be incorporated in ethylene vinyl acetate copolymers and low density polyethylene and blends thereof, and upon exposure to moisture caused to release iron ion at a controllable rate. Iron bearing chemicals utilizable include ferric chloride, ferrous sulfate, ferric oxide, ferric ammonium citrate, ferrous oxide, and the like, excepting those materials that decompose at extrusion temperatures such as ferric nitrate and ferric ammonium sulfate. Recipes for several formulations are shown below with extrusion conditions.
TABLE IX______________________________________Ingredient 9-A 9-B 9-C 9-D 9-E______________________________________LDPE 718 50 25 -- 50 50EPM 702 -- 25 -- 50 50EVA 763 -- -- 50 -- --Zinc Stearate 1 1 1 2 2FeCl.sub.3 . 6H.sub.2 O 25 -- -- -- --FeSO.sub.4 . 7H.sub.2 O -- 50 50 -- --Fe.sub.2 O.sub.3 -- -- -- 80 80Ammonium Sulfate -- -- -- 5 --ExtrusionBarrel Temp. 400° F. 420° F. 400° F. 370° F. 390° F.Die Temp. 400° F. 400° F. 400° F. 390° F. 410° F.______________________________________ Loss rate.sup.1 is demineralized water averaged over the postimmersion period from day 8 to day 151 is as follows:______________________________________9-A 0.052% Fe release per day9-B 0.17% Fe release per day9-C 0.216% Fe release per day9-D 0.0017% Fe release per day9-E 0.0010% Fe release per day______________________________________ .sup.1 Iron content in water is determined by the ferrozine method, L.L.Stookey, Anal. Chem. 42(7), 779, 1970.
EXAMPLE X--MANGANESE FORMULATIONS
Controlled-release manganese emittors were prepared in accordance with the principles outlined herein. Manganese chloride, manganese sulfate and manganese dioxide were used as the agents. Several illustrative recipes are presented below:
TABLE X______________________________________ (parts by weight)Ingredient 10-A 10-B 10-C 10-D 10-E 10-F 10-G 10-H______________________________________EVA 763 100 -- 25 50 50 50 25 --LDPE 718 -- -- 20 -- -- -- 20 --LDPE 703 -- -- -- -- -- -- -- 50EPM 702 -- 50 -- -- -- -- -- --Zinc Stearate 1 1 1 1 1 1 1 1ManganeseSulfate.sup.1 -- 51 51 50 60 -- -- --ManganeseChloride.sup.2 -- -- -- -- -- 25 30 30ManganeseDioxide 80 -- -- -- -- -- -- --AmmoniumSulfate -- -- -- 5 -- -- -- --______________________________________ .sup.1 MgSO.sub.4 . H.sub.2 O .sup.2 MgCl.sub.2 . 4H.sub.2 O
Said formulations were immersed in water and manganese release determined 1 periodically as depicted below. It is noted that manganese dioxide having a very low solubility possesses a correspondingly low release rate-approximately 0.001 percent total manganese per day.
______________________________________Release Rate of Manganese Compounds in Water Initial Mn Loss Rate; % Loss/DayFormulation Loss (30 days) Day 31 to Day 122______________________________________10-B 48.2% 0.18% -10-C 52.2% 0.27%10-D 43.0% 0.35%10-E 52.9% 0.27%10-F 46.9% 0.085%10-G 54.2% 0.06%10-H 21.6% 0.047%______________________________________
Both manganese sulfate and manganese chloride formulations show high initial loss over the first 30 days or so immersion. After that time, a steady state situation is reached. It is noted that the manganese sulfate emitting materials show a higher loss rate due to the greater water solubility of this agent. Formulation 10-D, an ethylene vinyl acetate copolymer matrix using ammonium sulfate as a porosigen exhibits the greatest degree of release.
EXAMPLE XI--CONTROLLED RELEASE BORON MATERIALS
Boron emitting materials were prepared in accordance with the principles outlined herein. Several such compounds are depicted below. Boric acid and sodium biborate, both being highly water soluble are preferred over other boron salts. Sodium bicarbonate was used as the porosigen.
TABLE XI______________________________________Ingredient Formulation______________________________________ 11-A 11-B 11-C 11-D______________________________________Vistalon 703 60 100 -- --LDPE 718 40 -- -- --EVA 763 -- -- 100 100Zinc Stearate 1 1 1 1Boric Acid (Na.sub.2 B.sub.4 O.sub.7) 50 50 50 50Sodium Bicarbonate -- -- -- 2______________________________________ 11-E 11-F______________________________________Vistalon 702 -- --LDPE 718 50 --EVA 763 40 100Zinc Stearate 1 2Boric Acid (Na.sub.2 B.sub.4 O.sub.7) 50 75Sodium Bicarbonate -- --______________________________________ 11-C 11-H 11-J 11-K 11-L______________________________________Vistalon 702 60 100 -- -- --LDPE 718 40 -- -- 50 --EVA 763 -- -- 100 40 100Zinc Stearate 1 1 1 1 2Na.sub.2 B.sub.4 O.sub.7 50 50 50 50 75NaHCO.sub.3 -- -- 2 -- --______________________________________
Immersion in water indicated the following release rates.
______________________________________Formulation Release Rate (%/Day) Remarks______________________________________BORIC ACID GROUP11-B 0.130% Vistalon 702 matrix11-A 0.135% Vistalon 702 modified with low density polyethylene11-F 0.321% EVA 763 matrix11-D 0.321% EVA 763 with NaHCO.sub. 3 as a porosigen (no effect) 5.78% boron content11-C 0.378% EVA 763 containing 5.85% boron content11-E 0.722% EVA 763 modified with low density polyethy- lene to provide much higher release rate 6.27% boron content______________________________________SODIUM BIBORATE GROUP11-L 0.390% EVA 763, no modifi- cation, contains 9.22% boron.11-K 0.552% EVA 763, modified with low density polyethylene, con- tains 7.72% boron11-J 0.765% EVA 763 with a poro- sigen, contains 7.14% boron11-G 0.63% Ethylene-propylene copolymer modified with low density polyethylene, with 7.12% boron11-H 0.66% Ethylene-propylene copolymer with no modification, with 7.21% boron______________________________________
Boron in water was determined by the method described in APHA Standard Methods 13 Ed. p. 72, 1971.
EXAMPLE XII--CONTROLLED RELEASE MOLYBDENUM MATERIALS
Controlled release molybdenum formulations were prepared in accordance with the recipes shown below:
TABLE XII______________________________________ Formulation No.Ingredient 12-A 12-B 12-C 12-D 12-E 12-F______________________________________Vistalon 702 50 -- -- -- -- --LDPE 718 50 100 -- -- -- --Zinc Stearate 2 2 1 1 1 2MoO.sub.3 75 75 75 50 50 --EVA 763 -- -- 100 100 -- --LDPE 703 -- -- -- -- 75 100Na.sub.2 MoO.sub.4 -- -- -- -- -- 75______________________________________ Formulation No.Ingredient 12-G 12-H 12-I 12-J 12-K______________________________________Vistalon 702 100 100 50 50 50Zinc Stearate 1 2 1 2 2Na.sub.2 MoO.sub.4 50 75 50 75 75LDPE 718 -- -- 50 50 50(NH.sub.4).sub.2 SO.sub.4 -- -- -- 3 --NaHCO.sub.3 -- -- -- -- 3______________________________________
Initial 24-hour release and average daily release after release is shown below. Molybdenum content in water was determined using the technique in Analytical Chemistry 25(9), 1363, 1953.
______________________________________ Mo. Initial Daily Release Rate Content 24-Hour (Day 7 throughFormulation (1%) Release Day 30)______________________________________12-A 28.2 0.38% 0.06%12-B 28.2 0.63% 0.09%12-C 28.2 0.80% 0.06%12-D 22.0 0.69% 0.04%12-E 26.4 0.67% 0.03%12-F 19.8 1.26% 0.09%12-G 15.4 15.9% 1.00%12-H 19.7 20.3% 1.18%12-I 15.4 17.8% 1.81%12-J 19.4 33.8% 1.45%12-K 19.4 34.5% 1.63%______________________________________
The effects of lower water solubility of MoO 3 , (0.1 g/100 g cold water), as compared to Na 2 MoO 4 , (44 g/100 g cold water) can readily be seen through comparing compounds 12-A through 12-E containing MoO 3 with compounds 12-F through 12-K wherein Na 2 MoO 4 in LDPE shows the relatively small initial loss rate in comparison with formulations 12-G through 12-K utilizing an ethylene-propylene matrix with or without an LDPE modifier. Examining of 12-H (19.7% Na 2 MoO 4 ) and 12-G (15.4% Na 2 MoO 4 ) it is seen that the loss rate is partially dependent upon the total agent loading. Comparison of compounds 12-C (28.2% MoO 3 ) and 12-D (22.0% MoO 3 ) one notes the same effect. Whereas 12-G (15.4% Na 2 MoO 4 in Vistalon 702) provides a 1.00% per day release in water, 12-I (15.4 % Na 2 MoO 4 ) wherein Vistalon 702 is modified with LDPE 718 a much higher, 1.81% per day, loss rate is indicated. Interestingly, compounds 12-J and 12-K, both using a porosigen additive, show extremely high initial loss rate of 33.8% and 34.5% for the first 24 hours post immersion, respectively. In this instance, the use of a porosigen is contraindicated.
EXAMPLE XIII--CONTROLLED RELEASE COBALT MATERIALS
Controlled release cobalt formulations, using cobalt sulfate as the agent, were prepared in accordance with the recipes shown below.
TABLE XIII__________________________________________________________________________ Formulation No.Ingredient 13-A 13-B 13-C 13-D 13-E 13-F 13-G 13-H 13-I__________________________________________________________________________Vistalon 702 60 60 -- -- -- -- -- -- --LDPE 718 40 40 100 -- -- -- -- -- --LDPE 703 -- -- -- -- 100 -- -- -- --EVA 763 -- -- -- 100 -- 100 100 100 100Zinc Stearate 1 1 1 1 1 1 1 1 1CoSO.sub.4 . 7H.sub.2 O 50 75 50 50 50 75 50 50 50(NH.sub.4).sub.2 SO.sub.4 -- -- -- -- -- -- 5 -- --NaHCO.sub.3 -- -- -- -- -- -- -- 5 --Carbon Black -- -- -- -- -- -- -- -- 5__________________________________________________________________________
Cobalt loss from an immersed pellet into demineralized water was measured in accordance with the technique prescribed by Pyatnitskii ("Analytical Chemistry of the Elements," p. 130, Humphrey Science Pub. Co., Ann Arbor, Mich. 1969). Emission rate over the immersion period from day 7 to day 30 and other pertinent data is shown below:
______________________________________ Emmission RateFormulation No. (per day) Remarks______________________________________13-E 0.13% Low density polyethylene (703) matrix no porosigen, 12.2% total cobalt content (W/W)13-C 0.29% Low density polyethylene (718) matrix, no porosi- gen 14.4% total cobalt content (W/W)13-A 0.24% Vistalon 702 EPM matrix modified with LDPE 718. Only 5.9% total cobalt content (W/W) No porosi- gen.13-B 0.39% Vistalon 702 EPM matrix modified with LDPE 718 but with a higher (12.3%) total cobalt content. No porosigen.13-D 0.53% EVA 763 matrix, no por- osigen. Total cobalt content 10.4% (W/W).13-F 0.69% EVA 763 matrix, no porosigen. Higher total cobalt content, 12.1% (W/W).13-I 0.90% EVA 763 matrix with carbon black as an addi- tive to increase free volume.13-G 0.95% EVA 763 matrix with ammonium sulfate addi- tive as a porosigen.13-H 1.05% EVA 763 matrix with sodium bicarbonate as a porisigen.______________________________________
Cobalt sulfate is a highly soluble material (60.4 g/100 g cold water) and thus essentially serves a porosigenic function in LDPE so that emission is possible.
EXAMPLE XIV--CONTROLLED RELEASE SELENIUM MATERIALS
The following controlled release materials, using sodium selenate as the agent, were prepared and immersed in dimineralized water.
TABLE XIV______________________________________ Formulation No.Ingredient 14-A 14-B 14-C 14-D______________________________________LDPE 718 25 25 25 25EVA 763 -- 25 -- 25Vistalon 702 25 -- 25 --Zinc Stearate 1 1 1 1Na.sub.2 SeO.sub.4 25 25 25 25(NH.sub.4).sub.2 SO.sub.4 -- -- 2 --NaHCO.sub.3 -- -- -- 2______________________________________
In accordance with agricultural needs, release rates are very low as measured over a 120-day period in demineralized water.
______________________________________14-A 0.0071% Se emission per day14-B 0.0066% Se emission per day14-C 0.0053% Se emission per day14-D 0.0055% Se emission per day______________________________________
EXAMPLES XV--CONTROLLED RELEASE MAGNESIUM FORMULATIONS
Recipes for several typical magnesium emitters are shown below:
TABLE XV______________________________________ Formulation No.Ingredient 15-A 15-B 15-C______________________________________Vistalon 702 25 -- 25EVA 763 -- 50 --LSPE 718 25 -- 25Zinc Stearate 1 1 1Mg CO.sub.3 15 15 --Mg SO.sub.4 -- -- 15______________________________________
Release in demineralized water was measured periodically and a rate of 0.15%/day (15-A), 0.09%/day (15-B), and 0.48%/day (15-C) noted. Magnesium analysis was performed by the method described in Flaschka, H. A., et al., Quantitative Analytical Chemistry, Vol. II, p. 140, Harper and Row, pub. Inc. N.Y., 1969.
EXAMPLE XVI--MULTIPLE ELEMENT RELEASE
With proper compounding, it is possible to release two or more elements simultaneously from the same matrix. In treating soil, that is cobalt poor, and which also requires a small supplement of zinc and iron formulation (16), shown below, can be utilized.
TABLE XVI______________________________________Ingredient Recipe______________________________________EVA 763 100Zinc Stearate 1Cobalt Sulfate* 25Iron Oxide** 25Zinc Oxide*** 10______________________________________ *CoSO.sub.4 . 7H.sub.2 O **Fe.sub.2 O.sub.3 ***ZnO
A daily loss rate of 0.25%/day cobalt, 0.002%/day iron and 0.01%/day zinc was measured.
Multiple emission from one matrix can thus be accomplished and a material tailored to meet specific soil needs in some instances. It is, however, more likely that a given trace element's need can be met by appropriately mixing the proper proportion of different emitters (i.e. different matrices) during application to a given soil.
While in accordance with the patent statutes, only the preferred embodiments of the invention have been described in detail, therefore, for the true scope of the invention, reference should be had to the appended claims. | Compositions of and a method for preparing polymeric formulations that gradually, continuously and uniformly release various compounds over a long period of time in ionic form that are well recognized as essential to the growth of agricultural commodities. The compounds, such as inorganic salts of varying water solubilities, are monolithically incorporated in a thermoplastic polymeric matrix usually of two thermoplastic polymers, for example, a copolymer of poly(ethylene-vinyl acetate) or a copolymer of ethylene and propylene. Release is generally conditioned upon the presence of moisture and is proportional to the moisture content of soil treated with the subject invention. Release rate is tailored to a given desirable condition by regulation of the free volume and/or porosity within the polymer matrix and through dispenser geometry. Free volume is maintained at the level conducive to agent release such as through the use of free volume modifying secondary thermoplastic additives such as low density polyethylene; and porosity is controlled through the use of porosity enhancing agents appropriately termed porosigens. Said porosigens can be the low or moderate soluble salts such as the carbonates, bicarbonates, sulfates, phosphates, nitrates, etc.; of the alkali metals, the alkaline earths, or ammonium. Upon exposure to moisture, water ingress into the dispensing pellet removes said porosigen through dissolution processes thus creating a porous network permitting water contact with the incorporated nutrient molecules and their gradual egress in said water over a period of time such as for about a couple months to four years, or longer. | 2 |
This is a continuation of application Ser. No. 059,736, filed July 23, 1979, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a method of jointing by friction welding a pipe of a metal which exhibits a comparatively small resistance against deformation, e.g. aluminum and a pipe made of a metal which exhibits a comparatively large resistance against the deformation e.g. copper.
Various welding methods can be used for producing weld joint of thin-walled pipes of a wall thickness of 5 mm or less, such as gas welding, resistance welding including flash welding, butt welding, and flash butt welding, brazing, soldering and so forth. Particularly, flash butt welding and doffisopm bonding are usually used for jointing two metals which exhibit small weldability to each other. These methods, however, suffer from inferior working properties.
A welding method which is usually referred to as friction welding provides an efficient and prompt jointing of two pipes. This method, however, cannot be suitably used for jointing thin-walled pipes having wall thickness of 5 mm or less and pipes having small outside diameter e.g. 20 mm or less, because such pipes usually have small resistance against deformation and are easily buckled or all subjected axial misalignment during the friction welding.
Thus, when an aluminum thin-walled pipe 2 having a small resistance against the deformation is jointed by a friction welding to a thin-walled copper pipe 1, the aluminum pipe 2 is buckled as illustrated in FIG. 1a, or axially misaligned with the copper pipe as illustrated in FIG. 1b to impair the quality of the weld joint. It is liable to occur that, since the aluminum thin-walled pipe 1 has a small resistance against deformation, the aluminum pipe is inconveniently deformed as illustrated in FIG. 1c by a comparatively small pressing force, so that the temperature rise required for the welding cannot be obtained. In such a case, it is not possible to effect a good weld.
For these reasons, the welding of thin-walled and small-diameter pipes has to be made by the aforementioned various welding methods at a cost of low efficiency of the work, rather than by the friction welding which permits an efficient and prompt welding operation.
SUMMARY OF THE INVENTION
It is, therefore, an object of the invention to provide a method which makes it possible to joint a thin-walled pipe of a metal having a comparatively small resistance against deformation, e.g. aluminum, to a thin-walled pipe of a comparatively large resistance against deformation, e.g. copper or iron, by a friction welding which cannot be adopted conventionally for this kind of purpose, at a high welding strength and with a minimum amount of internal burrs to eliminate as much as possible the subsequent cutting of the inner surface for removing the burrs.
The above stated object is fulfilled by the invention as will be understood from the following description. Namely, according to the invention, one of the pipes to be welded made of a relatively hard metal such as copper or iron having a comparatively small resistance against deformation has a tapered peripheral surface at its one end. The pipe of the hard metal is clamped by a chuck which is rotated at a high speed.
The other pipe to be welded which is made of a relatively soft material such as aluminum having a comparatively large resistance to the deformation is inserted into a bore of a ring which is made of a heat insulating material. The bore of the ring has a straight section of a diameter smaller than the sum (dB+2tA) of the outside diameter dB of the hard pipe and a double of the thickness of the soft pipe and a tapered section the diameter of which is gradually decreased substantially to the outside diameter dA of the soft pipe. The soft pipe is then pressed against the tapered end of the hard pipe while the latter is being rotated. As a result, the tapered end of the hard pipe is driven into the soft pipe to expand the latter and, simultaneously, ironed by the straight section of the bore to produce a heat thereby to preheat the joint area. Then, the soft pipe is pressed between the tapered end of the hard pipe and the tapered portion of the ring so that the tapered end of the hard pipe is friction welded to the corresponding portion of the soft pipe while the latter is being backed up by the tapered section of the bore.
Finally, the rotating pipe is abruptly stopped and the friction-welded joint is moved out of the heat insulating ring and is cooled by the ambient air, thus completing the friction welding.
As stated above, according to the invention, the hard pipe has a tapered end surface it which it is driven into the soft pipe to expand the latter. By so doing, it is possible to keep the pipes in axial alignment with each other during the friction welding.
In addition, a ring having a strength greater than that of at least the soft pipe and having a tapered bore is used to make it possible to apply a considerable axial pressing force to the joint surfaces.
Further, in order to attain a quick temperature rise at the joint surfaces, the ring is made of a heat insulating material.
Also, since the end surface of the hard pipe is tapered, a large joint surface area which is about three times as large as the original joint surface is obtained, so that it is possible to joint thin-walled pipes which inherently have small joint areas.
The straight section of the bore of the heat insulating ring, having a diameter smaller than the sum (dB+2tA) of the outside diameter dB of the hard pipe and the wall thickness tA of the soft pipe conveniently provides an ironing effect of about 20% of the wall thickness on the soft pipe. The heat generated during this ironing effectively preheats the joint surfaces which in turn affords a temperature rise in a short period of time when the tapered surfaces are friction welded to each other.
Moreover, the invention excludes various defects such as undesirable thinning of the tapered portion of the welded soft pipe, closing of the pipe due to a too large penetration of the hard pipe into the soft pipe and so forth. Also, the invention ensures a greater strength of the weld joint, due to the presence of the straight section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b and 1c illustrate various phenomena which are observed when an aluminum pipe is jointed to a copper pipe by means of a conventional friction welding method;
FIG. 2 is a schematic plan view of a friction welding apparatus which is constructed in accordance with a first embodiment of the invention;
FIG. 3 is enlarged sectional view of a pipe holder of the apparatus shown in FIG. 2, the holder being adapted to hold the stationary one of the pipes to be welded;
FIG. 4 is a side elevational view of the end of the rotary one of the pipes to be welded;
FIG. 5 is a sectional view of a heat insulating ring;
FIG. 6 is a sectional view showing the state in which the stationary pipe to be welded is gradually ironed and expanded by the rotary pipe to be welded within the heat insulating ring; and
FIG. 7 is a schematic illustration of a pipe joint made by the friction welding method in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 shows a plan view of a friction welding apparatus constructed in accordance with an embodiment of the invention. The apparatus has a rotary part generally designated at a numeral 40 and a stationary part generally designated at a numeral 50. The description will be made first as to the rotary part 40.
A reference numeral 1 denotes a pipe to be welded, made of a comparatively hard metal which is in this case copper. The pipe 1 has one end with a peripheral surface tapered at an angle α to the axis of the pipe 1 as shown in FIG. 4. Thanks to the provision of the tapered end surface, it is possible to smoothly introduce the rotary side pipe 1 to a later-mentioned stationary side pipe 2, even when these pipes have equal diameters, so that the undesirable axial misalignment of these pipes is conveniently avoided. A detailed description will be given as to this advantageous feature.
A drill chuck 3 adapted to grasp and hold the copper pipe 1 is supported at its shaft 5 by an angular bearing 4. A reference numeral 6 denotes a clutch/brake unit which is connected to the shaft 5 through a coupling 7. The clutch/brake unit 6 has a pulley 8 attached thereto. A reference numeral 9 denotes a motor having a reduction gear 10 unitary therewith. A V-belt is stretched between the aforementioned pulley 8 and a pulley 11 attached to the motor shaft.
Turning now to the stationary part 50, the aforementioned stationary side pipe 2 to be welded is adapted to be held by a pipe holder 13. The pipe holder 13 will be described later with specific reference to FIG. 3. The pipe holder 13 is adapted to be clamped by means of a collet chuck 14 which is adapted to be fixed by a chuck holder 15. The chuck holder 15 is provided at its lower surface with two bearings (not shown) which is adapted to make sliding engagement with the rails 16 and 17, so that the chuck holder 15 is movable to the left and right as viewed in FIG. 2.
A pneumatic cylinder 18 has a piston rod 19 which is fixed to a chuck holder 15.
Referring now to FIG. 3 showing the detail of the pipe holder 13, the aforementioned stationary side pipe 2 to be welded has the same outside diameter as the rotary side pipe 1 and is made of a soft metal which is in this case aluminum. A ring 20 made of a heat insulating material is adapted to be fitted around the end of the pipe 2, and is provided with a tapered inner surface as shown in FIG. 5. The size d 1 is so selected that an ironing of 20 to 50% of the wall thickness tA of the pipe 2 is effected on the latter, as the pipe 2 is expanded by the pipe 1. thus, the size d 1 is represented by the following equation.
d.sub.1 ≈dB+(0.5 to 0.8)×2tA=dB+(1 to 1.6)×tA
Also, the size d 2 is selected to be substantially equal to the outside diameter dA of the pipe 2 to permit the insertion of the latter. Namely, the size d 2 is selected to satisfy the equation of:
d.sub.2 ≈dA+0.05
Since a preheating effect is provided by the ironing force at the straight portion, it is possible to obtain a good weld without substantially increasing the contact pressure at the joint surfaces in the direction normal to the surface. In addition, according to the invention, the bonding strength is increased by an increase of the area of jointing. For these reasons, the angle β is preferably selected to fall within the range of between 8° and 30°. Thus, the angle β is selected in relation to the angle α of chamfering of the pipe 1 to satisfy the following equation.
8°≦α<β≦30°
The material of the ring 20 has to have a sufficiently high heat insulating property and a strength higher than that of copper. For instance, rigid body impregnated asbestos which is commercially available at a comparatively low cost can be used as the material of the ring 20. However, ceramics are preferably used as the material of the ring 20, although they are more expensive.
A reference numeral 21 denotes a collect chuck which is adapted to be fitted around the pipe 2. Reference numerals 22 and 23 denote, respectively, a jig for tightening the collet and a jig for attaching the collet, respectively.
For fixing the pipe 2, the pipe 2 is inserted into the collet 21, and the collet tightening jig is tightened against the collet attaching jig 23. As a result, the clearance or notch (not shown) of the collet 21 is narrowed to make the collet 21 firmly clamp the pipe 2. The heat insulating ring 20 is attached and is fixed as a ring holder 25 is tightened.
The rotary part 40 and the stationary part 50 of the apparatus are so arranged that the pipes 1 and 2 are axially aligned with each other. It is also essential that, when pipes of different material having different resistances against the deformation are welded, the pipe having the smaller resistance is attached to the stationary side of the apparatus. For instance, in order to joint an aluminum pipe and a copper pipe to each other, the copper pipe and the aluminum pipe are attached to the rotary and stationary sides, respectively.
In operation, as the motor 9 is energized, the torque of the motor 9 is transmitted to the pulley 8 through the reduction gear 10, pulley 11 and the V-belt 12, and further to the drill chuck 3 through the clutch/brake unit 6 and the shaft 5, thereby to rotate the pipe 1. Meanwhile, as a pressurized air is delivered by a pressure source (not shown) to the pneumatic cylinder 18, the piston rod 19 is extended to move the chuck holder 15 along the rail 17, thereby to press the pipe 2 attached to the pipe holder 13 against the pipe 1 of the rotary side.
Since the peripheral surface of the end of the pipe 1 is tapered as stated before, the pipe 2 is driven onto the pipe 1, although they have an equal outside diameter. In this state, the pipe 2 is expanded spread between the tapered surfaces of the pipe 1 and the heat insulating ring 20. During this operation, the pipe 2 is ironed by the straight portion of the inner bore d 1 of the heat insulating ring and also by the pipe 1 to generate a heat. This heat is not radiated outwardly because of the ring 20 made of the heat insulating material and, therefore, is effectively used for preheating the pipes. Accordingly, an abrupt temperature rise is caused when the tapered surfaces make a friction engagement with each other and the boundary surfaces are molten in a short period of time. In this state, the clutch/brake unit is operated to abruptly stop the rotation of the pipe 1, and, while maintaining the contact pressure, the collet tightening jig 22 is loosened. Then, the heat insulating ring 20 is moved to the right as viewed in FIG. 2 to allow the joint area to be cooled by the ambient air, thereby to complete the welding of the pipes 1 and 2 to each other.
FIG. 7 schematically shows in section the weld joint as obtained by the above-stated operation of the friction welding apparatus of the invention, in which a fusion layer is designated at reference numeral 26.
Two examples of friction welding of the thin-walled pipes of copper and aluminum as performed by the apparatus shown in FIG. 2 are shown below.
Table 1 shows the principal data for the friction weldings. In each case, two pipes were frictioned for 4 seconds and the air-cooling period after the stopping of the rotary part pipe (copper pipe) was 5 seconds.
TABLE 1__________________________________________________________________________Principal Data for Friction Welding Pressing Load of Rotary Pipe Station- Chamfer- Size of Ring Rotating ary Pipe PCase ing d.sub.1 d.sub.2 β l Speed of PressingNo Size of Pipe Angle α° (See FIG. 5) Pipe Speed V__________________________________________________________________________1 Copper: α = 10° d.sub.1 = 9.3 mmφ Copper: P = 230 Kg Outside Dia. d.sub.2 = 8.05 mmφ 3,000 rpm V = 4 mm/sec 8 mm β = 20° Wall Thickness l = 5 mm Aluminum: Aluminum: Outside Dia. Stationary 8 mm Wall Thickness 1 mm2 Copper: α = 10° d.sub.1 = 7.3 mmφ Copper: P = 230 Kg Outside Dia. d.sub.2 = 6.4 mmφ 3,000 rpm V = 4 mm/sec 6.35 mm β = 20° Wall Thickness l = 5 mm 0.8 mm Aluminum: Aluminum: Outside Dia. Stationary 6.35 mm Wall Thickness 0.8 mm__________________________________________________________________________
In each case, the friction welding was possible even when the outside diameters and the thickness of both pipes were reduced to 3 mm and 0.5 mm, respectively.
The characteristics of the copper-aluminum weld joints thus obtained are shown in Table 2 below. From Table 2, it will be apparent that the weld joint of each case exhibits a sufficiently high pressure resistance.
TABLE 2______________________________________Characteristics ofWeld Pipe Joint pressure maximum resistance thickness tensile point of (40 Kg/cm.sup.2 3 of fusedcase strength breakage min. N.sub.2 gas) compound______________________________________1 200 Kg aluminum no leak about matrix 8 μm2 160 Kg aluminum no leak about matrix 10 μm______________________________________
Particularly, since the preheating effect is provided by an ironing effected on the aluminum pipe by the straight portion, it is possible to abruptly raise the temperature at the tapered junction surfaces. As a result, it is possible to obtain a good weld by a friction time which is as short as 2 to 4 seconds as stated before. Also, the undesirable thinning of the tapered portion denoted by numeral 27 in FIG. 7, which impairs the shape and the characteristic of the weld joint, is fairly avoided. Further, the depth of insertion of the copper pipe into the aluminum pipe is minimized to maintain the diameter d i at a level of d i ≧0.7d o thereby to eliminate the necessity of the subsequent cutting of the inner peripheral surface of the weld joint.
In the described embodiment, the stationary pipe is moved into pressure contact with the rotary pipe. This, however, is not exclusive and the arrangement may be such that the rotary pipe is moved and pressed against the stationary pipe.
It is also possible to effect the friction welding by rotating at high speed the pipe around which the heat insulating ring is fitted, while keeping stationary the chamfered pipe.
As will be apparent from the foregoing description, the present invention offers the following advantages.
Conventionally, it has been impossible to joint by friction welding two pipes which are liable to be deformed due to small thickness or diameter, particularly when these pipes are made of different materials which exhibit poor weldability to each other, e.g. copper pipe and aluminum pipe. However, according to the invention, it is possible to joint these pipes by friction welding in quite a short period of time which is 10 seconds or shorter including the friction time and the cooling time.
It is also to be appreciated that the amount of projection of weld part on the inner peripheral surface of the weld joint is diminished to eliminate the necessity of the subsequent cutting of the inner peripheral surface of the weld joint, which in turn contributes greatly to the improvement in the efficiency of the work. | A method for jointing two pipes such as an aluminum pipe and a copper pipe by friction welding. The aluminum pipe is inserted into a bore of a ring made of a heat resistant material, the bore having a straight section and a tapered section continuous from the straight section. The copper pipe has a tapered end peripheral surface. The copper pipe is pressed at its tapered end, in a rotating state, against the end of the aluminum pipe so as to expand the latter. As a result, an ironing is effected on the aluminum pipe by the straight section of the bore of the ring, such that the aluminum pipe overlies the straight section of the copper pipe in close contact with the latter. Consequently, the tapered surface of the copper pipe is friction welded to corresponding portion of the aluminum pipe while the latter is being backed up by the tapered section of the bore of the ring. | 1 |
FIELD OF THE INVENTION
The invention relates generally to sensors for measuring tire operational parameters and generating tire-specific measurements data during vehicle use at high speed and, more specifically, to bearing assemblies for such wheel based sensors.
BACKGROUND OF THE INVENTION
In the operation of passenger cars and racecars, it is desirable to measure and test tires, wherever practical, in real time and under actual road conditions. For passenger cars, the venues of interest may be carefully selected road conditions while, for racecars, it is the operating conditions on a particular racetrack. The purpose for observing, testing, and measuring tire operating parameters in real time and under actual road conditions is to provide real world feedback on tire performance and to allow for the creation of more accurate tire durability test procedures and methods.
The specific tire parameters to be measured and evaluated may include tire slip and camber angles or tire deflection. Heretofore, the ability of the industry to test, measure, and evaluate tires for such tire parameters while the tire is at high speeds has not been available. Consequently, the tire testing procedures and methods utilized within the industry have been created without benefit of real time measurement of such tires under actual operating conditions.
SUMMARY OF THE INVENTION
An aspect of the invention embodies a wheel-based sensor assembly. The assembly includes a rotational wheel assembly, the wheel assembly including a wheel rim and a tire mounted thereto. One or more sensor device(s) are provided for operatively measuring one or more wheel assembly parameter(s) while the wheel assembly rotates during vehicle use. A bracket assembly mounts to the vehicle and operatively positions the sensor device(s).
In another aspect, the bracket assembly includes a first bracket arm segment extending at least partially along an outer sidewall of the tire in a radial direction and a sensor device adjustably repositionable along the arm segment. The bracket assembly may further include a second bracket segment extending at least partially along a tread region of the tire in an axial direction, preferably to a side of the tire opposite a normatively forward vehicular direction of travel. A secondary sensor device may be mounted to the second bracket arm segment adjacent the tread region of the tire.
In another aspect, the first and second bracket arm segments are relatively disposed at a ninety degree angle and include a channel along a tire-facing bracket side to operatively receive and route electrical wiring along the bracket assembly. The bracket assembly may be constructed in a U-shaped configuration connecting the second bracket member segment to an inner side of the wheel assembly by a third bracket arm segment. The sensor units may include a slip angle sensor mounted to the first bracket arm segment and a camber angle sensor mounted to the second bracket arm segment.
According to a further aspect, a remote end of the first bracket arm segment operatively connects to a bearing assembly; the bearing assembly including: a wheel plate; a stator housing affixed to an outward surface of the wheel plate; a stator shaft extending outward from the stator housing and connecting at an outward end to the first bracket arm; and multiple elongate extension members coupled to an inward side of the wheel plate and connecting at an inward end to a vehicle. The extension members are configured to have a length operative to position the stator shaft outward end in an optimal, substantially coplanar relationship, with the first bracket arm.
DEFINITIONS
“Aspect ratio” of the tire means the ratio of its section height (SH) to its section width (SW) multiplied by 100 percent for expression as a percentage.
“Asymmetric tread” means a tread that has a tread pattern not symmetrical about the center plane or equatorial plane EP of the tire.
“Axial” and “axially” means lines or directions that are parallel to the axis of rotation of the tire.
“Camber angle” means the angular tilt of the front wheels of a vehicle. Outwards at the top from perpendicular is positive camber; inwards at the top is negative camber.
“Circumferential” means lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction.
“Equatorial Centerplane (CP)” means the plane perpendicular to the tire's axis of rotation and passing through the center of the tread.
“Footprint” means the contact patch or area of contact of the tire tread with a flat surface at zero speed and under normal load and pressure.
“Groove” means an elongated void area in a tread that may extend circumferentially or laterally about the tread in a straight, curved, or zigzag manner. Circumferentially and laterally extending grooves sometimes have common portions. The “groove width” is equal to tread surface area occupied by a groove or groove portion, the width of which is in question, divided by the length of such groove or groove portion; thus, the groove width is its average width over its length. Grooves may be of varying depths in a tire. The depth of a groove may vary around the circumference of the tread, or the depth of one groove may be constant but vary from the depth of another groove in the tire. If such narrow or wide grooves are substantially reduced depth as compared to wide circumferential grooves which the interconnect, they are regarded as forming “tie bars” tending to maintain a rib-like character in tread region involved.
“Inboard side” means the side of the tire nearest the vehicle when the tire is mounted on a wheel and the wheel is mounted on the vehicle.
“Lateral” means an axial direction.
“Lateral edges” means a line tangent to the axially outermost tread contact patch or footprint as measured under normal load and tire inflation, the lines being parallel to the equatorial centerplane.
“Net contact area” means the total area of ground contacting tread elements between the lateral edges around the entire circumference of the tread divided by the gross area of the entire tread between the lateral edges.
“Non-directional tread” means a tread that has no preferred direction of forward travel and is not required to be positioned on a vehicle in a specific wheel position or positions to ensure that the tread pattern is aligned with the preferred direction of travel. Conversely, a directional tread pattern has a preferred direction of travel requiring specific wheel positioning.
“Outboard side” means the side of the tire farthest away from the vehicle when the tire is mounted on a wheel and the wheel is mounted on the vehicle.
“Radial” and “radially” means directions radially toward or away from the axis of rotation of the tire.
“Rib” means a circumferentially extending strip of rubber on the tread which is defined by at least one circumferential groove and either a second such groove or a lateral edge, the strip being laterally undivided by full-depth grooves.
“Sipe” means small slots molded into the tread elements of the tire that subdivide the tread surface and improve traction, sipes are generally narrow in width and close in the tires footprint as opposed to grooves that remain open in the tire's footprint.
“Slip angle” means the angle of deviation between the plane of rotation and the direction of travel of a tire.
“Tread element” or “traction element” means a rib or a block element defined by having a shape adjacent grooves.
“Tread Arc Width” means the arc length of the tread as measured between the lateral edges of the tread.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is a front perspective view of a wheel and sensor assembly configured using a mounted rotating load cell.
FIG. 2 is a side elevation view thereof.
FIG. 3 is a front elevation view thereof; and
FIG. 4 is an exploded perspective view of the bracket assembly.
FIG. 5 is a front perspective view of a wheel and sensor assembly configured using a bearing assembly in place of the load cell of FIG. 1 .
FIG. 6 is an enlarged front perspective view of the bearing assembly.
FIG. 7 is a front exploded perspective view of the bearing assembly.
FIG. 8 is a rear perspective view of the bearing assembly.
FIG. 9 is a rear exploded perspective view of the bearing assembly.
FIG. 10 is a longitudinal section view through the bearing assembly taken along the line 10 - 10 of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-4 , the subject wheel and sensor assembly 10 is shown to include a wheel assembly 12 in which a tire 16 is mounted to a rim 14 in conventional fashion. The assembly 10 is a component of a vehicle (not shown) such as a passenger car or truck. However, as will be explained, the invention has particular utility in conjunction with measuring tire set-up and performance on a race car. The tire 16 mounted to rim 14 is, accordingly, intended to be of a general depiction without regard to vehicle type or use. The tire 16 is of conventional construction having a sidewall 18 extending to a tread region 20 .
The assembly 10 further includes a bracket assembly 22 mounted as shown to the wheel assembly 12 . The bracket assembly 22 generally is of U-shape defined by a first bracket arm segment 24 , a second bracket arm segment 26 forming the bight of the assembly 22 , and a third bracket arm segment 26 . Each of the segments 24 , 28 has a connector coupling at a remote end, the coupling of segment 24 being in the form of a sized C-clamp 30 . The segments forming bracket assembly 22 are formed from suitably sturdy material such as steel. The first segment 24 has an elongate narrow body 32 through which a longitudinal, medially located, slot 33 extends. Extending into an upper edge of the body 32 is a channel 34 . The channel 34 extends the length of the body 32 and is sized to admit electrical wiring (not shown) used for power transmission to sensor units mounted to the bracket assembly 22 as well as data transmission from the sensor units as will be explained.
The end segment 36 of the first segment 24 opposite the C-clamp 20 end angles inwardly to a remote flange 38 through which an assembly aperture 40 extends. The second segment 26 of the bracket assembly 22 attaches to the flange 38 . The second segment 26 is of elongate construction, generally L-shaped in transverse sectional configuration. The bracket segment 26 is formed by a horizontal elongate side 42 intersecting at a right angle along a longitudinal edge with a vertical side 44 . The sides 42 , 44 extend between opposite triangular end flanges 46 through which assembly apertures 48 pass. Suitable assembly hardware is provided to affix the segment 26 to the first and third segments 24 , 28 such as coupling screws and nuts 49 A, B respectively. Spaced apart apertures 50 extend through the side 44 and serve as mounting locations for sensor device(s) attaching to the side 44 as will be explained. Assembly hardware such as pins 51 are provided for the attachment of sensor units to the side 44 .
A mounting plate 52 is included within the bracket assembly 22 and attaches to the body 32 of the arm segment 24 . The plate 52 includes a vertical coupling tongue projection 53 having spaced apart elongate mounting slots 54 extending therethrough. A rectangular plate body 56 has appropriately located mounting through apertures 58 sized for attachment hardware such as pins 60 . A sensor device 62 mounts to the plate body 56 by means of extension of the pins 60 through the apertures 58 . The sensor device 62 is preferably but not necessarily of the type used to measure slip angle of a tire, such as the Commercial Unit Product No. SFII P, sold by Corrsys-Datron Co. located at 39205 Country Club Dr., No. C20, Farmington Hills, Mich. The slip angle sensor device 62 mounts to the mounting plate 52 . The plate 52 attaches by set screws 55 extending through plate slots 54 and through the slot 33 along the arm body 32 . So attached, the plate 52 and slip angle sensor device 62 affixed thereto depend from the arm body 32 and are repositionable along the arm slot 33 into an optimal location relative to the ground surface for tire slip angle measurement.
A camber angle sensor device is assembled to include a pair of spaced apart laser units 66 , 68 that attach through the spaced apart apertures 50 in the second arm segment 26 . The sensor device 66 , 68 measures camber angle of the tire 16 and are of a commercially available type such as Product Unit No. OADM 20145/405174 sold by Baumer Electric, Ltd., located at 122 Spring Street, Unit C-6, Southington, Conn. The laser units 66 , 68 are provided with assembly holes 70 to facilitate attachment to the second arm segment 26 . The attachment of the slip angle sensor 62 and camber angle sensors 66 , 68 to respective arm segments is preferably effected after the arm segments 24 , 26 , 28 are mutually assembled into the U-shaped configuration shown in FIGS. 1 through 3 . To attach the completed bracket assembly 22 with the sensor units 62 and 66 , 68 to the wheel assembly 12 , the U-shaped bracket assembly 22 is positioned in straddling relationship with the tire 16 . The ends of the segments 24 , 28 attach to components of the wheel assembly 12 on opposite respective sides of the tire 16 . In the assembled position, the arm segments 24 , 28 extend in a radial direction along opposite sidewalls 18 of the tire 16 and the arm segment 26 extends in an axial direction opposite the tread region 20 of the tire 16 . The spacing of the arm segments 24 , 28 from respective sidewalls 18 is preferably closely adjacent, in the range of 0.5 to 3 inches to position the slip angle sensor 62 as close as possible to the tire sidewall. Minimizing the protrusion of the sensor 62 acts to minimize the potential for damaging contact between the sensor 62 and surrounding objects. The sensor 62 includes a downwardly directed laser element that measures the angle of the tire 16 relative to the ground surface during vehicle operation and thereby provides data for the calculation of the slip angle of the tire.
The location of the second arm segment 26 and the camber angle sensor 66 , 68 is as shown to be closely adjacent the tread region 20 of the tire 16 , at a distance of 0.5 inches or more. The mounting of the arm segment 26 is preferable to the side of the wheel assembly 12 opposite the direction of forward vehicle travel 78 in order to protect the tire in the event of a bracket failure. The through passages 60 through the arm segment 26 reduces the bracket weight. The sensor units 66 , 68 include downwardly directed laser elements that measure to the ground surface and the angular cant of the tire during vehicle operation, whereby providing data for the calculation of the camber angle of the tire.
While the subject bracket assembly 22 and sensor units mounted thereto can effect measurement from tires used in myriad vehicle applications, the assembly is particularly useful and effective in determining the wheel and tire set up in a race car in preparation for a race. The coupling C-clamp 30 of the assembly 22 may be affixed to the stator 74 of a load cell 72 within the wheel assembly 12 as shown. A load cell such as shown at 72 is commercially available under Product No. 77016-00A-E0000 from Sensor Development Inc., located at 1050 West Silverbell Road, Lake Orion, Mich. The opposite arm segment 28 of the bracket assembly 22 may attach to the brake assembly 76 on the opposite side of the wheel. So located and attached, the sensors 62 and 66 , 68 are located close to the tire 16 to generate accurate camber and slip angle data as well as to minimize the degree to which bracket and sensors protrude. Vehicles may be, in the course of normal operation, particularly in race cars, driven close to outside obstructions and other vehicles. The close proximity and location of the bracket and sensors of the invention to the tire minimizes the risk of contact with such outside influences. Location of the second arm segment and sensor behind the tire, on the opposite side of normatively forward direction of travel 78 , likewise protects the bracket and sensor assembly.
While the attach points of the bracket assembly to the wheel assembly 12 are preferably as shown, other means and locations of attachment of the bracket may be employed if desired. In addition, while slip angle and camber angle sensor units 62 and 66 , 68 are described above, other types of sensors may be deployed through utilization of the bracket assembly 22 and deployment scheme. For example, without intent to delimit the invention, a tire deflection detector or camera may be mounted to the bracket arm segments 224 , 26 , 28 and utilized to detect and measure the existence, location, and geometry of tire anomalies during vehicle use. A thermal detector may also be mounted to the bracket assembly 22 to detect the thermal properties of a tire during vehicle use. Power to and data communication from such devices may be wired along the channel 34 of the arm segment 24 . The bracket assembly and deployment scheme described above allows for the measurement of the tire 16 while in actual use on a road surface. Such real time evaluation under actual working conditions results in a more thorough and accurate evaluation than laboratory testing. The bracket and sensors measure the tire under actual working conditions to provide not only information on tire performance but also tire response and reaction to a specific track or roadway. For a racecar, for example, specifically correlating tire response and conditional parameters to a particular racetrack is extremely important to the racecar setup.
In addition, mounting the bracket assembly 22 and sensor units to a steer wheel assembly 12 allows for tire evaluation through turns since the bracket assembly 22 and sensor units will turn with the tire. Such capability effects a more thorough and accurate evaluation of the tire and roadway surface than could otherwise be made by the mounting of slip angle and camber angle sensors on the body of the vehicle adjacent to a tire. The subject bracket and sensor assembly turns with the wheel to which it is mounted and measure the slip angle directly as opposed vehicle based sensors that measure the slip angle base on the entire car chassis. Improved accuracy therefore is achieved by the invention assembly.
The channel 34 formed within the arm segment 24 extends the length of the body 32 and is sized to admit electrical wiring (not shown) used for power transmission to sensor units 62 and 66 , 68 as well as data transmission from the sensor units to a data storage or collection device. The electrical wiring is thus protected from interfering with the operation of the wheel assembly and from potential damage from contact with foreign objects.
FIGS. 1 through 4 illustrate the use of a load cell and stator shaft embodiment of the invention in which the load cell 72 has a dimensional configuration to place an outward end of the stator 74 in generally a coplanar relationship with the first bracket arm 24 to which the stator 74 is coupled. Thus, the stator extends outward to an extent enabling the bracket arm 24 to extend along the outward side of the tire 16 parallel with the tire sidewall 18 and couple to the stator 74 .
It may be preferable to configure the wheel and sensor assembly 10 in a manner which will enable the bracket 22 to be used in other wheel assemblies and not necessarily require the deployment of a rotating load cell. An alternative versatile bearing assembly 80 is shown in FIGS. 5 through 10 . The assembly 80 allows the camber and slip angle bracket to be used in conjunction with regular track wheels and to take measurements while a racecar is operating at high-speeds. The heavy rotating load cell is thereby eliminated.
With reference to FIGS. 5-10 , the bearing assembly 80 includes a stator shaft 82 having an outward shaft end 82 and an inward shaft end 86 . A stator housing 88 is provided having mounting threaded bores 89 and an internal chamber 90 dimensioned and of a geometric shape for admitting a pair of sealed ball bearings 92 , 94 . An external snap ring 96 and an inward snap ring 98 are provided for securing the stator shaft in place within the housing 88 . A circular wheel standoff plate 100 is included having five spaced apart circumferential mounting apertures 102 extending through the plate 100 from an outward plate surface 104 to an inward facing surface 106 . Plate 100 has a large central through center hole 108 .
Continuing, the assembly 80 has spaced apart openings 110 therethrough. Five extender studs 112 are provided of generally elongate configuration circular in section. The studs 112 each have an outward segment 114 ; a hexagonal collar 116 to the rear of segment 114 ; a circular abutment flange 118 to the rear of the collar 116 ; and a rearward extender shaft 119 to the rear of collar 116 . Five locking nuts 120 are provided as well as five assembly screws 122 . The screws 122 are sized for close receipt through spaced apart mounting apertures 124 of the plate 100 .
Assembly of the bearing assembly proceeds as follows. The forward ends 114 of the extender studs 112 project through respective mounting apertures 102 of the plate 100 until the hexagonal collar 116 of each stud abuts the inward surface 106 of the plate 100 . The screws 120 affix to the outward stud ends 114 to secure the studs to the plate 100 . The stator housing 88 attaches to the outward surface 104 of the plate 100 as screws 122 project through plate apertures 124 and into the threaded bores 89 of the stator housing 88 . The stator shaft 82 extends through the bearings 92 , 94 , the snap rings 96 , 98 , housing 88 , and plate center opening 88 with the snap rings 96 , 98 retaining the shaft 82 in place through the housing 88 and the bearings 92 , 94 within the housing 88 as shown best by FIG. 10 .
The completes assembly is illustrated by FIGS. 6 , 8 , and 10 and shown assembled to the tire assembly by FIG. 5 . It will be seen that the extender studs 112 are configured having a length sufficient to place the plate 100 outward from the wheels a prescribed distance. The studs 112 of the bearing assembly 80 correspondingly move the outward end 84 of the stator shaft 82 outward into a coplanar relationship with the bracket arm 24 suitable to facilitate a coupling between the stator shaft end 84 and the bracket arm 24 . The bearing assembly 80 is relatively light weight compared to the load cell 72 which it replaces. The heavy rotating load cell 72 of FIG. 1 may thus be eliminated. Moreover, the bearing assembly 80 is universal in the sense that it may be used with regular wheel units. Such versatility permits the bracket 22 through the implementation of bearing assembly 80 to be used in conjunction with regular track wheels, whereby allowing measurements to be taken while a racecar is operating at high-speeds on a track. The bracket can, through the use of the bearing assembly 80 , thus be used to measure tire camber and slip angle during actual operating conditions.
The nut extenders 112 fasten the wheel to a race car hub using female threads that of compatible configuration as the wheel studs. The taper of the nut extenders 112 match the wheel nuts. The stand off plate 100 is of suitable material composition such as steel or aluminum. The bolt holes through the plate are designed to mate with standard wheel nuts. The stator shaft 82 is of suitable composition such as aluminum. The shaft attaches to the plate 100 and presses into the bearing assembly within housing 88 . The shaft is retained in assembly by shoulders 83 and 86 respectively by snap rings 96 , 98 . The stator housing 88 is of suitable composition such as aluminum and houses 2 deep groove ball bearings 92 , 94 by means of the snap rings 96 , 98 . The bearings 92 , 94 are of conventional configuration commercially available, such a single, double row angular contact ball bearings.
Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims. | A wheel and sensor assembly includes a U-shaped bracket assembly mounting to and moving with a wheel assembly. One or more sensor device(s) such as camber angle and slip angle sensors mount to the bracket assembly for operatively measuring one or more wheel assembly parameter(s) during vehicle use. The bracket assembly mounts to the wheel assembly and turns therewith. The bracket assembly positions the sensor device(s) in operative optimal proximity to the road surface during vehicle use under actual operating conditions. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to a novel process for the continuous preparation of acetals at industrial scale in a simulated moving bed reactor (SMBR).
BACKGROUND OF THE INVENTION
[0002] The acetals with chemical structure R 2 —CH—(O—R 1 ) 2 are oxygenated compounds produced by the reaction between an aldehyde (R 2 —CHO) and an alcohol(R 1 —OH) in the presence of an acid catalyst, accordingly to:
[0000]
[0003] Traditionally, the reaction is catalyzed by mineral or carboxylic acids (U.S. Pat. No. 2,519,540, U.S. Pat. No. 5,362,918 and U.S. Pat. No. 5,527,969). The disadvantage of using soluble catalyst is that they must be neutralized after reaction and separated from the product. Therefore, heterogeneous catalysts as ion exchange resins (acid type) or zeolites are used, which have the advantage of being easily separated from reaction product and having a long lifetime (patents EP 1 167 333 A2 and U.S. Pat. No. 4,579,979).
[0004] The synthesis of acetals is a reversible reaction. In order to obtain acceptable acetal yields, the equilibrium must be displaced in the direction of acetal synthesis. Several methods are used to displace equilibrium towards acetal formation, such as:
1. to use a large excess of one of the reactants, in general the alcohol, which then requires elimination of that excess in a step of purification of the desired product (U.S. Pat. No. 5,362,918); 2. to use an organic solvent to eliminate water by azeotropic distillation between a solvent and water or by liquid-liquid extraction, a further step of separation is necessary to remove the solvent from the end product (U.S. Pat. No. 2,519, 540, U.S. Pat. No. 4,579,979, U.S. Pat. No. 5,362,918 e U.S. Pat. No. 5,527,969); 3. to use reactive separations in order to remove the products from the reaction medium, being the reactive distillation process the most common (U.S. Pat. No. 5,362,918).
[0008] The processes described above introduce some improvement in the acetals production; however, they also have several disadvantages. For the first method, the conversion of the limiting reactant increases but the yield of the reaction decreases. The second one presents higher conversions but it is necessary to use a solvent; consequently, the costs of raw materials and equipment increase. The reactive distillation could not be applied to all systems, due to azeotropes formation and/or to the incompatible volatilities of reactants and products. It is also possible by-products formation.
[0009] In recent times, in addition to the well-known acetals applications, they have been considered as diesel oil additives, mainly acetaldehyde diethylacetal. It is confirmed that the use of acetals decreases the emissions of particles and NO while keeping or improving the cetane number and helping in the combustion of the final products, without decreasing the ignition quality (patents DE 2 911 411, DE 3 136 030, WO 2001/181 154 A1, WO 2002/026 744 A1).
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 shows a schematic representation of the SMBR process of the present invention, where both reactants (alcohol and aldehyde) are introduced in a single feed stream.
[0011] FIG. 2 shows a second schematic representation of the SMBR process of the present invention, where the reactants (alcohol and aldehyde) are introduced separately in different feed streams.
[0012] FIG. 3 shows the internal concentration profiles in a SMBR at the middle of a switching time at cyclic steady-state.
SUMMARY OF THE INVENTION
[0013] The purpose of the invention is to provide an alternative process for acetals manufacture, achieving 100% of aldehyde conversion, without using additional organic solvents and without by-products formation.
[0014] The acetals produced by the process of the present invention are used in the formulation of perfumes and in the flavouring of alcoholic beverages. Acetal also finds widespread use as intermediate for the synthesis of various industrial chemicals used for agriculture and pharmaceuticals (vitamins and analgesics). Particularly, acetaldehyde diethylacetal is used as solvent and intermediate in the process where the protection of carboxylic groups of aldehydes is needed. Diethylacetal is also used as diesel oil additive, since decreases the emissions of particles and NO x .
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention is concerned with an efficient and continuous process for the preparation of acetals which comprises simultaneously reaction of a lower aliphatic aldehyde with a lower aliphatic alcohol in the presence of acid solid and separation of the produced acetals from the water formed in the SMBR unit.
[0016] The acid solids, that should be simultaneously catalysts and selective adsorbents, could be acidic ion exchange resins, zeolites (Y, mordenites, ZSM, ferrierites), alumina silicates (mortmorillonites and bentonites) or hydrotalcites. Examples of acid resins are Dowex 50 (Dow Chemical), Amberlite IR 120, Amberlyst A15 and A36 (Rohm & Haas), Lewatit (Bayer). These acid solids adsorb preferentially water rather than acetals. Alternatively, it is possible to use a mixture of acid solids as catalyst and as selective adsorbent.
[0017] The Simulated Moving Bed Reactor technology is being recently applied for the preparation of esters from carboxylic acids, see, e.g., U.S. Pat. No. 6,518,454 and U.S. Pat. No. 6,476,239. In Simulated Moving Bed based process, the different affinity to the solid adsorbent is used to separate the products.
[0018] More precisely, the present invention deals with the process of acetals preparation in a Simulated Moving Bed Reactor, which comprise the reaction between the alcohol and the aldehyde in the presence of an acid solid (or a mixture of a acid solid catalyst and a selective adsorbent) and the simultaneous separation of the reaction products (acetal and water) by adsorption.
[0019] Preferentially, this process comprises the following steps:
[0020] I. to feed a reactant mixture (alcohol and aldehyde) and a desorbent (alcohol) to the SMBR unit, equipped with a series of columns packed with acid solid (or a mixture of acid solids);
[0021] II. to react the alcohol with the aldehyde to produce acetal and water;
[0022] III. to remove two streams, a first liquid stream comprising a solution of acetal in the desorbent (raffinate); a second liquid stream comprising the water formed and the desorbent (extract).
[0023] The reactor is equipped with a number of inlet and outlet ports, and a number of valves arranged in manner such that any feed stream may be introduced to any column and any outlet or effluent stream may be withdraw from any column. During the operation of the SMB unit, the columns to which the feed streams are fed and from which the outlet streams are withdrawn are periodically moved. To achieve separation of reaction products, the locations of the inlet and outlet streams are moved intermittently in the direction of the liquid flow. The intermittently port movement in the direction of the liquid flow simulates the counter-current of the bed or beds of the solid(s), e.g., the solid catalyst.
[0024] The simulated moving bed reactor utilized in the present invention is a known apparatus and comprises several columns per zone; each column is package with a solid or a mixture of solids. As depicted in FIG. 1 and FIG. 2 , The SMB reactor typically has 4 or 5 zones.
[0025] The lower alcohol has the following chemical structure
[0000] R—OH
[0000] , where R 1 represents an alkyl group C 1 -C 8 , linear or branched.
[0026] Preferably, the alcohol includes a group such as methyl, ethyl, propyl and butyl. Examples of those alcohols are methanol, ethanol, propanol and butanol.
[0027] The lower aldehyde has the following chemical structure
[0000] R—CHO
[0000] , where R 2 represents an alkyl group C 1 -C 8 , linear or branched.
[0028] Preferably, the aldehyde includes a group such as methyl, ethyl, propyl and butyl. Examples of those aldehyde s are formaldehyde, acetaldehyde, propionaldehyde and butyraldehyde.
[0029] Therefore, the produced acetal has the following chemical structure
[0000] R—CH—(O—R)
[0000] , where R 1 and R 2 are the alkyl groups mentioned before.
[0030] The process of the invention produces lower acetals (C 3 -C 24 ) having preferably from 3 to 12 carbon atoms, for example formaldehyde-dimethylacetal, -diethylacetal, -dipropylacetal, -dibutylacetal; acetaldehyde -dimethylacetal, -diethylacetal, -dipropylacetal, -dibutylacetal; propionaldehyde -dimethylacetal, -diethylacetal, -dipropylacetal, -dibutylacetal; butyraldehyde -dimethylacetal, -diethylacetal, -dipropylacetal and -dibutylacetal.
[0031] The acid solid catalysts are usually zeolites, alumina silicates, hydrotalcites or acidic ion exchange resins.
[0032] The adsorbent is usually an activated carbon, molecular sieves, zeolites, alumina silicates, alumina, silicates or acidic ion exchange resins.
[0033] The simulated moving bed reactor utilized in the present invention is a known apparatus and comprises 1 to 6 columns per zone; each column is packed with a solid or a mixture of solids. As depicted in FIG. 1 and FIG. 2 , The SMB reactor typically has 4 or 5 zones. The reactor is equipped with a number of inlet and outlet ports, and a number of valves arranged in manner such that any feed stream may be introduced to any column and any outlet or effluent stream may be withdraw from any column. During the operation of the SMB unit, the columns to which the feed streams are fed and from which the outlet streams are withdrawn are periodically moved. To achieve separation of reaction products, the locations of the inlet and outlet streams are moved intermittently in the direction of the liquid flow. The intermittently port movement in the direction of the liquid flow simulates the counter-current of the bed or beds of the solid(s), e.g., the solid catalyst.
[0034] In the present invention two streams (desorbent and one feed) or three streams (desorbent and two feeds) could be introduced in the SMBR unit, where the desorbent is the same alcohol used to produce the acetal.
[0035] The first model of operation considers just one feed stream, as shown in FIG. 1 . The feed is constituted by pure aldehyde, or a mixture of alcohol and aldehyde.
[0036] In the second operation model, the two reactants are introduced in two feed streams, accordingly to FIG. 2 . Each feed stream could contain one of the pure reactants: one with the pure alcohol and the other with the pure aldehyde; or both feed streams are mixtures of alcohol and aldehyde, one richer in the alcohol and the other richer in the aldehyde.
[0037] Usually, the SMBR operates at the temperature from about 5° C. to 150° C. and at the pressure from about 100 kPa to 3500 kPa.
[0038] Preferably, the SMBR is kept at temperature from about 10° C. to about 70° C.
[0039] In the process of the present invention, the inlet/outlet streams are shifted periodically from the position P′ to the position P, being that time named switching time.
[0040] The operation of the SMBR allows that the inlet/outlet streams shift, either forward or backward, in a synchronous or asynchronous way, within a switching period.
[0041] Experimental Section
[0042] The simulated moving bed reactor utilized in the present invention is a known apparatus (U.S. Pat. No. 2,985,589), comprising several columns connected in series; each column is packed with a solid or a mixture of solids. Two or three streams are introduced in the unit. One of them is the desorbent that is normally the alcohol used as reactant to form acetal; the desorbent is used to regenerate the solid in the first zone. The reactants (alcohol and aldehyde) could be introduced in a single feed stream ( FIG. 1 ) or in two feed streams ( FIG. 2 ). The products (acetal and water) are removed from the simulated moving bed reactor in two liquid streams; a first liquid stream comprising a solution of acetal in the desorbent (raffinate), and a second liquid stream comprising the water formed and the desorbent (extract). During the operation of the SMBR unit, the ports to which the feed streams are fed and from which the outlet streams are withdrawn are periodically shifted in the direction of the liquid flow. The intermittently port movement in the direction of the liquid flow simulates the counter-current between the solid(s) and the liquid. The reactor is equipped with a number of inlet and outlet ports, and a rotary valve or a number of valves arranged in manner such that any feed stream may be introduced to any column and any outlet or effluent stream may be withdraw from any column. The position of the inlet/outlet streams defines the different zones existing in the SMBR system, each one accomplishing a certain function and containing a variable number of columns.
[0043] In FIG. 1 , the zone I is comprised between the desorbent stream port (D) and the extract stream port (X); the zone II is comprised between the extract stream port (X) and the feed stream port (F); the zone III is comprised between the feed stream port (F) and the raffinate stream port (R); and the zone IV is comprised between the raffinate stream port (R) and the recycle stream port (Rec). The reactants (alcohol and aldehyde) introduced in the feed stream (F) are converted within zones II and III. In these zones, the separation of the products formed (acetal and water) is carried out; the acetal is removed from the raffinate port and the water is removed from the extract port. As the products are removed from the reaction medium as they are formed, the equilibrium is shifted towards products formation. Therefore the aldehyde conversion increases to values above the thermodynamic equilibrium; being possible to achieve complete conversion (100%). The successful design of SMBR involves the right choice of the operation conditions, mainly the switching time period and flow rates in each section of the unit. The appropriate choice of those parameters will ensure the regeneration of acid solid (or mixture of solids) containing adsorbed water, in zone I; the regeneration of the desorbent contaminated with acetal in zone IV; and the complete conversion of reactants and the separation of the formed products in zones II and III. The flowrates for each section are given by the following expressions: Q I =Q Rec +Q D ; Q II =Q I −Q X ; Q III =Q II +Q F ; Q IV =Q III −Q R =Q Rec . The switching time, t*, is the time necessary to shift all ports from the position P′ to the position P. This process of shifting the ports could be realized synchronously or asynchronously.
[0044] The process of the present invention could be performed in a wide range of temperature and pressure. The temperature could vary from 5° C. up to 150° C.; preferably, from 10° C. up to 70° C.; and it is limited by the boiling points of the components at the pressure of operation of the SMBR. The pressure usually is not a critical issue, unless it is used to avoid vaporization of the components. Therefore, the pressure range is from atmospheric pressure until 3500 kPa.
[0045] The SMBR process schematically represented in FIG. 2 is similar to the one described before corresponding to FIG. 1 . The main difference is that an additional feed stream is introduced to the system, leading to 5 zones of operation. This allows that the reactants are introduced separately in the system; one (the less adsorbed) carried out in stream F 1 and the other (the most adsorbed) in stream F 2 . Alternatively, the feed F 1 can be a mixture of reactants richer in the less adsorbed one and the feed F 2 is a mixture richer in the most adsorbed reactant. The operation of this SMBR process is similar to the previous one: the regeneration of the acid solid and the desorbent is accomplished in zones I and V, respectively; and the complete conversion of reactants and separation of the formed products occurs in zones II, III and IV.
EXAMPLE
[0046] The process described in the present invention is better illustrated by the next example. The samples were analysed on a gas chromatograph and the compounds were separated in a fused silica capillary column, using a thermal conductivity detector for peak detection. The example concerns the synthesis of acetaldehyde diethylacetal from ethanol and acetaldehyde in a Simulated Moving Bed Reactor, using the acidic ion exchange resin Amberlyst 15 both as catalyst and as selective adsorbent. For this reaction, at room temperature and for a 2.2 initial molar ration of ethanol/acetaldehyde, the equilibrium conversion is of 55%.
[0047] The SMBR experiments were performed in a pilot unit LICOSEP 12-26 by Novasep (Vandoeuvre-dès- Nancy, France). Twelve columns Superformance SP 230×26 (length×i.d., m), by Götec Labortechnik (Mühltal, Germany), packed with the acid resin Amberlyst 15 (Rohm and Haas) were connected to the SMBR pilot unit. Each column is jacketed to ensure temperature control and the jackets are connected to one another by silicone hoses and to a thermostat bath (Lauda). Between every two columns there is a four-port valve actuated by the control system. When required, the valves allow either pumping of feed/eluent into the system or withdrawal of extract/raffinate streams. Each of the inlet (feed and eluent) and outlet (extract and raffinate) streams is pumped by means of HPLC pumps. The recycling pump is a positive displacement three-head membrane pump (Milton Roy, Pont St. Pierre, France), which may deliver flowrates as low as 20 ml/min up to 120 ml/min. The other flows (desorbent, extract, feed and raffinate) are controlled by four Merck—Hitachi pumps (Merck-Hitachi models L-6000 and L-6200, Darmstadt, Germany), connected to computer via RS-232. The maximum flow-rate in the desorbed and extract pumps is 30 ml/min, while in the feed and raffinate pumps is 10 ml/min. The maximum allowable pressure is 6 MPa. Between the twelfth and the first column there is a six-port valve, which is used to collect samples for internal concentration profile measurements. The equipment has its own process control software, which is able to accomplish the following tasks:
Switch the inlet and outlet streams at regular time intervals (as assigned by user) by opening and closing on-off pneumatic valves; Keep steady and constant section flowrates as assigned; Keep suction pressure at the recycling pump around a set point assigned by the user (usually 1500 kPa).
[0051] Each column was packed with Amberlyst 15, with an average particle diameter of 800 m m. The columns length, porosity and bulk density were of 23 cm, 0.4 and 390 kg/m 3 , respectively. Tracer experiments were performed in all columns in order to determine the Peclet number (Pe), which allows the evaluation of the axial dispersion effects. The average value calculated to all twelve columns in the flowrates range used in the SMBR is Pe=300.
[0052] The feed was a mixture of ethanol (30%)/acetaldehyde (70%) and the desorbent was ethanol (99.5%). The flowrates were Q D =50.0 ml/min; Q F =10 ml/min; Q R =25 ml/min; Q X =35 ml/min and Q Rec =20 ml/min. The switching time was set at 3.70 minutes and three columns per zone were used ( FIG. 1 ). The internal concentration profiles at the middle of the switching time after the cyclic steady state be achieved are shown in FIG. 3 . It is possible to observe that the acetaldehyde is practically completed converted, meaning that the conversion is near 100%. As it was mentioned before, the products are removed in different streams; the diethylacetal is carried out in the raffinate stream and the water in the extract. The product obtained in a fixed bed adsorptive reactor (FBAR) operating at steady state is compared with the raffinate product obtained in the SMBR, in terms of weight percentage, in the following table:
[0000]
Process
Ethanol
Acetaldehyde
Diethylacetal
Water
FBAR
31.89%
12.50%
48.25%
7.36%
SMBR
28.74%
0.08%
71.04%
0.14%
[0053] The acetaldehyde conversion at the outlet of the FBAR is 54.5%, near equilibrium value. For the SMBR the conversion is of 99.7%. Moreover, the raffinate product obtained in the SMBR contains 71% of diethylacetal with a weight purity of 99.7% without ethanol (98.4% molar); while the product of the FBAR contains 48% of diethylacetal with a weight purity of 70.8% without ethanol (37.1% molar).
REFERENCES
[0000]
T. Aizawa, H. Nakamura, K. Wakabayashi, T. Kudo, H. Hasegawa, “Process for Producing Acetaldehyde Dimethylacetal”, U.S. Pat. No. 5,362,918 (1994).
J. Andrade, D. Arntz, G. Prescher, “Method for Preparation of Acetals”, U.S. Pat. No. 4,579,979 (1986).
L. W. Blair, S. T. Perri, B. K. Arumugam, B. D. Boyd, N. A. Collins, D. A. Larkin, C. W. Sink, “Preparation of Esters of Carboxylic Acids”, U.S. Pat. No. 6,518,454 (2003).
L. W. Blair, E. B. Mackenzie, S. T. Perri, J. R. Zoeller, B. K. Arumugam, “Process for the Preparation of Ascorbic Acid”, U.S. Pat. No. 6,476,239 (2002).
K. Boennhoff, “1,1-Diethoxyethane as Diesel Fuel”, DE Patent No. 2 911 411 (1980).
K. Boennhoff, “Method for enhancing the ignition performance of dialkoxyalkanes used as diesel fuel, in particular 1,1-diethoxyethane”, DE Patent No. 3 136 030 (1983).
V. Boesch, J. R. Herguijuela, “Process and Manufacturing Equipment for Preparing Acetals and Ketals”, EP Patent No. 1 167 333 A2 (2001).
P. L. Bramwyche, M. Mudgan, H. M. Stanley, “Manufacture of Diethyl Acetal”, U.S. Pat. No. 2,519,540 (1950).
A. Golubkov, “Motor Fuel for Diesel Engines”, WO Patent No. 2001/0 181 154 A1 (2001).
A. Golubkov, I. Golubkov, “Motor Fuel for Diesel, Gas-Turbine and Turbojet Engines”, US Patent No. 2002/0 026 744 A1 (2002).
M. M. Kaufhold, M. T. El-Chabawi, “Process for Preparing Acetaldehyde Diethyl Acetal”, U.S. Pat. No. 5,527,969 (1996). | The present invention is an industrial process for the preparation of acetals using a simulated moving bed (SMB) reactor system to accomplish the conversion of reactants (aldehyde and alcohol) and simultaneously, the separation of the reaction products (acetal and water) by selective adsorption. The SMB reactor consists of a set of interconnected columns packed with an acid solid (or mixture of acid solids: catalysts and adsorbents) effective for catalyzing the reaction between aldehydes and alcohols and for separating the reaction products by selective adsorption of at least one product. In a general embodiment, this process involves (1) feeding a mixture of aldehydes and alcohols and a desorbent which is the alcohol, to a simulated moving bed reactor; (2) reacting aldehydes and alcohols to form acetals; and (3) removing from the simulated moving bed reactor two liquid streams, a first liquid stream comprising a solution of acetal in the desorbent (raffinate), a second liquid stream comprising the water formed and the desorbent (extract). | 2 |
This application claims the benefit of U.S. Provisional Patent Application No. 60/637,895, filed Dec. 21, 2004.
Diabetes is caused by multiple factors and is most simply characterized by elevated levels of plasma glucose (hyperglycemia) in the fasting state. There are two generally recognized forms of diabetes: Type 1 diabetes, or insulin-dependent diabetes mellitus (IDDM), in which patients produce little or no insulin, the hormone which regulates glucose utilization, and Type 2 diabetes, or noninsulin-dependent diabetes mellitus (NIDDM), wherein patients produce insulin and even exhibit hyperinsulinemia (plasma insulin levels that are the same or even elevated in comparison with non-diabetic subjects), while at the same time demonstrating hyperglycemia. Type 1 diabetes is typically treated with exogenous insulin administered via injection. However, Type 2 diabetics often develop “insulin resistance”, such that the effect of insulin in stimulating glucose and lipid metabolism in the main insulin-sensitive tissues, namely, muscle, liver, and adipose tissues, is diminished. Patients who are insulin resistant but not diabetic have elevated insulin levels that compensate for their insulin resistance, so that serum glucose levels are not elevated. In patients with NIDDM, the plasma insulin levels, even when they are elevated, are insufficient to overcome the pronounced insulin resistance, resulting in hyperglycemia.
Insulin resistance is primarily due to a receptor signaling defect that is not yet completely understood. Resistance to insulin results in insufficient activation of glucose uptake, diminished oxidation of glucose and storage of glycogen in muscle, inadequate insulin repression of lipolysis in adipose tissue, and inadequate glucose production and secretion by the liver.
Persistent or uncontrolled hyperglycemia that occurs in diabetics is associated with increased morbidity and premature mortality. Abnormal glucose homeostasis is also associated both directly and indirectly with obesity, hypertension, and alterations in lipid, lipoprotein, and apolipoprotein metabolism. Type 2 diabetics are at increased risk of developing cardiovascular complications, e.g., atherosclerosis, coronary heart disease, stroke, peripheral vascular disease, hypertension, nephropathy, neuropathy, and retinopathy. Therefore, therapeutic control of glucose homeostasis, lipid metabolism, obesity, and hypertension are critically important in the clinical management and treatment of diabetes mellitus.
Many patients who have insulin resistance but have not developed Type 2 diabetes are also at risk of developing “Syndrome X” or “metabolic syndrome”. Syndrome X or metabolic syndrome is a condition characterized by insulin resistance, along with abdominal obesity, hyper insulinemia, high blood pressure, low HDL and High VLDL. These patients, whether or not they develop overt diabetes mellitus, are at increased risk of developing the cardiovascular complications listed above.
Evidence in rodents and humans links 11-beta hydroxysteroid dehydrogenase 1 (“11-β-HSD1”) to metabolic syndrome. Evidence suggests that a drug which specifically inhibits 11-β-HSD1 in type 2 obese diabetic patients will lower blood glucose by reducing hepatic gluconeogenesis, reduce central obesity, improve atherogenic lipoprotein phenotypes, lower blood pressure, and reduce insulin resistance. Insulin effects in muscle will be enhanced, and insulin secretion from the beta cells of the islet may also be increased.
There is a continuing need for new methods of treating diabetes and related conditions, such as metabolic syndrome. It is an object of this invention to meet this and other needs.
SUMMARY OF THE INVENTION
The present invention provides a compound structurally represented by formula I:
or a pharmaceutically acceptable salt thereof wherein
R 0 is
wherein the zig-zag mark represents the point of attachment to the R 0 position in Formula I;
G 1 is methylene or ethylene;
L is a divalent linking group selected from —(C 1 -C 4 )alkylene-, —S—, —CH(OH)—, or —O—;
A is methylene, —S—, —O—, or —NH—;
R 1 is
Hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), or —CH 2 OR 7 wherein R 7 is hydrogen or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens);
R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; G 2 is methylene, ethylene, or 1-propylene; X is hydrogen, hydroxyl, or —CH 2 OH; Y is hydrogen or methyl, provided that at least one of X and Y is not hydrogen; or X and Y together with the carbon to which they are attached form a carbonyl; R 8 and R 9 are each independently hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens); R 10 is hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens);
R 3 is
hydrogen, hydroxy (provided that when L is —S— or —CH(OH)— then R 3 cannot be hydroxy), or —(C 1 -C 4 )alkyl;
R 4 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy, halo, cyano, —SCF 3 , —OCF 3 , Ar 1 , Het 1 , Ar 1 —(C 1 -C 4 )alkyl, Het 1 -(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-C(O)O—(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-OH, or —(C 1 -C 4 )alkyl-C(O)N(R 11 )(R 12 ); wherein R 11 and R 12 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 11 and R 12 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 5 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, —SCF 3 , —OCF 3 , Ar 1 , Het 1 , Ar 1 —(C 1 -C 4 )alkyl, Het 1 -(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-C(O)O—(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-OH, or —(C 1 -C 4 )alkyl-C(O)N(R 11 )(R 12 ); wherein R 11 and R 12 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 11 and R 12 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl
R 6 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, Ar 2 , Het 1 , Het 2 , Ar 2 —(C 1 -C 4 )alkyl, Het 2 —(C 1 -C 4 )alkyl, —C(O)—(C 1 -C 4 )alkyl, —C(O)—Ar 2 , —C(O)—Het 2 , —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-Ar 2 , —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl; or when R 0 is
then R 5 and R 6 may combine with the ring atoms to which they are attached to form
Ar 1 is phenyl or naphthyl;
Ar 2 is
Ar 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), —O—(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), imidazolyl, pyridinyl, or —(C 1 -C 4 )alkyl-imidazolyl; wherein R 15 and R 16 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Het 1 is
a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, benzofuranyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, benzothiophenyl, thiophenyl, quinolinyl, isoquinolinyl, quinoxalinyl, quinazolinyl, or phthalazinyl;
Het 2 is
Het 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl)C(O)OH, —(C 1 -C 4 )alkyl-N(R 17 )(R 11 ), —O—(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), imidazolyl, pyridinyl, or —(C 1 -C 4 )alkyl-imidazolyl; wherein R 17 and R 18 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 19 is
hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH; and
R 20 is
Hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH.
The present invention provides compounds of formula I that are useful as potent and selective inhibitors of 11-beta hydroxysteroid dehydrogenase 1. The present invention further provides a pharmaceutical composition which comprises a compound of Formula I, or a pharmaceutical salt thereof, and a pharmaceutically acceptable carrier, diluent, or excipient. In addition, the present invention provides a method for the treatment of metabolic syndrome, and related disorders, which comprise administering to a patient in need thereof an effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof.
Due to their inhibition of 11-beta hydroxysteroid dehydrogenase 1, the present compounds are useful in the treatment of a wide range of conditions and disorders in which inhibition of 11-beta hydroxysteroid dehydrogenase 1 is beneficial. These disorders and conditions are defined herein as “diabetic disorders” and “metabolic syndrome disorders”. One of skill in the art is able to identify “diabetic disorders” and “metabolic syndrome disorders” by the involvement of 11-beta hydroxysteroid dehydrogenase 1 activity either in the pathophysiology of the disorder, or in the homeostatic response to the disorder. Thus, the compounds may find use for example to prevent, treat, or alleviate, diseases or conditions or associated symptoms or sequelae, of “Diabetic disorders” and “metabolic syndrome disorders”.
“Diabetic disorders” and “metabolic syndrome disorders” include, but are not limited to, diabetes, type 1 diabetes, type 2 diabetes, hyperglycemia, hyper insulinemia, beta-cell rest, improved beta-cell function by restoring first phase response, prandial hyperglycemia, preventing apoptosis, impaired fasting glucose (IFG), metabolic syndrome, hypoglycemia, hyper-/hypokalemia, normalizing glucagon levels, improved LDL/HDL ratio, reducing snacking, eating disorders, weight loss, polycystic ovarian syndrome (PCOS), obesity as a consequence of diabetes, latent autoimmune diabetes in adults (LADA), insulitis, islet transplantation, pediatric diabetes, gestational diabetes, diabetic late complications, micro-/macroalbuminuria, nephropathy, retinopathy, neuropathy, diabetic foot ulcers, reduced intestinal motility due to glucagon administration, short bowel syndrome, antidiarrheic, increasing gastric secretion, decreased blood flow, erectile dysfunction, glaucoma, post surgical stress, ameliorating organ tissue injury caused by reperfusion of blood flow after ischemia, ischemic heart damage, heart insufficiency, congestive heart failure, stroke, myocardial infarction, arrhythmia, premature death, wound healing, impaired glucose tolerance (IGT), insulin resistance syndromes, syndrome X, hyperlipidemia, dyslipidemia, hypertriglyceridemia, hyperlipoproteinemia, hypercholesterolemia, arteriosclerosis including atherosclerosis, glucagonomas, acute pancreatitis, cardiovascular diseases, hypertension, cardiac hypertrophy, gastrointestinal disorders, obesity, diabetes as a consequence of obesity, diabetic dyslipidemia, etc. Thus, the present invention also provides a method of treatment of “Diabetic disorders” and “metabolic syndrome disorders” while reducing and or eliminating one or more of the unwanted side effects associated with the current treatments.
Thus the present invention also provides a method of treatment of a condition selected from the group consisting of: (1) hyperglycemia, (2) low glucose tolerance, (3) insulin resistance, (4) obesity, (5) lipid disorders, (6) dyslipidemia, (7) hyperlipidemia, (8) hypertriglyceridemia, (9) hypercholesterolemia, (10) low HDL levels, (11) high LDL levels, (12) atherosclerosis and its sequelae, (13) vascular restenosis, (14) pancreatitis, (15) abdominal obesity, (16) neurodegenerative disease, (17) retinopathy, (18) nephropathy, (19) neuropathy, (20) Syndrome X, (21) osteoporosis, as well as other conditions and disorders where insulin resistance is a component, in a patient in need of such treatment, comprising administering to said patient a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
General terms used in the description of compounds herein described bear their usual meanings.
As used herein, the term “(C 1 -C 4 )alkyl” refers to straight-chain or branched-chain saturated aliphatic groups of 1 to 4 carbon atoms including methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, t-butyl, and the like.
Similarly, the term “(C 1 -C 4 )alkoxy” represents a C 1 -C 4 alkyl group attached through an oxygen atom and examples include methoxy, ethoxy, n-propoxy, isopropoxy, and the like.
The term “—(C 1 -C 4 )alkylene-” refers to straight-chain or branched-chain saturated divalent aliphatic groups such as methylene, ethylene, n-propylene, gemdimethyl methylene, and the like.
The term “halogen” refers to fluoro, chloro, bromo, and iodo.
“HET 1 ” and “HET 2 ” may be attached at any point which affords a stable structure.
The term “optionally substituted,” or “optional substituents,” as used herein, means that the groups in question are either unsubstituted or substituted with one or more of the substituents specified. When the groups in question are substituted with more than one substituent, the substituents may be the same or different. The terms “independently,” “independently are,” and “independently selected from” mean that the groups in question may be the same or different. Certain of the herein defined terms may occur more than once in the structural formulae, and upon such occurrence each term shall be defined independently of the other.
As used herein, the term “patient” refers to a warm-blooded animal or mammal that has or is at risk of developing a disease selected from (1) through (20) described below. It is understood that guinea pigs, dogs, cats, rats, mice, hamsters, and primates, including humans, are examples of patients within the scope of the meaning of the term “patient”. The term “patient” includes and livestock animals. Livestock animals are animals raised for food production. Ruminants or “cud-chewing” animals such as cows, bulls, heifers, steers, sheep, buffalo, bison, goats and antelopes are examples of livestock. Other examples of livestock include pigs and avians (poultry) such as chickens, ducks, turkeys and geese. Yet other examples of livestock include fish, shellfish and crustaceans raised in aquaculture. Also included are exotic animals used in food production such as alligators, water buffalo and ratites (e.g., emu, rheas or ostriches). The patient to be treated is preferably a mammal, in particular a human being.
The terms “treatment”, “treating” and “treat”, as used herein, include their generally accepted meanings, i.e., the management and care of a patient for the purpose of preventing, reducing the risk in incurring or developing a given condition or disease, prohibiting, restraining, alleviating, ameliorating, slowing, stopping, delaying, or reversing the progression or severity, and holding in check and/or treating existing characteristics, of a disease, disorder, or pathological condition, described herein, including the alleviation or relief of symptoms or complications, or the cure or elimination of the disease, disorder, or condition. The present method includes both medical therapeutic and/or prophylactic treatment, as appropriate.
As used herein, the term “therapeutically effective amount” means an amount of compound of the present invention that is capable of alleviating the symptoms of the various pathological conditions herein described. The specific dose of a compound administered according to this invention will, of course, be determined by the particular circumstances surrounding the case including, for example, the compound administered, the route of administration, the state of being of the patient, and the pathological condition being treated.
“Composition” means a pharmaceutical composition and is intended to encompass a pharmaceutical product comprising the active ingredient(s) including compound(s) of Formula I, and the inert ingredient(s) that make up the carrier. Accordingly, the pharmaceutical compositions of the present invention encompass any composition made by admixing a compound of the present invention and a pharmaceutically acceptable carrier.
The term “suitable solvent” refers to any solvent, or mixture of solvents, inert to the ongoing reaction that sufficiently solubilizes the reactants to afford a medium within which to effect the desired reaction.
The term “unit dosage form” means physically discrete units suitable as unitary dosages for human subjects and other non-human animals, each unit containing a predetermined quantity of active material calculated to produce the desired therapeutic effect, in association with a suitable pharmaceutical carrier.
As used herein, the term “stereoisomer” refers to a compound made up of the same atoms bonded by the same bonds but having different three-dimensional structures which are not interchangeable. The three-dimensional structures are called configurations. As used herein, the term “enantiomer” refers to two stereoisomers whose molecules are nonsuperimposable mirror images of one another. The term “chiral center” refers to a carbon atom to which four different groups are attached. As used herein, the term “diastereomers” refers to stereoisomers which are not enantiomers. In addition, two diastereomers which have a different configuration at only one chiral center are referred to herein as “epimers”. The terms “racemate”, “racemic mixture” or “racemic modification” refer to a mixture of equal parts of enantiomers.
The term “enantiomeric enrichment” as used herein refers to the increase in the amount of one enantiomer as compared to the other. A convenient method of expressing the enantiomeric enrichment achieved is the concept of enantiomeric excess, or “ee”, which is found using the following equation:
ee = E 1 - E 2 E 1 + E 2 × 100
wherein E 1 is the amount of the first enantiomer and E 2 is the amount of the second enantiomer. Thus, if the initial ratio of the two enantiomers is 50:50, such as is present in a racemic mixture, and an enantiomeric enrichment sufficient to produce a final ratio of 70:30 is achieved, the ee with respect to the first enantiomer is 40%. However, if the final ratio is 90:10, the ee with respect to the first enantiomer is 80%. An ee of greater than 90% is preferred, an ee of greater than 95% is most preferred and an ee of greater than 99% is most especially preferred. Enantiomeric enrichment is readily determined by one of ordinary skill in the art using standard techniques and procedures, such as gas or high performance liquid chromatography with a chiral column. Choice of the appropriate chiral column, eluent and conditions necessary to effect separation of the enantiomeric pair is well within the knowledge of one of ordinary skill in the art. In addition, the specific stereoisomers and enantiomers of compounds of formula I can be prepared by one of ordinary skill in the art utilizing well known techniques and processes, such as those disclosed by J. Jacques, et al., “ Enantiomers, Racemates, and Resolutions ”, John Wiley and Sons, Inc., 1981, and E. L. Eliel and S. H. Wilen, “ Stereochemistry of Organic Compounds ”, (Wiley-Interscience 1994), and European Patent Application No. EP-A-838448, published Apr. 29, 1998. Examples of resolutions include recrystallization techniques or chiral chromatography.
Some of the compounds of the present invention have one or more chiral centers and may exist in a variety of stereoisomeric configurations. As a consequence of these chiral centers, the compounds of the present invention occur as racemates, mixtures of enantiomers and as individual enantiomers, as well as diastereomers and mixtures of diastereomers. All such racemates, enantiomers, and diastereomers are within the scope of the present invention.
The terms “R” and “S” are used herein as commonly used in organic chemistry to denote specific configuration of a chiral center. The term “R” (rectus) refers to that configuration of a chiral center with a clockwise relationship of group priorities (highest to second lowest) when viewed along the bond toward the lowest priority group. The term “S” (sinister) refers to that configuration of a chiral center with a counterclockwise relationship of group priorities (highest to second lowest) when viewed along the bond toward the lowest priority group. The priority of groups is based upon their atomic number (in order of decreasing atomic number). A partial list of priorities and a discussion of stereochemistry is contained in “Nomenclature of Organic Compounds: Principles and Practice”, (J. H. Fletcher, et al., eds., 1974) at pages 103-120.
The designation refers to a bond that protrudes forward out of the plane of the page.
The designation refers to a bond that protrudes backward out of the plane of the page.
The designation refers to a bond wherein the stereochemistry is not defined.
In one embodiment, the present invention provides a compound of Formula I, or a pharmaceutically acceptable salt thereof, as described in detail above. While all of the compounds of the present invention are useful, certain of the compounds are particularly interesting and are preferred. The following listings set out several groups of preferred embodiments.
In a preferred embodiment, the present invention provides a compound structurally represented by formula I, or a pharmaceutically acceptable salt thereof, wherein
R 0 is
wherein the zig-zag mark represents the point of attachment to the R 0 position in Formula I;
G 1 is methylene or ethylene;
L is —CH 2 —;
A is —CH 2 —, —S—, —O—, or —NH—;
R 1 is hydrogen;
R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; G 2 is methylene, ethylene, or 1-propylene; X is hydrogen, hydroxyl, or —CH 2 OH; Y is hydrogen or methyl, provided that at least one of X and Y is not hydrogen; or X and Y together with the carbon to which they are attached form a carbonyl; R 8 and R 9 are each independently hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens); R 10 is hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens);
R 3 is hydrogen;
R 4 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy, halo, cyano, —SCF 3 , —OCF 3 , —(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-C(O)O—(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-OH, or —(C 1 -C 4 )alkyl-C(O)N(R 11 )(R 12 ); wherein R 11 and R 12 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 11 and R 12 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 5 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, —SCF 3 , —OCF 3 , —(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-C(O)O—(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-OH, or —(C 1 -C 4 )alkyl-C(O)N(R 11 )(R 12 ); wherein R 11 and R 12 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 11 and R 12 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl
R 6 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, Ar 2 , Het 1 , Het 2 , Ar 2 —(C 1 -C 4 )alkyl, Het 2 -(C 1 -C 4 )alkyl, —C(O)—(C 1 -C 4 )alkyl, —C(O)—Ar 2 , —C(O)—Het 2 , —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-Ar 2 , —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl; or when R 0 is
then R 5 and R 6 may combine with the ring atoms to which they are attached to form
Ar 1 is phenyl;
Ar 2 is
Ar 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), —O—(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), imidazolyl, pyridinyl, or —(C 1 -C 4 )alkyl-imidazolyl; wherein R 15 and R 16 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Het 1 is
a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, benzofuranyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, benzothiophenyl, thiophenyl, quinolinyl, isoquinolinyl, quinoxalinyl, quinazolinyl, or phthalazinyl;
Het 2 is
Het 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl)C(O)OH, —(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), —O—(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), imidazolyl, pyridinyl, or —(C 1 -C 4 )alkyl-imidazolyl; wherein R 17 and R 18 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 19 is
hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH; and
R 20 is
Hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH.
In a preferred embodiment, the present invention provides a compound structurally represented by formula I, or a pharmaceutically acceptable salt thereof, wherein
R 0 is
wherein the zig-zag mark represents the point of attachment to the R 0 position in Formula I;
G 1 is methylene;
L is —CH 2 —;
A is —CH 2 —, —S—, —O—, or —NH—;
R 1 is hydrogen;
R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; G 2 is methylene, X is hydrogen or —CH 2 OH; Y is hydrogen or methyl, provided that at least one of X and Y is not hydrogen; or X and Y together with the carbon to which they are attached form a carbonyl; R 8 and R 9 are each independently hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens); R 10 is hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens);
R 3 is hydrogen;
R 4 is
hydrogen, —CH 3 (optionally substituted with one to three halogens), or halo;
R 5 is
hydrogen, or halo;
R 6 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, Ar 2 , Het 1 , Het 2 , Ar 2 —(C 1 -C 4 )alkyl, Het 2 -(C 1 -C 4 )alkyl, —C(O)—(C 1 -C 4 )alkyl, —C(O)—Ar 2 , —C(O)—Het 2 , —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-Ar 2 , —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl; or when R 0 is
then R 5 and R 6 may combine with the ring atoms to which they are attached to form
Ar 1 is phenyl;
Ar 2 is
Ar 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), —O—(C 1 -C 4 )alkyl-N(R 15 )(R 16 ); wherein R 15 and R 16 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Het 1 is
a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, thiophenyl;
Het 2 is
Het 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl)C(O)OH, —(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), —O—(C 1 -C 4 )alkyl-N(R 17 )(R 18 ); wherein R 17 and R 18 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 19 is
hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH; and
R 20 is
Hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH.
In a preferred embodiment, the present invention provides a compound structurally represented by formula I, or a pharmaceutically acceptable salt thereof, wherein
R 0 is
wherein the zig-zag mark represents the point of attachment to the R 0 position in Formula I;
G 1 is ethylene;
L is —CH 2 —;
A is —CH 2 —, —S—, —O—, or —NH—;
R 1 is hydrogen;
R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; G 2 is methylene, X is hydrogen or —CH 2 OH; Y is hydrogen or methyl, provided that at least one of X and Y is not hydrogen; or X and Y together with the carbon to which they are attached form a carbonyl; R 8 and R 9 are each independently hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens); R 10 is hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens);
R 3 is hydrogen;
R 4 is
hydrogen, —CH 3 (optionally substituted with one to three halogens), or halo;
R 5 is
hydrogen, or halo;
R 6 is
hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, Ar 2 , Het 1 , Het 2 , Ar 2 —(C 1 -C 4 )alkyl, Het 2 —(C 1 -C 4 )alkyl, —C(O)—(C 1 -C 4 )alkyl, —C(O)—Ar 2 , —C(O)—Het 2 , —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-Ar 2 , —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl; or when R 0 is
then R 5 and R 6 may combine with the ring atoms to which they are attached to form
Ar 1 is phenyl;
Ar 1 is
Ar 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-N(R 15 )(R 6 ), —O—(C 1 -C 4 )alkyl-N(R 15 )(R 16 ); wherein R 15 and R 16 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Het 1 is
a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, thiophenyl;
Het 2 is
Het 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl)C(O)OH, —(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), —O—(C 1 -C 4 )alkyl-N(R 17 )(R 18 ); wherein R 17 and R 18 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 19 is
hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH; and
R 20 is
Hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH.
In a preferred embodiment, the present invention provides a compound structurally represented by formula I, or a pharmaceutically acceptable salt thereof, wherein
R 0 is
wherein the zig-zag mark represents the point of attachment to the R 0 position in Formula I;
G 1 is methylene;
L is —CH 2 —;
A is —S—, or —O—;
R 1 is hydrogen;
R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; G 2 is methylene, X and Y together with the carbon to which they are attached form a carbonyl; R 8 and R 9 are each independently hydrogen; R 10 is hydrogen;
R 3 is hydrogen;
R 4 is
hydrogen, —CH 3 (optionally substituted with one to three halogens), or halo;
R 5 is
hydrogen, or halo;
R 6 is
hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, Ar 2 , Het 1 , Het 2 , Ar 2 —(C 1 -C 4 )alkyl, Het 2 -(C 1 -C 4 )alkyl, —C(O)—(C 1 -C 4 )alkyl, —C(O)—Ar 2 , —C(O)—Het 2 , —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-Ar 2 , —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Ar 1 is phenyl;
Ar 2 is
Ar 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), —O—(C 1 -C 4 )alkyl-N(R 15 )(R 16 ); wherein R 15 and R 16 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Het 1 is
a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, thiophenyl;
Het 2 is
Het 1 optionally substituted with from one to three moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl)C(O)OH, —(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), —O—(C 1 -C 4 )alkyl-N(R 17 )(R 18 ); wherein R 17 and R 18 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 19 is
hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH; and
R 20 is
Hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH.
In another preferred embodiment the present invention provides a compound structurally represented by formula I, or a pharmaceutically acceptable salt thereof, wherein G 1 is methylene; L is methylene;
R 0 is
wherein the zig-zag mark represents the point of attachment to the R 0 position in Formula I;
R 1 is hydrogen;
R 2 is
wherein the dashed line represents the point of attachment to the R 2 position in formula I; R 3 is hydrogen; A is —S— or —O—; R 4 is hydrogen; R 5 is halo; and R 6 is hydrogen.
Other embodiments of the invention are provided wherein each of the embodiments described herein above is further narrowed as described in the following preferences. Specifically, each of the preferences below is independently combined with each of the embodiments above, and the particular combination provides another embodiment in which the variable indicated in the preference is narrowed according to the preference.
Preferably R 0 is
Preferably R 0 is
Preferably G 1 is methylene. Preferably G 1 is ethylene. Preferably L is —CH 2 —. Preferably A is —CH 2 —. Preferably A is —S—. Preferably A is —O—. Preferably A is —NH—. Preferably R 1 is hydrogen. Preferably R 1 is —CH 3 .
Preferably R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; G 2 is methylene, ethylene, or 1-propylene; X is hydrogen, hydroxyl, or —CH 2 OH; Y is hydrogen or methyl, provided that at least one of X and Y is not hydrogen; or X and Y together with the carbon to which they are attached form a carbonyl; R 8 and R 9 are each independently hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens).
Preferably R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; R 8 and R 9 are each independently hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens).
Preferably R 2 is
Preferably R 2 is
Preferably R 2 is
Preferably R 2 is
wherein the dashed line indicates the point of attachment to the R 2 position in formula I; R 10 is hydrogen, hydroxy, or —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens).
Preferably R 2 is
Preferably R 3 is hydrogen.
Preferably R 4 is hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy, halo, cyano, —SCF 3 , —OCF 3 . Preferably R 4 is hydrogen, or halo. Preferably R 4 is halo. Preferably R 4 is fluoro or chloro, or bromo.
Preferably R 5 is hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, —SCF 3 , —OCF 3 , —(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-C(O)O—(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-OH, or —(C 1 -C 4 )alkyl-C(O)N(R 11 )(R 12 ); wherein R 11 and R 12 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 11 and R 12 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably R 5 is hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, —SCF 3 , —OCF 3 . Preferably R 5 is hydrogen, —CH 3 (optionally substituted with one to three halogens), or halo. Preferably R 5 is hydrogen.
Preferably R 6 is hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, Ar 2 , Het 1 , Het 2 , Ar 2 —(C 1 -C 4 )alkyl, Het 2 —(C 1 -C 4 )alkyl, —C(O)—(C 1 -C 4 )alkyl, —C(O)—Ar 2 , —C(O)—Het 2 , —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-Ar 2 , —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably R 6 is hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, —C(O)—(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably R 6 is hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —(C 1 -C 4 )alkoxy(optionally substituted with one to three halogens), halo, cyano, —C(O)—(C 1 -C 4 )alkyl, —(C 1 -C 4 )alkyl-N(R 13 )(R 14 ), —O—(C 1 -C 4 )alkyl-C(O)OH, or —O—(C 1 -C 4 )alkyl-N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably R 6 is Ar 2 , Het 1 , Het 2 , Ar 2 —(C 1 -C 4 )alkyl, Het 2 -(C 1 -C 4 )alkyl, —C(O)—Ar 2 , —C(O)—Het 2 , —O—(C 1 -C 4 )alkyl-Ar 2 .
Preferably Ar 1 is phenyl.
Preferably Ar 2 is Ar 1 optionally substituted with from one or two moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), —O—(C 1 -C 4 )alkyl-N(R 15 )(R 6 ); wherein R 15 and R 16 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably Ar 2 is Ar 1 substituted once with a moiety independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl-C(O)OH, —(C 1 -C 4 )alkyl-N(R 15 )(R 16 ), —O—(C 1 -C 4 )alkyl-N(R 15 )(R 16 ); wherein R 15 and R 16 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably Het 1 is a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, thiophenyl. Preferably Het 1 is a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, furanyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, thiophenyl. Preferably Het 1 is pyridinyl.
Preferably Het 2 is Het 1 optionally substituted with from one or two moieties independently selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl)C(O)OH, —(C 1 -C 4 )alkyl-N(R 7 )(R 15 ), —O—(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), wherein R 17 and R 18 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably Het 2 is Het 1 substituted once by a moiety selected from halo, hydroxy, cyano, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), —C(O)OH, —C(O)OCH 3 , —(C 1 -C 4 )alkyl-C(O)OH, —O—(C 1 -C 4 )alkyl)C(O)OH, —(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), —O—(C 1 -C 4 )alkyl-N(R 17 )(R 18 ), wherein R 17 and R 18 are each independently hydrogen or —(C 1 -C 4 )alkyl, or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferably R 19 is hydroxy, or —CH 3 (optionally substituted with one to three halogens), or —CH 2 OH. Preferably R 19 is hydroxyl. Preferably R 19 is —CH 3 (optionally substituted with one to three halogens). Preferably R 19 is —CH 2 OH.
Preferably R 20 is hydrogen, hydroxy, —(C 1 -C 4 )alkyl(optionally substituted with one to three halogens), or —CH 2 OH. Preferably R 20 is hydrogen or hydroxyl.
In another embodiment the present invention provides a compound structurally represented by formula (IA), or a pharmaceutically acceptable salt thereof:
wherein
G 1 is methylene or ethylene;
L is a divalent linking group selected from C 1 -C 4 alkylene, —S—, —CH(OH)—, —O—, or —NH—;
A is methylene, —S—, —O—, or —NH—;
R 1 is hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, or —CH 2 OR 7 wherein R 7 is hydrogen or C 1 -C 4 alkyl;
R 2 is a monovalent radical having one of the following formulae
wherein X is hydrogen, hydroxy or —CH 2 OH and Y is hydrogen or methyl or X and Y together form (═O) and wherein R 8 and R 9 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl or phenyl, and R 10 is hydrogen, hydroxy, or C 1 -C 4 alkyl and G 2 is methylene, ethylene, or 1-propylene;
R 3 is hydrogen, hydroxy, or C 1 -C 4 alkyl;
R 4 and R 5 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, trifluoromethyl, trifluoromethylsulfanyl, trifluoromethoxy, Ar 1 , Het 1 , Ar 1 —(C 1 -C 4 alkyl), Het 1 -(C 1 -C 4 alkyl), —(C 1 -C 4 alkyl)COOH, —(C 1 -C 4 alkyl)COO(C 1 -C 4 alkyl), —(C 1 -C 4 alkyl)OH, or —(C 1 -C 4 alkyl)CON(R 11 )(R 12 ); wherein R 11 and R 12 are each independently hydrogen or C 1 -C 4 alkyl or R 11 and R 12 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 6 is hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, trifluoromethyl, Ar 2 , Het 2 , Ar 2 —(C 1 -C 4 alkyl), Het 2 -(C 1 -C 4 alkyl), —CO(C 1 -C 4 alkyl), —CO—Ar 2 , —CO-Het 2 , —(C 1 -C 4 alkyl)N(R 13 )(R 14 ), —O(C 1 -C 4 alkyl)-Ar 2 , —O(C 1 -C 4 alkyl)COOH, or —O(C 1 -C 4 alkyl)N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or C 1 -C 4 alkyl or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
or R 5 and R 6 combine together on the ring which they are attached to form
Ar 1 is phenyl or naphthyl;
Ar 2 is Ar 1 optionally substituted with from one to three moieties selected from halo, hydroxy, cyano, trifluoromethyl, C 1 -C 4 alkyl, —COOH, —COOCH 3 , —(C 1 -C 4 alkyl)COOH, —O(C 1 -C 4 alkyl)COOH, —(C 1 -C 4 alkyl)N(R 15 )(R 16 ), —O(C 1 -C 4 alkyl)N(R 15 )(R 16 ), imidazolyl, pyridyl, or —(C 1 -C 4 alkyl)-imidazolyl; wherein R 15 and R 16 are each independently hydrogen or C 1 -C 4 alkyl or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Het 1 is a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, benzofuranyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, benzothiophenyl, thiophenyl, quinolinyl, isoquinolinyl, quinoxalinyl, quinazolinyl, or phthalazinyl; and
Het 2 is Het 1 optionally substituted with from one to three moieties selected from halo, hydroxy, cyano, trifluoromethyl, C 1 -C 4 alkyl, —COOH, —COOCH 3 , —(C 1 -C 4 alkyl)COOH, —O(C 1 -C 4 alkyl)COOH, —(C 1 -C 4 alkyl)N(R 17 )(R 18 ), —O(C 1 -C 4 alkyl)N(R 17 )(R 18 ), imidazolyl, pyridyl, or —(C 1 -C 4 alkyl)-imidazolyl; wherein R 17 and R 18 are each independently hydrogen or C 1 -C 4 alkyl or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
In another embodiment the present invention provides a compound structurally represented by formula (IB), or a pharmaceutically acceptable salt thereof:
wherein
G 1 is methylene or ethylene;
L is a divalent linking group selected from C 1 -C 4 alkylene, —S—, —CH(OH)—, —O—, or —NH—;
A is methylene, —S—, —O—, or —NH—;
R 1 is hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, or —CH 2 OR 7 wherein R 7 is hydrogen or C 1 -C 4 alkyl;
R 2 is a monovalent radical having one of the following formulae
wherein X is hydrogen, hydroxy or —CH 2 OH and Y is hydrogen or methyl or X and Y together form (═O) and wherein R 8 and R 9 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl or phenyl, and R 10 is hydrogen, hydroxy, or C 1 -C 4 alkyl and G 2 is methylene, ethylene, or 1-propylene;
R 3 is hydrogen, hydroxy, or C 1 -C 4 alkyl;
R 4 and R 5 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, trifluoromethyl, trifluoromethylsulfanyl, trifluoromethoxy, Ar 1 , Het 1 , Ar 1 —(C 1 -C 4 alkyl), Het 1 -(C 1 -C 4 alkyl), —(C 1 -C 4 alkyl)COOH, —(C 1 -C 4 alkyl)COO(C 1 -C 4 alkyl), —(C 1 -C 4 alkyl)OH, or —(C 1 -C 4 alkyl)CON(R 11 )(R 12 ); wherein R 11 and R 12 are each independently hydrogen or C 1 -C 4 alkyl or R 11 and R 12 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
R 6 is hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, trifluoromethyl, Ar 2 , Het 2 , Ar 2 —(C 1 -C 4 alkyl), Het 2 -(C 1 -C 4 alkyl), —CO(C 1 -C 4 alkyl), —CO—Ar 2 , —CO-Het 2 , —(C 1 -C 4 alkyl)N(R 13 )(R 14 ), —O(C 1 -C 4 alkyl)-Ar 2 , —O(C 1 -C 4 alkyl)COOH, or —O(C 1 -C 4 alkyl)N(R 13 )(R 14 ); wherein R 13 and R 14 are each independently hydrogen or C 1 -C 4 alkyl or R 13 and R 14 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
or R 5 and R 6 combine together on the ring which they are attached form
Ar 1 is phenyl or naphthyl;
Ar 2 is Ar 1 optionally substituted with from one to three moieties selected from halo, hydroxy, cyano, trifluoromethyl, C 1 -C 4 alkyl, —COOH, —COOCH 3 , —(C 1 -C 4 alkyl)COOH, —O(C 1 -C 4 alkyl)COOH, —(C 1 -C 4 alkyl)N(R 15 )(R 16 ), —O(C 1 -C 4 alkyl)N(R 15 )(R 16 ), imidazolyl, pyridyl, or —(C 1 -C 4 alkyl)-imidazolyl; wherein R 15 and R 16 are each independently hydrogen or C 1 -C 4 alkyl or R 15 and R 16 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl;
Het 1 is a heterocyclic radical selected from pyridinyl, piperidinyl, pyrimidinyl, pyrazinyl, piperazinyl, pyridazinyl, indolyl, isoindolyl, indolinyl, furanyl, benzofuranyl, thiazolyl, oxazolyl, isoxazolyl, isothiazolyl, benzothiophenyl, thiophenyl, quinolinyl, isoquinolinyl, quinoxalinyl, quinazolinyl, or phthalazinyl; and
Het 2 is Het 1 optionally substituted with from one to three moieties selected from halo, hydroxy, cyano, trifluoromethyl, C 1 -C 4 alkyl, —COOH, —COOCH 3 , —(C 1 -C 4 alkyl)COOH, —O(C 1 -C 4 alkyl)COOH, —(C 1 -C 4 alkyl)N(R 17 )(R 18 ), —O(C 1 -C 4 alkyl)N(R 7 )(R 18 ), imidazolyl, pyridyl, or —(C 1 -C 4 alkyl)-imidazolyl; wherein R 17 and R 18 are each independently hydrogen or C 1 -C 4 alkyl or R 17 and R 18 taken together with the nitrogen to which they are attached form piperidinyl or pyrrolidinyl.
Preferred compounds of the invention include compounds or pharmaceutically acceptable salts of formulae (IA) or (IB) wherein:
(1) G 1 is methylene; (2) L is methylene; (3) R 1 is hydrogen or methyl; (4) R 2 is cyclohexyl, 6-hydroxycyclohexyl, or 1-adamantyl; (5) R 3 is hydrogen; (6) A is —S— or —O—; (7) R 4 and R 5 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, or trifluoromethyl; (8) R 6 is hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, or trifluoromethyl; (9) R 5 and R 6 combine together on the ring which they are attached to form
Further, any combination of the above groups, e.g., (1) and (2); (3) and (5); (3), (4), (5), (6), (7), and (8); and (1), (2), (3), (4), (5), (6), (7), and (8), are specifically contemplated.
Preferred compounds of the invention also include compounds or pharmaceutically acceptable salts of formula (IIA):
wherein
R 1 is hydrogen or methyl;
R 2 is a monovalent radical having one of the following formulae
wherein X is hydrogen, hydroxy or —CH 2 OH and Y is hydrogen or methyl or X and Y together form (═O) and wherein R 8 and R 9 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl or phenyl, and R 10 is hydrogen, hydroxy, or C 1 -C 4 alkyl and G 2 is methylene, ethylene, or 1-propylene;
A is methylene, —S—, —O—, or —NH—;
R 4 and R 5 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, or trifluoromethyl; and
R 6 is hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, or trifluoromethyl.
Preferred compounds of the invention also include compounds or pharmaceutically acceptable salts of formula (IB):
wherein
R 1 is hydrogen or methyl;
R 2 is a monovalent radical having one of the following formulae
wherein X is hydrogen, hydroxy or —CH 2 OH and Y is hydrogen or methyl or X and Y together form (═O) and wherein R 8 and R 9 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl or phenyl, and R 10 is hydrogen, hydroxy, or C 1 -C 4 alkyl and G 2 is methylene, ethylene, or 1-propylene;
A is methylene, —S—, —O—, or —NH—;
R 4 and R 5 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, or trifluoromethyl; and
R 6 is hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, or trifluoromethyl.
Other preferred compounds of the invention include compounds or pharmaceutically acceptable salts of formulae (IIA) or (IB) wherein
(1) R 1 is hydrogen; (2) R 2 is cyclohexyl or 1-adamantyl;
(a) (3) A is —O— or —S—;
(4) R 4 and R 5 are each independently hydrogen, hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, cyano, or trifluoromethyl; and (5) R 6 is hydrogen.
Further, any combination of the above groups, e.g., (1) and (2); (3) and (4); (1), (2), (3), and (4); (1), (2), (3), (4) and (5); (1) and (3); (2) and (3), and the like, are specifically contemplated.
Preferred compounds of the invention are represented by the following compounds and pharmaceutically acceptable salts thereof:
3-Benzo[b]thiophen-2-ylmethyl-1-cyclohexyl-pyrrolidin-2-one; 3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 3-Benzofuran-2-ylmethyl-1-cyclohexyl-pyrrolidin-2-one; 3-(7-Chloro-1,3-dioxa-5-thia-s-indacen-6-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 1-Cyclohexyl-3-(3-methyl-benzo[b]thiophen-2-ylmethyl)-pyrrolidin-2-one; 3-(3-Chloro-6-fluoro-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 3-(5-Chloro-benzo[b]thiophen-3-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 3-(3-Chloro-6-methoxy-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 3-(5-Bromo-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 3-(6-Bromo-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-1-(cis-4-hydroxy-cyclohexyl)-pyrrolidin-2-one; 3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-1-(4-hydroxy-cyclohexyl)-pyrrolidin-2-one; 1-(4-Hydroxy-cyclohexyl)-3-(3-methyl-benzofuran-2-ylmethyl)-pyrrolidin-2-one; 3-(3-Chloro-6-hydroxy-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one; 4-[3-Chloro-2-(1-cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-6-yloxymethyl]-benzoic acid; 3-[3-Chloro-6-(3-dimethylamino-propoxy)-benzo[b]thiophen-2-ylmethyl]-1-cyclohexyl-pyrrolidin-2-one hydrochloride salt; 3-[3-Chloro-6-(3-dimethylamino-propoxy)-benzo[b]thiophen-2-ylmethyl]-1-cyclohexyl-pyrrolidin-2-one; 4-[3-Chloro-2-(1-cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-6-yloxy]-butyric acid; 1-Cyclohexyl-3-[5-(2-fluoro-pyridin-4-yl)-benzo[b]thiophen-2-ylmethyl]-pyrrolidin-2-one; 4-[2-(1-Cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-5-yl]-benzoic acid; 3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-trans-1-(4-hyroxyl-cyclohexyl)-piperidin-2-one; 3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-1-(4-hyroxyl-cyclohexyl)-piperidin-2-one; and 3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-cis-1-(4-hyroxyl-cyclohexyl)-piperidin-2-one.
The compounds of Formula I, can be prepared by one of ordinary skill in the art following a variety of procedures, some of which are illustrated in the procedures and schemes set forth below. The particular order of steps required to produce the compounds of Formula I is dependent upon the particular compound to being synthesized, the starting compound, and the relative liability of the substituted moieties. The reagents or starting materials are readily available to one of skill in the art, and to the extent not commercially available, are readily synthesized by one of ordinary skill in the art following standard procedures commonly employed in the art, along with the various procedures and schemes set forth below.
The following Schemes, Preparations, Examples and Procedures are provided to better elucidate the practice of the present invention and should not be interpreted in any way as to limit the scope of the same. Those skilled in the art will recognize that various modifications may be made while not departing from the spirit and scope of the invention. All publications mentioned in the specification are indicative of the level of those skilled in the art to which this invention pertains.
The optimal time for performing the reactions of the Schemes, Preparations, Examples and Procedures can be determined by monitoring the progress of the reaction via conventional chromatographic techniques. Furthermore, it is preferred to conduct the reactions of the invention under an inert atmosphere, such as, for example, argon, or, particularly, nitrogen. Choice of solvent is generally not critical so long as the solvent employed is inert to the ongoing reaction and sufficiently solubilizes the reactants to effect the desired reaction. The compounds are preferably isolated and purified before their use in subsequent reactions. Some compounds may crystallize out of the reaction solution during their formation and then collected by filtration, or the reaction solvent may be removed by extraction, evaporation, or decantation. The intermediates and final products of Formula I may be further purified, if desired by common techniques such as recrystallization or chromatography over solid supports such as silica gel or alumina.
The skilled artisan will appreciate that not all substituents are compatible with all reaction conditions. These compounds may be protected or modified at a convenient point in the synthesis by methods well known in the art.
The terms and abbreviations used in the instant Schemes, Preparations, Examples and Procedures have their normal meanings unless otherwise designated. For example, as used herein, the following terms have the meanings indicated: “eq” refers to equivalents; “N” refers to normal or normality, “M” refers to molar or molarity, “g” refers to gram or grams, “mg” refers to milligrams; “L” refers to liters; “mL” refers to milliliters; “μL” refers to microliters; “mol” refers to moles; “mmol” refers to millimoles; “psi” refers to pounds per square inch; “min” refers to minutes; “h” or “hr” refers to hours; “° C.” refers to degrees Celsius.
“TLC” refers to thin layer chromatography; “HPLC” refers to high performance liquid chromatography; “R f ” refers to retention factor; “R t ” refers to retention time; “δ” refers to part per million down-field from tetramethylsilane; “MS” refers to mass spectrometry, Observed Mass indicates [M+H] unless indicated otherwise. “MS (FD)” refers to field desorption mass spectrometry, “MS(IS)” refers to ion spray mass spectrometry, “Mass spectrum (ion spray)” refers to ion-spray ionization mode. “MS(FIA)” refers to flow injection analysis mass spectrometry, “MS (FAB)” refers to fast atom bombardment mass spectrometry, “MS(EI)” refers to electron impact mass spectrometry, “MS(ES)” refers to electron spray mass spectrometry, “MS (EI)” refers to electron impact mass spectrometry-electrospray ionization, “MS (ES+)” refers to mass spectrometry-electrospray ionization, “MS(APCi) refers to atmospheric pressure chemical ionization mass spectrometry, “UV” refers to ultraviolet spectrometry, “ 1 H NMR” refers to proton nuclear magnetic resonance spectrometry. “LC-MS” refers to liquid chromatography-mass spectrometry, “GC/MS” refers to gas chromatography/mass spectrometry. “IR” refers to infra red spectrometry, and the absorption maxima listed for the IR spectra are only those of interest and not all of the maxima observed. “RT” refers to room temperature.
“THF” refers to tetrahydrofuran, “LAH” refers to lithium aluminum hydride, “LDA” refers to lithium diisopropylamide, “DMSO” refers to dimethylsulfoxide, “DMF” refers to dimethylforamide, “HCl” refers to hydrochloric acid, “EtOAc” refers to ethyl acetate, “Pd—C” refers to palladium on carbon, “DCM” refers to dichloromethane, “DMAP” refers to dimethylaminopyridine, “LiHMDS” refers to Lithium Hexamethyldisilisane, “TFA” refers to trifluoroacetic acid, “EDAC” refers to N-Ethyl-N′-(3-dimethylaminopropyl)carbodiimide hydrochloride, “HOBT” refers to 1-Hydroxy benzotriazole, “Bn-9-BBN” refers to Benzyl-9-borabicyclo[3.3.1]nonane, “Pd(dppf)Cl 2 ” refers to [1,1′-Bis(diphenylphosphino)-ferrocene)dichloropalladium(II), “EDCI” refers to N-Ethyl-N′-(3-dimethylaminopropyl)carbodiimide hydrochloride, “DBU” refers to 1,8-Diazabicyclo[5.4.0]undecene-7, “TBSCl” refers to tert-butyl-dimethyl-silanyloxymethyl chloride, “NBS” refers to N-Bromosuccinimide, “TsOH” refers to p-toluenesulfonic acid, “DCE” refers to dichloroethane, “DAST” refers to (Diethylamino)sulfur trifluoride, “EA/H” refers to ethyl acetate/hexanes mixture, “Pd 2 (dba) 3 ” refers to Bis(dibenzylideneacetone)palladium, “BINAP” refers to 2,2′-Bis(diphenylphospino-1,1′-binaphthalene, “NMP” refers to N-Methylpyrrollidine, “TMSCN” refers to Trimethylsilyl cyanide, “TBAF” refers to Tetrabutylammonium fluoride, “Tf 2 O” refers to trifluoromethanesulfonic anhydride, “TBSO” refers to tert-butyl-dimethyl-silanyloxy, “OTf” refers to trifluoromethanesulfonate, MeTi(Oi-Pr) 3 refers to methyltitanium triisopropoxide. DIAD refers to diisopropyl azodicarboxylate. In a structure, “Ph” refers to phenyl, “Me” refers to methyl, “Et” refers to ethyl, “Bn” refers to benzyl, and “MeOH” refers to methanol.
General Procedures
Compounds of the present invention have been formed as specifically described in the examples. Alternative synthesis methods may also be effective and known to the skilled artisan. Unless otherwise indicated, all variables, such as L, G 1 , R 1 to R 20 , etc., are as defined for analogous variables in the summary of the invention, and otherwise as defined herein.
In Schemes A1 and A2 the lactam (1 or 1a) is conjugated with an alkylating agent R″X (2 or 2a) to give (3 or 3a). The reaction is carried out using lithium diisopropylamide (LDA) to form the lithium anion of the lactam but other bases could be used (lithium hexamethyl disilazide, sodium hydride, phosphazenes, potassium tert-butoxide) (Conditions used are a modification of the conditions to alkylate 1-methyl-pyrrolidinone, see: Hullet, P. et al. Can. J. Chem . (1976) 54, 1098-1104; For use of phosphazenes in alkylation of lactams, see: Goumri-Magnet et al. J. Org. Chem . (1999) 64, 3741-3744). The reaction is carried out in THF but other solvents could be used (i.e.; dichloromethane, ether, toluene, etc. to facilitate solubility of the components). The reaction can be run with either an excess of the lactam and LDA or with an excess of the alkylating agent. The ease of purification of the product from the starting materials and the relative expense of the components and the preference of the chemist lead to different choices of which ratios of starting materials to use. In general the reaction affords good to moderate yields of product especially for benzylic alkylating reagents. The reaction is initiated at temperatures of −78° C. and warmed to room temperature. Depending on the reactivity of the alkylating reagent, the time varies. Alkyl alkylating agents take longer (1-3 hours or more, while the subset of benzyl alkylating agents proceed rapidly at −78° C. (<15 minutes). The alkylating agents are halides; generally the iodides, bromides, or chlorides; however one skilled in the art would recognize that tosylates, triflates, nosylates, and other alkylating agents would work. When R 1 is not hydrogen, the major product of the alkylation is the trans-isomer and this is the preferred method for the preparation of these compounds.
In Schemes B1 and B2 the alkylating agents (7) can be prepared by modifications of a variety of literature conditions a few of which are illustrated here. Substituted aldehydes (4 or 4a) or carbonyl chlorides (5 or 5a), which are readily available from the corresponding carboxylic acids with thionyl chloride or oxalyl chloride, and the subclass of benzo[b]thiophene-3-chloro-2-carbonyl chlorides are readily available from the appropriate cinnamic acid and thionyl chloride ( J. Heterocyclic Chem . (1986) 1571-1577), are reduced readily by dropwise addition into a mixture of sodium borohydride in ethanol/THF to form the substituted alcohols (6 or 6a). Conversion of the substituted alcohols (6 or 6a) to the bromides (7 or 7a) can generally be achieved by adding a moderate excess of phosphorous tribromide to a solution of the alcohol in a solvent (either ether or dichloromethane; but other solvents compatible with phosphorous tribromide would work). Other literature procedures can effect the conversion of (6 or 6a) to (7 or 7a); i.e.; treatment with HBr in AcOH with some substrates; conversion of the alcohol to a mesylate followed by Br-displacement, or treatment with CBr 4 and triphenylphosphine to name but three of many possibilities. The iodides or chlorides can be made by modifications of the above procedures.
In cases where there is but one alkyl moiety attached to the heteroaryl moiety as in (8 or 8a), conversion of the methyl moiety to the halide (7 or 7a) can be effected by treatment with a radical precursor (AIBN, benzyl peroxide, a peroxide, etc.) in a suitable solvent with a bromide radical precursor (NBS, bromine, etc.) to afford the bromide (7 or 7a). Replacement of the bromide radical precursor with a chloride or iodide radical precursor can afford the corresponding chlorides or iodides.
In cases where R is not a halomethyl heteroaromatic moiety, the alkyl iodides are generally the best alkylating agent for the reaction in General Scheme A. A versatile method of preparing these alkylating partners is to first make the tosylate (triflate and mesylate with alternative bases than triethyl amine can also be effectively used) from an alcohol (9) and then displace the tosylate with iodide ion in acetone.
Chloromethyl-heteroaromatics in certain cases can be easily made from paraformaldehyde or freshly cracked formaldehyde or another formaldehyde synthetic equivalent via acid catalyzed aromatic substitution ( J. Med Chem . (1988) 31, 72-83).
In Schemes C1 and C2, an alternative to using an alkylating agent to prepare (3 or 3a) is described. Substituted lactams (1) can be converted to the alcohols (13 or 13a) ( J. Med. Chem . (1991) 34, 887-900) by treatment of the lactam with LDA followed by treatment with an aldehyde. Alternatively, these alcohols could be made from carboxylic esters via a Claisen reaction to form an intermediate ketone, followed by a hydride reduction ( Liebigs, Ann. Chemie . (1983) 165-180). Elimination of the alcohol to the α,β-unsaturated lactam (14 or 14a) can be effected by formation of the mesylate with methanesulfonyl chloride and triethyl amine as base; followed by treatment with DBU ( Chem. Pharm. Bull . (1990) 38 393-399). Other conditions to affect this transformation (i.e.; different bases to substitute for triethyl amine or DBU or different activation agents to replace DBU) could be used and should be evident to those trained in the art. Reduction of the double bond moiety of (14 or 14a) by catalytic hydrogenation affords (3 or 3a). Catalytic hydrogenation could potentially be replaced with 1,4-conjugate addition of hydride or alkyl metal species to form (3 or 3a) or alkylated variants thereof.
When R 1 does not equal hydrogen, the major compound of these reduction is the cis-isomer and this is the preferred method for the preparation of these compounds.
In Scheme D1 and D2 the lactam (3) is conjugated with an alkylating agent (2) to give (15). As in the case of Scheme A, other bases and solvents can be used. When R 1 does not equal H, the major product has a trans-relationship between the 3-substitutent on the lactam and R 1 . It is evident to those trained in the art that both isomers of (15) when L=(CH 2 ) n can be preferentially made as the major product by judicious choice of which alkylating agent, R 3 X or ArLX, to introduce first.
In Scheme E 1 and E 2 the lactone (16) is reacted with a primary amine to form the lactam starting material ( J. Am. Chem. Soc . (1947) 69, 715-716). A large number of primary amines can be utilized in this procedure. Benzyl amines, substituted cycloalkyl amines (substituted with alkyl, amine, alcohols, etc), and fused bi- and tri-cyclic amines (i.e., adamantyl, norborenyl, camphoryl, etc) may be used. The reaction proceeds in two steps and involves a thermal elimination of water at high temperature. No solvent is used; but a high boiling solvent could be added if perceived to be desirable. It should be noted that if R 3 is at the 3-position of the lactam, then the product is the same as (3 or 3a) and an alkylation is not necessary. This procedure is done as shown in the second synthetic depiction in Schemes E 1 and E 2 . Alkylation of the lactone (17) with LDA and an alkylating agent using the conditions of Schemes A1 and A2 affords (18 and 18a) and condensation with the amine under thermal conditions without solvent forms (3 and 3a) directly.
In Scheme F, cyclic ketones (19) are condensed with methyl 4-aminobutyrate hydrochloride (20) in a reductive amination with sodium triacetoxyborohydride to afford the lactams (21) ( Syn Lett . (1994) 81-83). The reaction is done using a modification of the conditions described by Marynoff et al. The solvent is 1,2-dichloroethane and the reaction takes 1-4 days to complete depending upon the ketone. In some cases, the crude product is heated to reflux in toluene to force the ring closure and drive the reaction to completion. This cyclization can be done with 5-, 6-, and 7-member ring ketones (19); substituted and not, and with ketals (Y and Z connect to form ═OCH 2 CH 2 O) on the ring to aid in the further preparation of advanced intermediates.
In Scheme G1 and G2, a route to chiral 3-substituted lactams is shown. Acylation of the chiral auxiliary (22) with pent-4-enoyl chloride (acylation with longer unsaturated acyl chlorides would give 6- and higher member ring lactams via analogy) affords the imide (24). Alkylation of the imide (24) using the general alkylation conditions of general Scheme A affords in high diastereomeric excess the drawn diastereomer (25 and 25a). It is probable that other chiral auxiliaries similar to (22) could be utilized with similar or higher diastereomeric excess. Ozonolysis of the olefin affords an aldehyde intermediate that is immediately reductively cyclized with a primary amine in conditions similar to those of Scheme F to afford the lactam (26 and 26a) ( Bioorg. Med. Chem. Lett . (2003) 2035-2040). Of course, utilization of the other enantiomer of (22) gives the other enantiomer of (26 and 26a) and both enantiomers are claimed.
In Scheme H, substituted cyclohexyl amines are acylated with 4-chlorobutyryl chloride using triethylamine, pyridine, or another appropriate acid scavenger base. The second cyclization sometimes occurs in this acylation, but usually a stronger base such as NaH or KH is necessary to effect the second cyclization. Other strong bases such as tert-BuOK could potentially be used. This procedure is particularly effective to make lactams with a 1-alkyl substituent on the cyclic amine moiety.
In Schemes I1 and I2, the silylated lactam (30) is alkylated via treatment with LDA, followed by treatment with an alkylating agent (2 or 2a) in conditions similar to Scheme A. The silyl moiety is removed in the aqueous workup of the reaction. The substituted lactam product (31 and 31a) can be N-alkylated by treatment with NaH in THF with a substituted or unsubstituted 3-halo-cyclohex-1-ene to form the lactam (33 or 33a).
In Scheme J1 and J2, the cyclohexenyl product (33 or 33a) can be optionally oxidized via literature procedures to cyclohexyl alcohols (34 or 34a), diols (35 or 35a), reduced to the cyclohexyl moiety (36 or 36a), or be oxidized to an epoxide intermediate (37 or 37a). Epoxide intermediate (37 or 37a) can be further functionalized with a nucleophile to form substituted alcohols (38 or 38a).
In Scheme K, substituted cyclohexyl alcohols (39), which are readily available either commercially or by known literature procedures can be converted to azides via treatment with diphenylphosphoryl azide (DPPA) and triphenyl azide and DEAD in THF to form the azide (40). During this reaction, the relative stereochemistry of the starting alcohol is inverted and is evident to those trained in the art. Treatment of the azide (40) with butyrylactone forms the lactam (41). During the Schmidt reaction the relative stereochemistry of the N-moiety to the substituents R 8 and R 9 is conserved as is evident to those trained in the art and is illustrated in the examples below.
In Scheme L, a variety of substituted cyclohexyl amines can be easily acquired from the substituted carboxylic acids (42), which are easily prepared via known literature methods [i.e., alkylation of a parent carboxylic acid with RX (X=halide or triflate)]. In this procedure the carboxylic acid is first subjected to Curtius rearrangement in the presence of benzyl alcohol to form the CBZ carbamate (43). In this reaction the relative stereochemistry of the starting material (42) is conserved as is evident to those trained in the art. Hydrogenation of the CBZ carbamate forms the amine (44). A variety of hydrogenation conditions can be used to effect this transformation as is evident to those trained in the art (i.e.; see Green's protecting group book for numerous conditions) (Greene, Protective Groups in Organic Synthesis, John Wiley & Sons, New York, N.Y.). These amine starting materials (44) are useful starting materials for Schemes E, G, H, and M to prepare the claimed lactams.
In Schemes M1 and M2, amines are acylated and cyclized with 2,4-dibromobutryl chloride to produce the N-alkylated-3-bromopyrrolidinones (45) in good yield ( J. Med. Chem . (1987) 30, 1995-1998). The bromide can be displaced by hydroxybenzothiophenes, hydroxybenzofurans, thiobenzothiophenes, thiobenzofurans, aminobenzofurans, aminobenzothiophenes, alcohols, thiols, and amines to form the lactams (46 or 46a) [L=O, S].
In Scheme N1 and N2, a hydroxyl substituted lactam (47) stereochemistry is inverted with the Mitsunobu reaction to form its diastereomer (48) (trans to cis conversion illustrated here; but the reverse could easily be done). The alcohol substituted lactams are conveniently alkylated by first protecting the alcohol moiety with a silyl protecting group (TBS used but a variety of protecting groups from Green's Protecting Groups in Org Synthesis could be employed), and then alkylated employing the conditions of Scheme A. Deprotection of the alcohol with appropriate conditions (acid/HCl or fluoride deprotection of silyl moieties are convenient) yield the hydroxylated lactams (49 and 49a).
In Schemes O1 and O2, heteroaryl “Br” lactams (50 or 50a) (bromine as indicated by Br* can also be I, Cl, or OTf and this same chemistry would produce the drawn compounds with the appropriate catalysts known in the literature by those trained in the art) are converted to the biaryl/aryl-heteroaryl compounds by coupling to the appropriate aryl/heteroaryl boronic acid (51 or 51a) via reaction route 1 to produce the lactams (52 or 52a) directly. The linker (L) can be any of the following [CH 2 , CHR, O, S, or (CH 2 ) n ]. It is also convenient to make the boronic acid convergent intermediate (53 and 53a) and couple with the appropriate Pd(cat) ligand system with a variety of aryl/heteroaryl halides/triflates (54) to form the lactams in two steps as shown in reaction route 2. This route is convenient and more versatile if the boronic acids (51) are not easy to prepare or acquire from commercial sources or literature methods.
In Schemes P1 and P2, the heteroaryl bromides (Br could also be expected to be replaced with OTf, I) are conveniently converted into substituted arylalkyl lactams (eg., Br, I, Cl or Tf conversion to alkyl). This conversion (reaction route 1) is achieved via Pd-catalyzed insertion of (R 6 ) 3 B (54) or BBN—R6 [a subclass of (54) (made from either BBN—H regioselective addition to primary alkenes, or via organometallic addition of R 6 -Metal to BBN—OMe)]. In reaction route 2, organometallic conversion to introduce alkyl moieties containing nitrile, ester and other functionality is a Pd-catalyzed Negishi insertion of an R 6 zinc halide (56) to the halide/triflate (50 or 50a) to produce the lactams (57 or 57a). This route is the preferred method for preparation of compounds of the structure where R 6 ═(CH 2 ) n FG (FG=COOR, CN). A similar Negishi reaction can be used to produce (57 or 57a) where R 6 ═CN when R 6 ZnX (56) is replaced with ZnCN in the reaction.
In Schemes Q1 and Q2, the boronic acids (53 or 53a) prepared in Scheme O1 and O2, are conveniently converted into hydroxyl substituted heteroaromatic lactams (58 and 58a) via oxidation with N-methyl morpholine oxide in a suitable solvent or via treatment of the boronic acid with another oxidizing agent such as peroxides. Other oxidants known in the literature could likely also be utilized. These hydroxyl substituted heteroaromatic lactams (58 and 58a) are useful starting materials in alkylations as in Scheme R.
In Schemes R1 and R2, the methoxy functionalized lactams prepared via one of the above schemes, can be further elaborated via demethylation of the OCH 3 moiety of the lactam (59 or 59a) to make a hydroxyl substituted heteroaromatic lactam (58 or 58a) which can be alkylated with (CH 2 ) n FG (FG=functionalized group) to produce the lactam (60 or 60a). This chemistry is used to introduce moieties where R═(CH 2 ) n FG where FG=ester, acid, primary, secondary, and tertiary amines. It is expected that Mitsunobu reactions of the hydroxyl substituted heteroaromatic lactams (58 or 58a) with alcohols could also produce the lactams (60 or 60a). This should be the preferred method for more functionalized and sensitive R 6 -substituents.
In Schemes S1 and S2, the nitrites (61 or 61a) prepared via Scheme P) or the esters (61 or 61a) (on biaryl substituted compounds to date prepared via Scheme O) are hydrolyzed under standard basic or acidic conditions (the optimal condition varies with the sensitivity of R 4 and R 5 ) to afford the carboxylic acid compound (62 or 62a) which is further elaborated using standard dicarbodiimide coupling methods to prepare amides (63 or 63a). Other amide coupling techniques (which are numerous and known to those trained in the art) would give amides (63 or 63a).
General Experimental Details
A Varian INOVA 400 MHz spectrometer is used to obtain 1 H NMR Specta the in the solvent indicated. A Finnigan LCQ Duo instrument using a mobile phase of 50% acetonitrile, 25% methanol, and 25% 2 mM aqueous ammonium acetate is used to obtain the Electrospray mass spectra. A Varian Prostar 210 instrument equipped with a PDA detector is used to run the analytical HPLC. A 5-cm YMC ODS-AQ column with a particle size of 3 microns is used as the stationary phase and 0.1% TFA in water is used as mobile phase A and 0.05% TFA in acetonitrile is used as mobile phase B. The standard method is a gradient of 5 to 95% B over 5 minutes, unless otherwise indicated. Starting materials are either purchased commercially, prepared as described, or prepared by the literature procedure indicated. ChemDraw version 7.0.1 (CambridgeSoft) is used to name the preparations and examples.
PREPARATIONS AND EXAMPLES
Preparation 1
1-(trans-4-hydroxy-cyclohexyl)-pyrrolidin-2-one
Add trans-4-aminocyclohexanol (230 g; 2.0 mol) to γ-butyrolactone (140 mL; 1.82 mol) in a 1 L round-bottom flask equipped with large magnetic stirrer, thermometer and condenser/nitrogen bubbler. Heat at 190° C. for 68 hours. Cool to ambient temperature and dissolve in water (1 L). Extract into dichloromethane (10×1.5 L). Dry the extracts over magnesium sulfate, filter and evaporate to a brown solid. Triturate with diethyl ether to afford 144.7 g (43%) of the title compound: LC-MS (M+1=184).
Preparation 2
cis-4-Nitro-benzoic acid 4-(2-oxo-pyrrolidin-1-yl)-cyclohexyl ester
Dissolve 1-(trans-4-hydroxy-cyclohexyl)-pyrrolidin-2-one (preparation 1) (144 g; 0.79 mol) in dry tetrahydrofuran (5 L) and cool to −5° C. under nitrogen. Add triphenylphosphine (310 g; 1.185 mol) and 4-nitrobenzoic acid (198 g; 1.185 mol). Add diisopropyl azodicarboxylate (230 mL; 1.185 mol) drop-wise and stir at room temperature overnight. Add saturated aqueous sodium hydrogencarbonate (1 L) extract into dichloromethane (2×2.5 L) in a 20 L separating funnel. Dry the combined organic layers over magnesium sulfate, filter and concentrate. Purify over silica gel (iso-hexane/ethyl acetate 50-100% then 10% methanol in ethyl acetate) to afford 163 g (62%) of the title compound.
Preparation 3
cis-1-(4-hydroxy-cyclohexyl)-pyrrolidin-2-one
Dissolve cis-4-nitro-benzoic acid 4-(2-oxo-pyrrolidin-1-yl)-cyclohexyl ester (preparation 2) (87.9 g; 264 mmol) in methanol (1.35 L) and water (150 mL) and add potassium carbonate (109.5 g; 800 mmol). Stir at room temperature overnight to give a white precipitate. Evaporate to dryness. Azeotrope with ethanol (×2). Stir in tetrahydrofuran (1 L) for 1 hour then filter. Evaporate the filtrate to an oil and crystallize from diethyl ether (100 mL) to afford 40 g (83%) of the title compound.
Preparation 4
cis-1-[4-(tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-pyrrolidin-2-one
Dissolve cis-1-(4-hydroxy-cyclohexyl)-pyrrolidin-2-one (preparation 3) (40 g; 220 mmol) in dry dichloromethane (1 L). Add imidazole (22.5 g; 330 mmol) followed by tert-butyldimethylsilyl chloride (50 g; 330 mmol). Stir under nitrogen at room temperature overnight. Wash with water (250 mL) and saturated aqueous sodium hydrogencarbonate (250 mL). Dry over magnesium sulfate, filter and evaporate to an oil. Pass through a silica gel pad with iso-hexane/ethyl acetate (0-50%) to afford 51 g (79%) the title compound as a clear, pale-yellow oil: LC-MS (M+1=298.5).
Preparation 5
7-Chloro-1,3-dioxa-5-thia-s-indacen-6-yl)-methanol
Slowly add a solution of 7-chloro-1,3-dioxa-5-thia-s-indacene-6-carbonyl chloride (2.00 g, 7.27 mmol) in THF (15 mL) to a mixture of sodium borohydride (6 molar equivalents) in EtOH (20 mL/g) at 0° C. Stir to room temperature for an hour. Quench with water (60 mL/g). Concentrate to the volume of the added water. Extract with ether, wash with water, brine, dry, and concentrate to afford the title compound as a white powder (1.64 g, 93%): 1 H NMR (CDCl 3 ) δ 7.17 (d, 2H), 6.05 (s, 2H), 4.92 (d, 2H), 1.89 (t, 1H).
Preparation 6
6-Bromomethyl-7-chloro-1,3-dioxa-5-thia-s-indacene
Add a solution of phosphorous tribromide (1.5 equivalents) in ether (10 mL/g) to a solution of (7-chloro-1,3-dioxa-5-thia-s-indacen-6-yl)-methanol (1.64 g, 6.8 mmol) in ether (20 mL/g) at 0° C. Stir to room temp for an hour. Pour onto ice water, wash with water, saturated sodium bicarbonate, brine, dry, and concentrate to afford the title compound as a white powder (1.96 g, 95%): 1 H NMR (CDCl 3 ) δ 7.17 (s, 1H), 7.13 (s, 1H), 6.05 (s, 2H), 4.72 (d, 2H).
Preparation 7
(3-Methyl-benzo[b]thiophen-2-yl)-methanol
Add a solution of methyl 3-methylbenzo[b]thiophen-2-carboxylate (5.00 g, 24.2 mmol) in THF (25 mL) dropwise to a 1M solution of lithium aluminum hydride in THF (121 mL, 121 mmol) at 0° C. Stir 1 hour. Add an excess of sodium sulfate decahydrate portionwise (slowly at first), stir for 30 minutes at 0° C., then 2 hours at room temperature. Filter, and wash the cake with THF. Concentrate the combined filtrates to afford the drawn product as a white solid (3.60 g, 83%): 1 H NMR (CDCl 3 ) δ 7.81 (m, 1H), 7.68 (m, 1H), 7.35 (m, 2H), 4.92 (d, 2H), 2.40 (s, 3H), 1.77 (t, 1H).
TABLE 1
The following examples are prepared essentially as described in Preparation 5 except
using the reagents in the “Reagents used” column.
Preparation
Structure and name
Reagents used
9
3-chloro-6-fluoro- benzo[b]thiophene-2- carbonyl chloride (2.00 g, 8.03 mmol)
1 H NMR (CDCl 3 ) δ 7.74 (dd, 1 H), 7.50 (dd, 1 H, 7.20 (m, 1 H), 4.96 (d, 2 H), 1.97 (t, 1 H).
11
3-methyl-benzofuran- 2-carbonyl chloride (5.00 g, 25.7 mmol)
1 H NMR (CDCl 3 ) δ 7.49 (m, 1 H), 7.43 (m, 1 H), 7.26 (m, 2 H), 4.76 (d, 2 H), 2.26 (s, 3 H), 1.84 (t, 1 H)
13
3-chloro-6-methoxy- benzo[b]thiophene-2- carbonyl chloride (1.82 g, 6.97 mmol)
1 H NMR (CDCl 3 ) δ 7.67 (d, 1 H), 7.26 (m, 1 H), 7.06 (dd, 1 H), 4.94 (d, 2 H), 3.88 (s, 3 H), 1.91 (t, 1 H)
TABLE 2
The following examples are prepared essentially as described in Preparation 6 except
using the reagents in the “Reagents used” column.
Preparation
Structure and name
Reagents used
8
3-methyl- benzo[b]thiophen-2- yl)-methanol (3.60 g, 20.2 mmol)
1 H NMR (CDCl 3 ) δ 7.77 (m, 1 H), 7.68 (m, 1 H), 7.37 (m, 2 H), 4.77 (s, 2 H), 2.39 (s, 3 H)
10
(3-chloro-6-fluoro- benzo[b]thiophen-2- yl)-methanol (1.65 g, 7.62 mmol)
1 H NMR (CDCl 3 ) δ 7.75 (dd, 1 H), 7.46 (dd, 1 H), 7.21 (m, 1 H), 4.78 (d, 2 H)
12
(3-methyl- benzofuran-2-yl)- methanol (4.02 g, 24.8 mmol)
1 H NMR (CDCl 3 ) δ 7.46 (m, 2 H), 7.31 (m, 1 H), 7.24 (m, 1 H), 4.64 (s, 2 H), 2.25 (s, 3 H)
14
(3-chloro-6-methoxy- benzo[b]thiophen-2- yl)-methanol (1.25 g, 5.47 mmol)
1 H NMR (CDCl 3 ) δ 7.67 (d, 1 H), 7.23 (d, 1 H), 7.06 (dd, 1 H), 4.79 (s, 2 H), 3.88 (s, 3 H)
16
(5-bromo- benzo[b]thiophen-2- yl)-methanol (10.3 g, 42 mmol)
1 H NMR (CDCl 3 ) δ 7.85- 7.87 (m, 1 H), 7.64 (d, J = 8.59 Hz, 1 H), 7.41- 7.45 (m, 1 H), 7.24-7.27 (m, 1 H), 4.76 (s, 2 H)
17
(6-bromo- benzo[b]thiophen-2- yl)-methanol (2.5 g, 10 mmol)
1 H NMR (CDCl 3 ) δ 7.92- 7.94 (m, 1 H), 7.56 (d, J = 8.59 Hz, 1 H), 7.45 (dd, J = 8.59, 1.95 Hz, 1 H), 7.28 (s, 1 H), 4.75 (s, 2 H)
Preparation 15
(5-Bromo-benzo[b]thiophen-2-yl)-methanol
Dissolve 5-bromo-benzo[b]thiophene-2-carboxylic acid (21.2 g, 82.5 mmol) in THF (150 mL). Cool to 0° C. with an ice bath. Add 2M BH3 dimethyl sulfide complex in THF (82.5 mL). Stir to room temperature over 2 hours. Quench by careful addition of water. Partition between ether and saturated NaHCO 3 , wash with water, brine, dry, and concentrate. Purify via column chromatography eluting with 3:1 hexanes:ethyl acetate to afford a white solid (10.3 g): 1 H NMR (CDCl 3 ) δ 7.87 (m, 1H), 7.67 (d, 1H), 7.41 (dd, 1H), 7.15 (m, 1H), 4.94 (d, 2H), 1.91 (t, 1H).
Preparation 18
4-[2-(1-Cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-5-yl]-benzoic acid methyl ester
Using the procedure to synthesize Example 17 and using reagents 3-(5-bromo-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one (250 mg, 0.64 mmol) and 4-methoxycarbonylphenylboronic acid (200 mg, 1 mmol) afford the title compound as a white powder (160 mg, 78%): MS (APCI-pos mode) m/z (rel intensity): 342.2 (M+H, 100%).
Preparation 19
Trans-1-(4-[tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-piperidin-2-one
Trans-(4-hydroxy-cyclohexyl)-carbamic acid benzyl ester Combine trans-cyclohexylamine hydrochloride (14.0 g, 92.3 mmol), sodium carbonate (19.6 g, 0.185 mol), DCM (50 mL), water (50 mL) and stir for 5 minutes at room temperature. Add benzoyl chloroformate (15.6 mL, 111 mmol) dropwise to the reaction mixture and stir at room temperature for 2 hours. Separate the organic layer, wash with water (3×50 mL) and dry over anhydrous Na 2 SO 4 . Evaporate the solvent to obtain the desired intermediate as a white solid (22.7 g, 99%).
Trans-[4-(tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-carbamic acid benzyl ester: Combine trans-(4-hydroxy-cyclohexyl)-carbamic acid benzyl ester (16.0 g, 0.064 mol), imidazole (13.9 g, 0.10 mol), and anhydrous THF (300 mL), add tert-butyldimethylsilyl chloride (14.5 g, 0.10 mol) and stir at room temperature for 18 hours. Wash the reaction mixture with water (250 mL), saturated aqueous NaHCO 3 (250 mL) and dry the organic layer over anhydrous Na 2 SO 4 . Remove the solvent and purify the residue by chromatography over silica gel (eluting with 0 to 30% EtOAc in hexane) to obtain the desired intermediate as clear oil (23.0 g, 98%).
Trans-4-(tert-butyl-dimethyl-silanyloxy)-cyclohexylamine: Combine trans-[4-(tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-carbamic acid benzyl ester (23.0 g, 0.06 mol), palladium, 10% wt. on activated carbon (0.5 g), in EtOAc (100 mL) and charge the flask with hydrogen (50 psi). After 3 hours, filter the reaction mixture through a pad of Celite® and evaporate the solvent to obtain the desired intermediate as a dark oil (14.4 g, 99%): MS (EI) m/z=229 (M+).
Trans-5-chloro-pentanoic acid-[4-tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-amide: Combine 5-chlorovaleric acid (19.7 g, 0.16 mol), thionyl chloride (20 mL) and reflux for 3 hours. Remove unreacted thionyl chloride by evaporation with toluene (3×10 mL) to obtain 5-chloro-pentanoyl chloride as a clear oil (24.1 g, 97%). Combine trans-4-(tert-butyl-dimethyl-silanyloxy)-cyclohexylamine (17.7 g, 0.08 mol), and anhydrous pyridine (10.9 mL, 0.23 mol) in anhydrous DCM (100 mL) and cool to 0° C. Add 5-chloro-pentanoyl chloride (14.2 g, 0.09 mol) dropwise to the reaction mixture and stir at room temperature for 1 hour. Partition the reaction mixture between brine and EtOAc. Dry the organic layer over Na 2 SO 4 , evaporate the solvent and purify the residue by chromatography over silica gel (eluting with 0 to 30% EtOAc in hexane) to obtain the desired intermediate as a colorless oil (22.7 g, 85%): MS (ES+) m/z=349 (M+H) + .
Trans-1-(4-[tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-piperidin-2-one: Dissolve trans-5-chloro-pentanoic acid-[4-(tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-amide (22.7 g, 65.1 mmol) in anhydrous THF (500 mL), add sodium hydride (60% dispersion in mineral oil, 13.0 g, 0.32 mol) by portions and heat the reaction mixture at 70° C. for 18 hours. Cool the reaction mixture to room temperature, quench with water (200 mL) and extract with DCM (3×100 mL). Dry the organic layer over anhydrous Na 2 SO 4 , remove the solvent and purify the residue by chromatography over silica gel (eluting with 0 to 50% EtOAc in hexane) to obtain the title compound as a white solid (15.0 g, 74%): MS (ES+) m/z=312 (M+H) + .
Preparation 20
Cis-1-[4-(tert-butyl-dimethyl-silaniloxy)-cyclohexyl]-piperidin-2-one
Trans-1-(4-hydroxy-cyclohexyl)-piperidin-2-one: Dissolve trans-1-(4-[tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-piperidin-2-one (10 g, 21.1 mmol) in ethanol containing concentrated hydrochloric acid (5% v/v, 30 mL) and stir at room temperature for 18 hours. Evaporate the solvent, take the residue up in DCM (300 mL) and wash with saturated aqueous NaHCO 3 (100 mL). Dry the organic layer over anhydrous Na 2 SO 4 and remove the solvent to obtain the desired intermediate as a clear oil (4.0 g, 95%): MS (ES+) m/z=198 (M+H) + .
Cis-4-nitro-benzoic acid-4-(2-oxo-piperidin-1-yl)-cyclohexyl-ester: Dissolve trans-1-(4-hydroxy-cyclohexyl)-piperidine-2-one (4.0 g, 20.0 mol) in THF (250 mL), cool to −5° C. and add triphenyl phosphine (12.0 g, 0.05 mol) and benzoic acid (8.4 g, 0.05 mol). Add diisopropylazodicarboxylate (10.1 g, 0.05 mol) dropwise to the reaction mixture, warm to room temperature and stir for 18 hours. Quench the reaction mixture with saturated aqueous NaHCO 3 and extract with DCM (3×100 mL). Dry the organic layer over anhydrous Na 2 SO 4 , remove the solvent and purify the residue by chromatography over silica gel eluting with EtOAc to obtain the desired intermediate (5.0 g, 72%): MS (ES+) m/z=347 (M+H) + .
Cis-1-[4-(tert-butyl-dimethyl-silaniloxy)-cyclohexyl]-piperidin-2-one: Dissolve cis-4-nitro-benzoic acid-4-(2-oxo-piperidin-1-yl)-cyclohexyl-ester (5.0 g, 14.4 mmol) in methanol (150 mL), add water (20 mL), K 2 CO 3 (8.7 g, 0.06 mol) and stir the reaction mixture at room temperature for 18 hours. Extract the reaction mixture with DCM (2×100 mL), dry the organic layer over Na 2 SO 4 and remove the solvent to obtain cis-1-(4-hydroxy-cyclohexyl)-piperidin-2-one as clear oil (6.0 g). Combine cis-1-(4-hydroxy-cyclohexyl)-piperidin-2-one (6.0 g, 0.03 mol), imidazole (3.1 g, 0.05 mol), tert-butyl chloro dimethyl silane (6.9 g, 0.05 mol) and stir at room temperature for 18 hours. Wash the reaction mixture with water (150 mL) and dry the organic layer over Na 2 SO 4 . Remove the solvent and purify the residue by chromatography over silica gel (eluting with 0 to 50% EtOAc in hexane) to obtain the title compound as a clear oil (3.4 g, 76%): MS (ES+) m/z=312 (M+H) + .
Preparation 21
trans-1-{4-(tert-Butyl-dimethyl-silanyloxy)-cyclohexy}3-(3-chloro-benzo[b]thiophen-2-ylmethyl)-piperidin-2-one
Place trans-1-[4-(tert-Butyl-dimethyl-silanyloxy)-cyclohexyl]-piperidin-2-one, (300 mg, 0.96 mmol) in 7.0 mL of THF, cool to −78° C. and treat with 2.0 M LDA (0.72 mL, 1.5 mmol). Stir for 5.0 minutes, treat with 2-bromomethyl-3-chloro-benzo[b]thiophene (375 mg, 1.5 mmol) and stir overnight at room temperature. Quench reaction with ammonium chloride, extract with dichloromethane, dry over sodium sulfate and purify via silica chromatography (ethyl acetate/hexanes 0-25%) affords 310 mg (65
Preparation 22
cis-1-{4-(tert-Butyl-dimethyl-silanyloxy)-cyclohexy}3-(3-chloro-benzo[b]thiophen-2-ylmethyl)-piperidin-2-one
Place cis-1-[4-(tert-Butyl-dimethyl-silanyloxy)-cyclohexyl]-piperidin-2-one, (300 mg, 0.96 mmol) in 7.0 mL of THF, cool to −78° C. and treat with 2.0 M LDA (0.72 mL, 1.5 mmol). Stir for 5.0 minutes, treat with 2-bromomethyl-3-chloro-benzo[b]thiophene (250 mg, 0.96 mmol) and stir at −78° C. for five hours, and warm to room temperature. Quench reaction with ammonium chloride, extract with dichloromethane, dry over sodium sulfate and purify via silica chromatography (ethyl acetate/hexanes 0-25%) affords 166 mg (35%).
Example 1
3-Benzo[b]thiophen-2-ylmethyl-1-cyclohexyl-pyrrolidin-2-one
Place 1-cyclohexyl-pyrrolidin-2-one (500 mg) in THF (30 mL) and cool to −78° C. Slowly add lithium diisopropylamide (LDA) (2M, 1.5 eq) and stir for 15 minutes. Add 2-bromomethyl-benzo[b]thiophene [ J. Med. Chem . (1992) 1176-1183] (815 mg, 3.59 mmol) and stir for 3 hours. Quench with ammonium chloride and extract with dichloromethane. Dry over sodium sulfate, filter, and concentrate. Purify by silica gel (20-50% ethyl acetate in hexanes) to give 670 mg, 71% of the title compound as a white powder. MS (APCI-pos mode) m/z (rel intensity) 314 (100).
TABLE 3
The following examples are prepared essentially as described in Example 1 except using
the reagents in the “Reagents used” column.
Example
Structure and name
Reagents used
Mass spec
2
1-cyclohexyl pyrrolidinone (959 mg, 5.73 mmol) and 2-bromomethyl-3- chloro- benzo[b]thiophene (US 4,939,140) (1.00 g, 3.82 mmol)
(APCI-pos mode) m/z (rel intensity) 348 (100), 350 (40)
3
1-cyclohexyl pyrrolidinone (357 mg, 2.13 mmol) and 2-bromomethyl- benzofuran [J. Med. Chem. (1987) 400- 405] (300 mg, 1.42 mmol)
(apci) m/z = 298.2 (M + H)
4
1-cyclohexyl pyrrolidinone (0.360 g, 2.15 mmol) and 6- bromomethyl-7- chloro-1,3-dioxa-5- thia-s-indacene (0.439 g, 1.44 mmol)
(APCI-pos mode) m/z (rel intensity) 392.2 (100), 394.1 (40)
5
1-cyclohexyl pyrrolidinone (620 mg, 3.70 mmol) and 2-bromomethyl-3- methyl- benzo[b]thiophene (600 mg, 2.47 mmol)
(apci) m/z = 328.2 (M + H)
6
1-cyclohexyl pyrrolidinone (0.396 mg, 2.37 mmol) and 2-bromomethyl-3- chloro-6-fluoro- benzo[b]thiophene (0.389, 1.39 mol)
(APCI-pos mode) m/z (rel intensity) 366.2 (100), 368.2 (40)
7
1-cyclohexyl pyrrolidinone (400 mg, 2.39 mmol) and 5-bromo-3- chloromethyl- benzo[b]thiophene (938 mg, 3.59 mmol)
(apci) m/z = 348.2 (M + H)
8
1-cyclohexyl pyrrolidinone (1.118 g, 6.69 mmol) and 2- bromomethyl-3- chloro-6-methoxy- benzo[b]thiophene (1.30 g, 4.46 mmol)
(apci) m/z = 378.2 (M + H)
9
1-cyclohexyl pyrrolidinone (6.8 g, 40 mmol) and 5- bromo-2- bromomethyl- benzo[b]thiophene (6.0 g, 20 mmol)
(APCI-pos mode) m/z (rel intensity): 392.1 (M + H, 100%)
10
1-cyclohexyl pyrrolidinone (0.7 g, 4 mmol) and 6- bromo-2- bromomethyl- benzo[b]thiophene (0.5 g, 2 mmol)
(APCI-pos mode) m/z (rel intensity): 392.1 (M + H, 100%)
Example 11
3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-1-(cis-4-hydroxy-cyclohexyl)-pyrrolidin-2-one
Charge a flask with cis-1-[4-(tert-butyl-dimethyl-silanyloxy)-cyclohexyl]-pyrrolidin-2-one (0.50 g, 1.68 mmol) (1.0 eq), dissolve with THF (0.2 M) and cool to −78° C. Add LDA (1.1 to 1.5 eq) and stir at −78° C. for 5 minutes. Add 2-bromomethyl-3-chloro-benzo[b]thiophene (U.S. Pat. No. 4,939,140) (0.53 g, 2.02 mmol) and warm to room temperature overnight. Dilute with methanol (0.2 M) and add concentrated HCl (10 eq.) and stir at room temperature. Pour into water after reaction complete by HPLC and extract with methylene chloride, dry over sodium sulfate, filter and concentrate in vacuo. Purification of the residue over silica gel (20% hexane in ethyl acetate) affords the title compound as a white powder (0.44 g, 71%): MS (APCI-pos mode) m/z (rel intensity) 364.1 (100), 366.1 (40).
Example 12
1-(4-Hydroxy-cyclohexyl)-3-(3-methyl-benzofuran-2-ylmethyl)-pyrrolidin-2-one
Using the procedure to synthesize Example 3 and using reagents 1-[4-(tert-butyldimethyl-silanyloxy)-cyclohexyl]-pyrrolidin-2-one (500 mg, 1.68 mmol) and 2-bromomethyl-3-methyl-benzofuran (567 g, 2.52 mmol) afford the title compound as a tan powder (295 mg, 54%): Mass spectrum (apci) m/z=328.1 (M+H).
Example 13
3-(3-Chloro-6-hydroxy-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one
Dissolve 3-(3-chloro-6-methoxy-benzo[b]thiophen-2-ylmethyl)-1-cyclohexylpyrrolidin-2-one (1.122 g, 2.97 mmol) and 2-methyl-2 propene (0.5 mL) in dichloromethane (30 mL) and cool to 0° C. Slowly add boron tribromide (2.23 g, 8.91 mmol) and warm to room temperature. Stir for 1 hour and quench with ice. Extract with dichloromethane, dry with sodium sulfate, filter, and concentrate to give the title compound (1.121 g, 99%) as a light brown solid: Mass spectrum (apci) m/z=364.2 (M+H).
Example 14
4-[3-Chloro-2-(1-cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-6-yloxymethyl]-benzoic acid
Charge a vial with 3-(3-chloro-6-hydroxy-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one (175 mg, 0.481 mmol) and dissolve in acetone (0.3 M). Add NaI (72 mg, 0.481 mmol) and Cs 2 CO 3 (1.25 g, 3.85 mmol) and stir at room temperature for 5 minutes. Add 4-bromomethyl-benzoic acid methyl ester (220 mg, 0.96 mmol) and heat to 50° C. overnight. Cool to room temperature, filter, concentrate, and purify over silica gel to afford 4-[3-chloro-2-(1-cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-6-yloxymethyl]-benzoic acid methyl ester. Dissolve in ethanol (5 mL) and water (1 mL) and add potassium hydroxide (162 mg, 2.88 mmol) and heat to 50° C. overnight. Cool to room temperature filter and dry to afford the title compound (146 mg, 61%) as a white solid: Mass spectrum (apci) m/z=498.2 (M+H).
Example 15
3-[3-Chloro-6-(3-dimethylamino-propoxy)-benzo[b]thiophen-2-ylmethyl]-1-cyclohexyl-pyrrolidin-2-one hydrochloride salt
Using the procedure to synthesize Example 12 and using reagents 3-(3-chloro-6-hydroxy-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one (150 mg, 0.412 mmol), (3-bromo-propyl)-dimethyl-amine hydrochloride (167 mg, 0.824 mmol), sodium iodide (62 mg, 0.412 mmol), and cesium carbonate (1.07 g, 3.30 mmol) afford the freebase of the title compound. Dissolve freebase in dichloromethane (5 mL) and add HCl in ether (2M, 0.4 mL), concentrate to give title compound (105 mg, 52%) as a yellow solid: Mass spectrum (apci) m/z=449.3 (M+H).
Example 16
4-[3-Chloro-2-(1-cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-6-yloxy]-butyric acid
Using the procedure to synthesize Example 12 and using reagents 3-(3-chloro-6-hydroxy-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one (175 mg, 0.481 mmol), 4-bromo-butyric acid tert-butyl ester (215 mg, 0.962 mmol), sodium iodide (72 mg, 0.481 mmol), and cesium carbonate (1.25 g, 3.85 mmol) afford crude 4-[3-chloro-2-(1-cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-6-yloxy]-butyric acid tert-butyl ester. Dissolve ester in trifluoroacetic acid (25 mL) and stir for 1.5 hr. Evaporate and dissolve in 1M NaOH and wash with ether. Bring aqueous layer to a pH of ˜2 with 6M HCl, filter, and dry. Purified on silica gel (30-50% ethyl acetate in hexanes) to give the title compound (105 mg, 49%) as a tan solid: Mass spectrum (apci) m/z=450.1 (M+H).
Example 17
1-Cyclohexyl-3-[5-(2-fluoro-pyridin-4-yl)-benzo[b]thiophen-2-ylmethyl]-pyrrolidin-2-one
Add 3-(5-bromo-benzo[b]thiophen-2-ylmethyl)-1-cyclohexyl-pyrrolidin-2-one (250 mg, 0.64 mmol), 2-fluoropyridine-4-boronic acid (200 mg, 1 mmol), LiCl (10 eq) and Pd(PPh 3 ) 4 (0.05 eq) into a solution of dioxane (10 mL) and 2M Na 2 CO 3 (2 mL) and heat at 80° C. for 1 hour. Pour the reaction mixture into water and extract with ethyl acetate. Dry over sodium sulfate, filter, and concentrate. Purify by silica gel (20-50% ethyl acetate in hexanes) to give the title compound as a pale yellow powder (260 mg, 58%): MS (APCI-pos mode) m/z (rel intensity): 409.2 (M+H, 100%).
Example 18
4-[2-(1-Cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-5-yl]-benzoic acid
Heat a mixture of 4-[2-(1-cyclohexyl-2-oxo-pyrrolidin-3-ylmethyl)-benzo[b]thiophen-5-yl]-benzoic acid methyl ester (250 mg, 0.64 mmol), LiOH.H 2 O (10 eq) into a dioxane (5 mL) and water (2 mL) at 80° C. for 1 hour. Add 2 M HCl (1 mL) and extract the mixture with ethyl acetate. Dry over sodium sulfate, filter, and concentrate. Purify by silica gel (20-50% ethyl acetate in hexanes) to give the title compound as a white powder (110 mg, 65%): MS (APCI-pos mode) m/z (rel intensity): 434.1 (M+H, 100%).
Example 19
3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-trans-1-(4-hyroxyl-cyclohexyl)-piperidin-2-one
Place trans-1-{4-(tert-Butyl-dimethyl-silanyloxy)-cyclohexy}3-(3-chloro-benzo[b]thiophen-2-ylmethyl)-piperidin-2-one, obtained below, (310 mg, 0.63 mmol) in 5% HCl/EtOH (10 ml), and stir 2 h at room temperature. Evaporate, dissolve residue in methylene chloride, wash with sodium bicarbonate, and dry over sodium sulfate. Evaporate and silica gel chromatography (Ethyl acetate-hexanes 0-100%) affords 194 mg (81%) of the title compound: Mass spectrum (apci) m/z=377 (M+H).
Example 20
3-(3-Chloro-benzo[b]thiophen-2-ylmethyl)-cis-1-(4-hyroxyl-cyclohexyl)-piperidin-2-one
Place cis-1-{4-(tert-Butyl-dimethyl-silanyloxy)-cyclohexy}3-(3-chloro-benzo[b]thiophen-2-ylmethyl)-piperidin-2-one, obtained below, (166 mg, 0.33 mmol) in 5% HCl/EtOH (10 ml), and stir 2 h at room temperature. Evaporate, dissolve residue in methylene chloride, wash with sodium bicarbonate, and dry over sodium sulfate. Evaporate and silica gel chromatography (Ethyl acetate-hexanes 0-100%) affords 21 mg (19%) of the title compound: Mass spectrum (apci) m/z=377 (M+H).
Pharmacological Methods
In the following section binding assays as well as functional assays useful for evaluating the efficiency of the compounds of the invention are described.
11β-HSD Type 1 Enzyme Assay
Human 11β-HSD type 1 activity is measured by assaying NADPH production by fluorescence assay. Solid compounds are dissolved in DMSO to a concentration of 10 mM. Twenty microliters of each are then transferred to a column of a 96-well polypropylene Nunc plate where they are further diluted 50-fold followed by subsequent two-fold titration, ten times across the plate with additional DMSO using a Tecan Genesis 200 automated system. Plates are then transferred to a Tecan Freedom 200 system with an attached Tecan Temo 96-well head and an Ultra 384 plate reader. Reagents are supplied in 96-well polypropylene Nunc plates and are dispensed individually into black 96-well Molecular Devices High Efficiency assay plates (40 μL/well capacity) in the following fashion: 9 μL/well of substrate (2.22 mM NADP, 55.5 μM Cortisol, 10 mM Tris, 0.25% Prionex, 0.1% Triton X100), 3 μL/well of water to compound wells or 3 μL to control and standard wells, 6 μL/well recombinant human 11β-HSD type 1 enzyme, 2 μL/well of compound dilutions. For ultimate calculation of percent inhibition, a series of wells are added that represent assay minimum and maximum: one set containing substrate with 667 μM carbenoxolone (background), and another set containing substrate and enzyme without compound (maximum signal). Final DMSO concentration is 0.5% for all compounds, controls and standards. Plates are then placed on a shaker by the robotic arm of the Tecan for 15 seconds before being covered and stacked for a three hour incubation period at room temperature. Upon completion of this incubation, the Tecan robotic arm removes each plate individually from the stacker and places them in position for addition of 5 μL/well of a 250 μM carbenoxolone solution to stop the enzymatic reaction. Plates are then shaken once more for 15 seconds then placed into an Ultra 384 microplate reader (355EX/460EM) for detection of NADPH fluorescence.
Acute In Vivo Cortisone Conversion Assay
In general, compounds are dosed orally into mice, the mice are challenged with a subcutaneous injection of cortisone at a set timepoint after compound injection, and the blood of each animal is collected some time later. Separated serum is then isolated and analyzed for levels of cortisone and cortisol by LC-MS/MS, followed by calculation of mean cortisol and percent inhibition of each dosing group. Specifically, male C57BL/6 mice are obtained from Harlan Sprague Dawley at average weight of 25 grams. Exact weights are taken upon arrival and the mice randomized into groups of similar weights. Compounds are prepared in 1% w-w HEC, 0.25% w-w polysorbate 80, 0.05% w-w Dow Corning antifoam #1510-US at various doses based on assumed average weight of 25 grams. Compounds are dosed orally, 200 μl per animal, followed by a subcutaneous dose, 200 μlper animal, of 30 mg/kg cortisone at 1 to 24 hours post compound dose. At 10 minutes post cortisone challenge, each animal is euthanized for 1 minute in a CO 2 chamber, followed by blood collection via cardiac puncture into serum separator tubes. Once fully clotted, tubes are spun at 2500×g, 4° C. for 15 minutes, the serum is transferred to wells of 96-well plates (Corning Inc, Costar #4410, cluster tubes, 1.2 ml, polypropylene), and the plates frozen at −20° C. until analysis by LC-MS/MS. For analysis, serum samples are thawed and the proteins are precipitated by the addition of acetonitrile containing d 4 -cortisol internal standard. Samples are vortex mixed and centrifuged. The supernatant is removed and dried under a stream of warm nitrogen. Extracts are reconstituted in methanol/water (1:1) and injected onto the LC-MS/MS system. The levels of cortisone and cortisol are assayed by selective reaction monitoring mode following positive ACPI ionization on a triple quadrupole mass spectrophotometer.
All of the examples provided herein have activity in the 11β-HSD type 1 enzyme assay with IC 50 of less than 20 μM. The assay results are given below for the indicated compound in the 11β-HSD type 1 enzyme assay.
11β-HSD
type 1
enzyme
assay
Example
IC 50 (nM)
190
682
162
508
257
427
276
A compound of formula (I) can be formulated with common excipients, diluents, or carriers, and formed into tablets, capsules, and the like. Examples of excipients, diluents, and carriers that are suitable for formulation include the following: fillers and extenders such as starch, sugars, mannitol, and silicic derivatives; binding agents such as carboxymethyl cellulose and other cellulose derivatives, alginates, gelatin, and polyvinyl pyrrolidone; moisturizing agents such as glycerol; disintegrating agents such as agar, calcium carbonate, and sodium bicarbonate; agents for retarding dissolution such as paraffin; resorption accelerators such as quaternary ammonium compounds; surface active agents such as cetyl alcohol, glycerol monostearate; adsorptive carriers such as kaolin and bentonite; and lubricants such as talc, calcium and magnesium stearate and solid polyethyl glycols. Final pharmaceutical forms may be: pills, tablets, powders, lozenges, syrups, aerosols, saches, cachets, elixirs, suspensions, emulsions, ointments, suppositories, sterile injectable solutions, or sterile packaged powders, depending on the type of excipient used.
Additionally, a compound of formula (I) or a pharmaceutically acceptable salt thereof, is suited to formulation as sustained release dosage forms. The formulations can also be so constituted that they release the active ingredient only or preferably in a particular part of the intestinal tract, possibly over a period of time. Such formulations would involve coatings, envelopes, or protective matrices that may be made from polymeric substances or waxes.
The particular dosage of a compound of formula (I) or a pharmaceutically acceptable salt thereof required to constitute an effective amount according to this invention will depend upon the particular circumstances of the conditions to be treated. Considerations such as dosage, route of administration, and frequency of dosing are best decided by the attending physician. Generally, accepted and effective dose ranges for oral or parenteral administration will be from about 0.1 mg/kg/day to about 10 mg/kg/day which translates into about 6 mg to 600 mg, and more typically between 30 mg and 200 mg for human patients. Such dosages will be administered to a patient in need of treatment from one to three times each day or as often as needed to effectively treat a disease selected from (1) to (20) above.
The compounds of the present invention can be administered alone or in the form of a pharmaceutical composition, that is, combined with pharmaceutically acceptable carriers, or excipients, the proportion and nature of which are determined by the solubility and chemical properties of the compound selected, the chosen route of administration, and standard pharmaceutical practice. The compounds of the present invention, while effective themselves, may be formulated and administered in the form of their pharmaceutically acceptable salts, for purposes of stability, convenience of crystallization, increased solubility, and the like.
The compounds claimed herein can be administered by a variety of routes. In effecting treatment of a patient afflicted with or at risk of developing the disorders described herein, a compound of formula (I) or a pharmaceutically acceptable salt thereof can be administered in any form or mode that makes the compound bioavailable in an effective amount, including oral and parenteral routes. For example, the active compounds can be administered rectally, orally, by inhalation, or by the subcutaneous, intramuscular, intravenous, transdermal, intranasal, rectal, occular, topical, sublingual, buccal, or other routes. Oral administration may be preferred for treatment of the disorders described herein. However, oral administration is the preferred route. Other routes include the intravenous route as a matter of convenience or to avoid potential complications related to oral administration.
One skilled in the art of preparing formulations can readily select the proper form and mode of administration depending upon the particular characteristics of the compound selected, the disorder or condition to be treated, the stage of the disorder or condition, and other relevant circumstances. (Remington's Pharmaceutical Sciences, 18th Edition, Mack Publishing Co. (1990)).
The pharmaceutical compositions are prepared in a manner well known in the pharmaceutical art. The carrier or excipient may be a solid, semi-solid, or liquid material that can serve as a vehicle or medium for the active ingredient. Suitable carriers or excipients are well known in the art. The pharmaceutical composition may be adapted for oral, inhalation, parenteral, or topical use and may be administered to the patient in the form of tablets, capsules, aerosols, inhalants, suppositories, solutions, suspensions, or the like.
For the purpose of oral therapeutic administration, the compounds may be incorporated with excipients and used in the form of tablets, troches, capsules, elixirs, suspensions, syrups, wafers, chewing gums and the like. These preparations should contain at least 4% of the active ingredients, but may be varied depending upon the particular form and may conveniently be between 4% to about 70% of the weight of the unit. The amount of the compound present in compositions is such that a suitable dosage will be obtained. Preferred compositions and preparations according to the present invention may be determined by a person skilled in the art.
The tablets, pills, capsules, troches, and the like may also contain one or more of the following adjuvants: binders such as povidone, hydroxypropyl cellulose, microcrystalline cellulose, gum tragacanth or gelatin; excipients such as dicalcium phosphate, starch, or lactose; disintegrating agents such as alginic acid, Primogel, corn starch and the like; lubricants such as talc, hydrogenated vegetable oil, magnesium stearate or Sterotex; glidants such as colloidal silicon dioxide; and sweetening agents, such as sucrose, aspartame, or saccharin, or a flavoring agent, such as peppermint, methyl salicylate or orange flavoring, may be added. When the dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier such as polyethylene glycol or a fatty oil. Other dosage unit forms may contain other various materials that modify the physical form of the dosage unit, for example, coatings. Thus, tablets or pills may be coated with sugar, shellac, or other coating agents. Syrups may contain, in addition to the present compounds, sucrose as a sweetening agent and certain preservatives, dyes and colorings and flavors. Materials used in preparing these various compositions should be pharmaceutically pure and non-toxic in the amounts used. In those instances where oral administration is impossible or not preferred, the composition may be made available in a form suitable for parenteral administration, e.g., intravenous, intraperitoneal or intramuscular. | The present invention provides compounds of formula I that are useful as potent and selective inhibitors of 11-beta hydroxysteroid dehydrogenase 1. The present invention further provides a pharmaceutical composition which comprises a compound of Formula I, or a pharmaceutical salt thereof, and a pharmaceutically acceptable carrier, diluent, or excipient. In addition, the present invention provides compositions comprising compounds of formula I for the treatment of metabolic syndrome, diabetes, hyperglycemia, obesity, hypertension, hyperlipidemia, other symptoms associated with hyperglycemia, and related disorders. Formula (I) wherein, R 0 is (II), or (III) G 1 is methylene or ethylene; L is a divalent linking group selected from —(C 1 -C 4 ) alkylene-, —S—, —CH(OH)—, or —O—; A is methylene, —S—, —O—, or —NH—; and the other substituents are as defined in the claims. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a knitting-machine needle comprising a hook portion, a shank portion, and a butt portion, the shank portion having a straight, tapering front section contiguous with the hook portion and a rear section of uniform width contiguous with the butt portion.
Knitting-machine needles of this kind are used particularly in circular knitting machines intended for manufacturing stockings, for example, and working continuously. The needles are mounted in grooves of a needle bed, and control means impart to them a programmed forward-and-backward movement, each needle being moved in turn during the rotation of the carriage.
Needles of this kind must meet contradictory requirements in the sense that, while their dimensions should be as fine as possible, they must nevertheless possess good resistance to the considerable stresses to which they are subjected. Moreover, the main dimensions of the needles, especially their overall length, their thickness, and the distance by which the shank projects from the needle bed in its forwardmost position, are governed by the structure of the knitted fabric and are, consequently, obligatory.
Thus the contradictory requirements mentioned above, plus the fact that efforts are constantly being made to increase the speed at which the machines operate, oblige the manufacturers of needles to seek new designs which enable users of these highspeed machines to get the most out of them. In order to make the needle lighter, especially the rearward portion of it, while still ensuring satisfactory guidance of the butt in the groove in which the needle is engaged, the tendency has been to reduce the width of the butt to a certain extent and to provide needles having a trapezoidal zone at the base of the butt. However, this improvement has not remedied one drawback which appears in the machines operating at the highest speeds to be found at the present time. This drawback is the vibration of the hook after the forward thrust of the needle and after its rapid return backwards, which vibration causes breakage of the hook after some time.
SUMMARY OF THE INVENTION
It is the object of this invention to remedy that drawback by providing a needle design which meets the required conditions, especially as concerns the length of the shank and the width of its rear portion.
To this end, in the needle according to the present invention, at least part of the rear section of the shank portion curves along an undulating line.
BRIEF DESCRIPTION OF THE DRAWING
Two possible embodiments of the invention will now be described in detail with reference to the accompanying drawing, in which:
FIG. 1 is a plan view of a first embodiment of the needle, and
FIG. 2 is a perspective view of the rear portion of the needle in a second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a hook 1 equipped with a latch 2 pivoting at the rearward end of the hook 1 about an axis 3, and a shank 4 having a front section 4a which gradually increases in width towards the rear and a rear section 4b of uniform width W. Also shown are a butt 5 comprising a rectangular upright 5a and a base 5b limited by a first edge perpendicular to the upright 5a and a second edge which runs first at a slant from the base of the upright 5a and then parallel to the longitudinal axis of the needle. The butt 5 has a shallow notch 5c at the base of the upright 5a and a deeper notch 5d at the forward end of the base 5b in the projection of the edge which is perpendicular to the upright 5a. In a reduction of the invention to practice, the needle has an overall length of about 71 mm, and the part of the shank which is intended to extend beyond the needle bed when in advanced position measures 50 mm. starting from the end of the hook. Since the total length of the butt is on the order of 10 mm. in order to ensure the rigidity and guidance of the needle, it will be seen that there remains a distance of about 11 mm. between the front end of the butt and the borderline of the part which is to extend beyond the needle bed.
As may be seen in FIG. 1, this rearmost portion of the shank 4 curves along an undulating line, forming two undulations 4c and 4d. The contour of the undulations 4c and 4d is formed by arcs joining one another tangentially at the median axis of the undulations. The radius of the arcs generated by rotating the center line of the shank 4 is approximately equal to the width of the rear section 4b of the shank 4. Thus, for example, in a practical model where the rear section of the shank measures 1.4 mm. in width, the radius of the inner edge of the undulation 4c is 0.6 mm., while the radius of its outer edge is 2 mm. Hence the two undulations occupy the 11-mm.-long space between the end of the butt and the straight portion of the shank, and the length of the undulating portion is approximately equal to one-fifth the length of the part intended to extend beyond the needle bed.
In FIG. 2, a butt 15 is of approximately the same size and shape as the butt 5 of FIG. 1, and the rearmost portion of a shank 14 contiguous with the butt 15 likewise has an undulating form for a length of about 11 mm. In this undulating zone, the width of the shank 14 is the same as in the straight portion of its rear section 14b, but the arcs which determine the shape of the undulating zone are larger than in the first embodiment, so that the undulating zone comprises only one undulation, 14c.
In both embodiments, the needle has a thickness of a few tenths of a millimeter throughout its length. It may be produced by two different methods.
According to the first method, the starting material is a piece of steel wire of a predetermined diameter. The portion of this piece of wire which is intended to form the shank as a whole is subjected to a drawing operation which greatly reduces its diameter. The rearmost portion of the shank is then bent to form the undulations described above. The rear portion of the butt may also be bent, after which the entire body of the needle is pressed until the aforementioned thickness is achieved. Lastly, the butt is given its final shape by a blanking operation.
According to the second method, the starting material is once more a piece of wire as in the first method, but only the part intended to form the straight portion of the shank is drawn. The second operation is then that of flattening in the press; and during the blanking operation, not only the butt but also the rearmost portion of the shank with the undulations is blanked.
The trials carried out with needles according to FIGS. 1 and 2 have shown that the breakages of the hook which occurred with needles of the same dimensions, but not provided with the undulations 4c and 4d or 14c, when they were used on very highspeed machines, no longer occurred with the needles described above. This unexpected result has made is possible to effect an appreciable increase in the speed of the machines in service and, consequently, to increase their output.
The effect produced by the undulations likewise derives from improved guidance of the needle, and it will be seen that this is obtained without weighing down the butt. The needle may be made of ordinary steel of the same type as is currently used for the known needles, so that the cost-price of the needle remains substantially unchanged.
Thus the arrangement described makes it possible to provide circular knitting machines rotating even more rapidly than has hitherto been possible and consequently having a greater output. | A knitting machine needle is divided into a hook portion, a shank portion, and a butt portion. The shank portion has a front section of constant width and a rear section that has at least one undulation, also of constant width. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to compounds having pharmacological activity towards the 5-HT7 receptor, and more particularly to some tetrahydroisoquinoline substituted sulfonamide compounds, to processes of preparation of such compounds, to pharmaceutical compositions comprising them, and to their use in therapy, in particular for the treatment and or prophylaxis of a disease in which 5-HT 7 is involved, such as CNS disorders.
BACKGROUND OF THE INVENTION
[0002] The search for new therapeutic agents has been greatly aided in recent years by better understanding of the structure of proteins and other biomolecules associated with target diseases. One important class of proteins that has been the subject of extensive study is the family of 5-hydroxytryptamine (serotonin, 5-HT) receptors. The 5-HT 7 receptor discovered in 1993 belongs to this family and has attracted great interest as a valuable new drug target (Terrón, J. A. Idrugs, 1998, vol. 1, no. 3, pages 302-310 : “The 5 HT 7 receptor: A target for novel therapeutic avenues? ”).
[0003] 5-HT 7 receptors have been cloned from rat, mouse, guinea pig and human cDNA and exhibit a high degree of interspecies homology (approx. 95%), but it is unique in that it has a low sequence homology with other 5-HT receptors (less than 40%). Its expression pattern, in particular structures of the central nervous system (CNS) (highest in hypothalamus (in particular suprachiasmatic nuclei) and thalamus) and other peripheral tissues (spleen, kidney, intestinal, heart and coronary arthery), implicates the 5-HT 7 receptor in a variety of functions and pathologies. This idea is reinforced by the fact that several therapeutic agents, such as tricyclic antidepressants, typical and atypical antipsychotics and some 5-HT 2 receptor antagonists, display moderate to high affinity for both recombinant and functional 5-HT 7 receptors.
[0004] Functionally, the 5-HT 7 receptor has been implicated in regulation of circadian rhythms in mammals (Lovenberg, T. W. et al. Neuron, 1993, 11:449-458 “A novel adenylyl cyclase - activating serotonin receptor (5- HT 7 ) implicated in the regulation of circadian rhythms” ). It is known that disruption of circadian rhythms is related to a number of CNS disorders including depression, seasonal affective disorder, sleep disorders, shift worker syndrome and jet lag among others.
[0005] Distribution and early pharmacological data also suggest that the 5-HT 7 receptor is involved in the vasodilatation of blood vessels. This has been demonstrated in vivo (Terrón, J. A., Br J Pharmacol, 1997, 121:563-571 “Role of 5- HT 7 receptors in the long lasting hypotensive response induced by 5- hydroxytryptamine in the rat ”). Thus selective 5-HT 7 receptor agonists have a potential as novel hypertensive agents.
[0006] The 5-HT 7 receptor has also been related with the pathophysiology of migraine through smooth muscle relaxation of cerebral vessels (Schoeffter, P. et al., 1996 , Br J Pharmacol, 117:993-994; Terrón, J. A., 2002 , Eur. J. Pharmacol., 439:1-11 “Is the 5- HT 7 receptor involved in the pathogenesis and prophylactic treatment of migraine? ”). In a similar manner, involvement of 5-HT 7 in intestinal and colon tissue smooth muscle relaxation makes this receptor a target for the treatment of irritable bowel syndrome (De Ponti, F. et al., 2001 , Drugs, 61:317-332 “Irritable bowel syndrome. New agents targeting serotonin receptor subtypes ”). Recently, it has also been related to urinary incontinence ( British J of Pharmacology , September 2003, 140(1) 53-60: “Evidence for the involvement of central 5HT-7 receptors in the micurition reflex in anaeshetized female rats”).
[0007] In view of the potential therapeutic applications of agonists or antagonists of the 5HT 7 receptor, a great effort has been directed to find selective ligands. Despite intense research efforts in this area, very few compounds with selective 5-HT 7 antagonist activity have been reported (Wesolowska, A., Polish J. Pharmacol., 2002, 54: 327-341 , “In the search for selective ligands of 5- HT 5 , 5- HT 6 and 5- HT 7 serotonin receptors ”).
[0008] WO 97/48681 discloses sulfonamide derivatives, which are 5-HT 7 receptor antagonists, for the treatment of CNS disorders. The sulphur atom is linked to an aromatic group and to a N-containing heterocyclic group, optionally containing a further heteroatom selected from oxygen or sulphur.
[0009] WO 97/29097 describes sulfonamide derivatives for the treatment of disorders in which antagonism of the 5-HT 7 receptor is beneficial. The sulphur atom is linked to an aromatic group and to a C 1 -C 6 alkyl substituted N atom.
[0010] WO97/49695 describes further sulfonamide derivatives in which the N linked to the sulphur atom is also fully substituted, for example forming part of a piperidine.
[0011] WO 03/048118 describes another group of 5HT 7 receptor antagonists. In this case aryl and heteroaryl sulfonamide derivatives wherein the sulfonamide group is a substituent on a cycloalkane or cycloalkene ring which additionally bears an amino susbtituent. The N linked to sulphur atom is fully substituted.
[0012] WO99/24022 discloses tetrahydroisoquinoline derivatives for use against CNS disorders and binding to serotonin receptors, in particular 5-HT 7 .
[0013] WO 00/00472 refers to compounds which are 5-HT7 receptor antagonists. The compounds contain a N-containing fused heterocycle such as tetrahydroisoquinoline.
[0014] EP 21580 and EP 76072 describe sulfonamide compounds having antiarrhythmic activity, corresponding to the formula R 2 N(CH 2 ) n —NH—SO 2 R 1 , 5-HT 7 activity is not mentioned.
[0015] There is still a need to find compounds that have pharmacological activity towards the receptor 5-HT 7 , being both effective and selective, and having good “drugability” properties, i.e. good pharmaceutical properties related to administration, distribution, metabolism and excretion.
SUMMARY OF THE INVENTION
[0016] We have now found a family of structurally distinct class of sulfonamide compounds which are particularly selective inhibitors of the 5-HT 7 receptor. The compounds present a tetrahydroisoquinoline moiety, linked through a 3, or 4-methylene piperidine with a sulfonamide moiety. We have found that the compounds display IC-50 values in the nM range (10-100 nM) at human 5-HT7 receptors and exhibit selectivity for these receptors vs 5-HT1A, 5-HT2A, 5-HT2B, 5-HT2C, 5-HT3, 5-HT4, 5-HT5A, D1, D2, D3, D4, adrenergic α1A, α1B, α1B, β1, and β2 receptors.
[0017] In one aspect the invention is directed to a compound of the formula I:
wherein
W is a substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted aryl, substituted or unsubstituted heterocyclyl;
R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are each independently selected from the group formed by hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted aryl, substituted or unsubstituted heterocyclyl, —COR 8 , —C(O)OR 8 , —C(O)NR 8 R 9 , —HC═NR 8 , —CN, —OR 8 , —OC(O)R 8 , —S(O) t —R 8 , —NR 8 R 9 , —NR 8 C(O)R 9 , —NO 2 , —N═CR 8 R 9 or halogen; wherein
t is 1, 2 or 3;
R 8 and R 9 are each independently selected from hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted aryl, substituted or unsubstituted heterocyclyl, substituted or unsubstituted alkoxy, substituted or unsubstituted aryloxy, halogen;
and wherein the 1,2,3,4-tetrahydroisoquinoline group is linked through metilene to positions 3 or 4 of the piperidine ring;
or a pharmaceutically acceptable salt, isomer, prodrug or solvate thereof.
[0018] In another aspect the invention is directed to a pharmaceutical composition which comprises a compound as above defined or a pharmaceutically acceptable salt, enantiomer, prodrug or solvate thereof, and a pharmaceutically acceptable carrier, adjuvant or vehicle.
[0019] In a further aspect the invention is directed to the use of a compound as defined above in the manufacture of a medicament for the treatment of a 5-HT 7 mediated disease or condition, i.e. diseases caused by failures in central and peripheral serotonin-controlling functions, such as pain, sleep disorder, shift worker syndrome, jet lag, depression, seasonal affective disorder, migraine, anxiethy, psychosis, schizophrenia, cognition and memory disorders, neuronal degeneration resulting from ischemic events, cardiovascular diseases such as hypertension, irritable bowel syndrome, inflammatory bowel disease, spastic colon or urinary incontinence.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The typical compounds of this invention effectively and selectively inhibit the 5-HT7 receptor vs. other 5-HT receptors such as 5-HT1A, 5-HT2A, 5-HT2B, 5-HT2C, 5-HT3, 5-HT4,5-HT5A, D1, D2, D3, D4, adrenergic α1A, α1B, α1B, β1, and β2 receptors, Tachykinin NK-1 opiate, GABA, estrogen, glutamate, adenosine, nicotinic, muscarinic receptors and calcium, potassium and sodium channels and neurotransmitter transporters (serotonin, dopamine, norepinephrine, GABA).
[0021] In the above definition of compounds of formula (I) the following terms have the meaning indicated:
[0022] “Alkyl” refers to a straight or branched hydrocarbon chain radical consisting of carbon and hydrogen atoms, containing no saturation, having one to eight carbon atoms, and which is attached to the rest of the molecule by a single bond, e.g., methyl, ethyl, n-propyl, i-propyl, n-butyl, t-butyl, n-pentyl, etc. Alkyl radicals may be optionally substituted by one or more substituents such as a aryl, halo, hydroxy, alkoxy, carboxy, cyano, carbonyl, acyl, alkoxycarbonyl, amino, nitro, mercapto, alkylthio, etc. If substituted by aryl we have an “Aralkyl” radical, such as benzyl and phenethyl.
[0023] “Alkenyl” refers to an alkyl radical having at least 2 C atoms and having one or more unsaturated bonds.
[0024] “Cycloalkyl” refers to a stable 3-to 10-membered monocyclic or bicyclic radical which is saturated or partially saturated, and which consist solely of carbon and hydrogen atoms, such as cyclohexyl or adamantyl. Unless otherwise stated specifically in the specification, the term “cycloalkyl” is meant to include cycloalkyl radicals which are optionally substituted by one or more substituents such as alkyl, halo, hydroxy, amino, cyano, nitro, alkoxy, carboxy, alkoxycarbonyl, etc.
[0025] “Aryl” refers to single and multiple ring radicals, including multiple ring radicals that contain separate and/or fused aryl groups. Typical aryl groups contain from 1 to 3 separated or fused rings and from 6 to about 18 carbon ring atoms, such as phenyl, naphthyl, indenyl, fenanthryl or anthracyl radical. The aryl radical may be optionally substituted by one or more substituents such as hydroxy, mercapto, halo, alkyl, phenyl, alkoxy, haloalkyl, nitro, cyano, dialkylamino, aminoalkyl, acyl, alkoxycarbonyl, etc.
[0026] “Heterocyclyl” refers to a stable 3-to 15 membered ring radical which consists of carbon atoms and from one to five heteroatoms selected from the group consisting of nitrogen, oxygen, and sulfur, preferably a 4-to 8-membered ring with one or more heteroatoms, more preferably a 5-or 6-membered ring with one or more heteroatoms. For the purposes of this invention, the heterocycle may be a monocyclic, bicyclic or tricyclic ring system, which may include fused ring systems; and the nitrogen, carbon or sulfur atoms in the heterocyclyl radical may be optionally oxidised; the nitrogen atom may be optionally quaternized; and the heterocyclyl radical may be partially or fully saturated or aromatic. Examples of such heterocycles include, but are not limited to, azepines, benzimidazole, benzothiazole, furan, isothiazole, imidazole, indole, piperidine, piperazine, purine, quinoline, thiadiazole, tetrahydrofuran, coumarine, morpholine; pyrrole, pyrazole, oxazole, isoxazole, triazole, imidazole, etc.
[0027] “Alkoxy” refers to a radical of the formula —ORa where Ra is an alkyl radical as defined above, e.g., methoxy, ethoxy, propoxy, etc.
[0028] “Alkoxycarbonyl” refers to a radical of the formula-C(O)ORa where Ra is an alkyl radical as defined above, e.g., methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, etc.
[0029] “Alkylthio” refers to a radical of the formula-SRa where Ra is an alkyl radical as defined above, e.g., methylthio, ethylthio, propylthio, etc.
[0030] “Amino” refers to a radical of the formula-NH2, —NHRa or —NRaRb, optionally quaternized.
[0031] “Halo” or “hal” refers to bromo, chloro, iodo or fluoro.
[0032] References herein to substituted groups in the compounds of the present invention refer to the specified moiety that may be substituted at one or more available positions by one or more suitable groups, e.g., halogen such as fluoro, chloro, bromo and iodo; cyano; hydroxyl; nitro; azido; alkanoyl such as a C1-6 alkanoyl group such as acyl and the like; carboxamido; alkyl groups including those groups having 1 to about 12 carbon atoms or from 1 to about 6 carbon atoms and more preferably 1-3 carbon atoms; alkenyl and alkynyl groups including groups having one or more unsaturated linkages and from 2 to about 12 carbon or from 2 to about 6 carbon atoms; alkoxy groups having one or more oxygen linkages and from 1 to about 12 carbon atoms or 1 to about 6 carbon atoms; aryloxy such as phenoxy; alkylthio groups including those moieties having one or more thioether linkages and from 1 to about 12 carbon atoms or from 1 to about 6 carbon atoms; alkylsulfinyl groups including those moieties having one or more sulfinyl linkages and from 1 to about 12 carbon atoms or from 1 to about 6 carbon atoms; alkylsulfonyl groups including those moieties having one or more sulfonyl linkages and from 1 to about 12 carbon atoms or from 1 to about 6 carbon atoms; aminoalkyl groups such as groups having one or more N atoms and from 1 to about 12 carbon atoms or from 1 to about 6 carbon atoms; carbocylic aryl having 6 or more carbons, particularly phenyl or naphthyl and aralkyl such as benzyl. Unless otherwise indicated, an optionally substituted group may have a substituent at each substitutable position of the group, and each substitution is independent of the other.
[0033] Particular individual compounds of the invention include the compounds 1-78 in the examples, either as salts or as free bases.
[0034] In an embodiment the tetrahydroisoquinoline in the compounds of formula I above is not substituted, R 1 to R 7 are all H. Good activity results are obtained with such compounds.
[0035] In another embodiment R 2 is alkoxy, preferably methoxy and the rest of the substitutents of the tetrahydroisoquinoline (R 1 and R 3 to R 7 ) are H.
[0036] In another embodiment R 2 and R 3 are alkoxy, preferably methoxy and the rest of the substitutents of the tetrahydroisoquinoline (R 1 and R 4 to R 7 ) are H.
[0037] In another embodiment the group W linked to the sulfonamide is aromatic, such as substituted or unsubstituted aryl, substituted or unsubstituted heterocyclyl, preferably substituted or unsubstituted phenyl. Good results were obtained when W is alkyl, alkoxy and/or halo substituted phenyl. In particular halo substituted phenyl, having one or more halo substituents being the same or different are preferred.
[0038] In an embodiment it is important that 1,2,3,4-tetrahydroisoquinoline group is linked through metilene to position 4 of the piperidine ring. Best results were obtained with this position linking the tetrahydroisoquinoline.
[0039] The above embodiments and preferences for W, R 1 to R 7 and the position of linkage can be combined to give further preferred compounds.
[0040] Representative compounds of the above embodiments which are preferred are: 2-[1-(5-Chloro-2,4-difluoro-benzene sulfonyl)-piperidin-4-ylmethyl]-1,2,3,4-tetrahydroisoquinoline hydrochloride, 2-[1-(2-Chloro-benzenesulfonyl)-piperidin-4-ylmethyl]-1,2,3,4-tetrahydro-isoquinoline hydrochloride, 2-[1-(2,5-Dichloro-benzenesulfonyl)-piperidin-4-ylmethyl]-1,2,3,4-tetrahydro-isoquinoline hydrochloride, 2-[1-(Toluene-3-sulfonyl)-piperidin-4-ylmethyl]-1,2,3,4-tetrahydroisoquinoline hydrochloride, 2-[1-(2-Chloro-4,5-difluoro-benzenesulfonyl)-piperidin-4-ylmethyl]-1,2,3,4-tetrahydroisoquinoline hydrochloride, 2-[1-(4-Chloro-2,5-dimethyl-benzenesulfonyl)-piperidin-4-ylmethyl]-1,2,3,4-tetrahydroisoquinoline hydrochloride, 2-[1-(2-Bromo-benzenesulfonyl)-piperidin-4ylmethyl]-1,2,3,4-tetrahydro-isoquinoline hydrochloride, 2-[1-(Naphtalene-1-sulfonyl)-piperidin-4-ylmethyl]-1,2,3,4-tetrahydroisoquinoline hydrochloride.
[0041] The compounds of the present invention represented by the above described formula (I) may include enantiomers depending on the presence of chiral centres or isomers depending on the presence of multiple bonds (e.g. Z, E). The single isomers, enantiomers or diastereoisomers and mixtures thereof fall within the scope of the present invention.
[0042] Unless otherwise stated, the compounds of the invention are also meant to include compounds which differ only in the presence of one or more isotopically enriched atoms.
[0043] For example, compounds having the present structures except for the replacement of a hydrogen by a deuterium or tritium, or the replacement of a carbon by a 13 C- or 14 C-enriched carbon or 15 N-enriched nitrogen are within the scope of this invention.
[0044] The term “pharmaceutically acceptable salts, solvates, prodrugs” refers to any pharmaceutically acceptable salt, ester, solvate, or any other compound which, upon administration to the recipient is capable of providing (directly or indirectly) a compound as described herein. However, it will be appreciated that non-pharmaceutically acceptable salts also fall within the scope of the invention since those may be useful in the preparation of pharmaceutically acceptable salts. The preparation of salts, prodrugs and derivatives can be carried out by methods known in the art.
[0045] For instance, pharmaceutically acceptable salts of compounds provided herein are synthesized from the parent compound which contains a basic or acidic moiety by conventional chemical methods. Generally, such salts are, for example, prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent or in a mixture of the two. Generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol or acetonitrile are preferred. Examples of the acid addition salts include mineral acid addition salts such as, for example, hydrochloride, hydrobromide, hydroiodide, sulphate, nitrate, phosphate, and organic acid addition salts such as, for example, acetate, maleate, fumarate, citrate, oxalate, succinate, tartrate, malate, mandelate, methanesulphonate and p-toluenesulphonate. Examples of the alkali addition salts include inorganic salts such as, for example, sodium, potassium, calcium, ammonium, magnesium, aluminium and lithium salts, and organic alkali salts such as, for example, ethylenediamine, ethanolamine, N,N-dialkylenethanolamine, triethanolamine, glucamine and basic aminoacids salts.
[0046] Particularly favored derivatives or prodrugs are those that increase the bioavailability of the compounds of this invention when such compounds are administered to a patient (e.g., by allowing an orally administered compound to be more readily absorbed into the blood) or which enhance delivery of the parent compound to a biological compartment (e.g., the brain or lymphatic system) relative to the parent species.
[0047] Any compound that is a prodrug of a compound of formula (I) is within the scope of the invention. The term “prodrug” is used in its broadest sense and encompasses those derivatives that are converted in vivo to the compounds of the invention. Such derivatives would readily occur to those skilled in the art, and include, depending on the functional groups present in the molecule and without limitation, the following derivatives of the present compounds: esters, amino acid esters, phosphate esters, metal salts sulfonate esters, carbamates, and amides.
[0048] The compounds of the invention may be in crystalline form either as free compounds or as solvates and it is intended that both forms are within the scope of the present invention. Methods of solvation are generally known within the art. Suitable solvates are pharmaceutically acceptable solvates. In a particular embodiment the solvate is a hydrate.
[0049] The compounds of formula (I) or their salts or solvates are preferably in pharmaceutically acceptable or substantially pure form. By pharmaceutically acceptable form is meant, inter alia, having a pharmaceutically acceptable level of purity excluding normal pharmaceutical additives such as diluents and carriers, and including no material considered toxic at normal dosage levels. Purity levels for the drug substance are preferably above 50%, more preferably above 70%, most preferably above 90%. In a preferred embodiment it is above 95% of the compound of formula (I), or of its salts, solvates or prodrugs.
[0050] The compounds of formula (I) defined above can be obtained by available synthetic procedures.
[0051] Compounds of Formula (Ia) or (Ib) can be prepared by the coupling of compounds of Formula (IIa) or (IIb):
[0052] in which R 1 -R 7 are as defined in Formula (I), with a compound of Formula (III):
[0053] in which W is as defined in Formula (I) and X is an halogen, typically Cl.
[0054] The reaction of compounds of formulas (II) and (III) is preferably carried out in an aprotic solvent, but not limited to, such as dichloromethane in the presence of an organic base, such as diisopropylethylamine or triethylamine.
[0055] Compounds of Formula (III) are commercially available or can be prepared by conventional methods.
[0056] Compounds of Formula (II) can be commercially available or prepared from compounds of Formula (IV). Compounds of Formula (IV) can also be commercially available or synthesized by conventional methods, such as Pictet-Spengler reaction from substituted phenylethyl amines and ketones or aldehydes substituted with R 5 , as shown in Scheme 1.
[0057] Compounds of Formula (II) can be synthesized by the methods described below. The reactions are performed in a solvent appropriate to the reagents and materials employed and suitable for the transformations. The functionality present on the molecule should be consistent with the transformations proposed. This will sometimes require a selection of a particular process scheme over another in order to obtain the desired compound of the invention. Preferred methods included, but are not limited to, those described below.
[0058] Compounds of Formula (II) can be prepared by an amide formation from compounds of Formula (IV) and a isonipecotic acid (piperidine-4-carboxylic acid, Va) derivative or nipecotic acid (piperidine-4-carboxylic acid, Vb) derivative, which should have the amino group protected, to give an intermediate of Formula (VI), followed by a deprotection of the amino group and a reduction of the amido group, as shown in Scheme 2. The commercially available acid derivatives (Va) and (Vb) with the amino group protected are those with a carbamate, such as BOC or CBZ, or with a benzyl group.
[0059] If Z=OH, the amidation can be performed by the activation of the carboxylic acid with a carbodiimide, such as 1,1-dicyclohexylcarbodiimide or 1-Ethyl 3-(3-dimethylamino propyl) carbodiimide, in the presence of a catalytic amount of an organic base, such as DMAP in an appropriate solvent, such as dichloromethane.
[0060] The amidation can also be achieved using piperidinecarbonyl chlorides, if Z=Cl, derived from isonipecotic acid or nipecotic acid in the presence of an aprotic solvent, but not limited to, such as dichloromethane and an organic base, such as diisopropylethylamine or triethylamine.
[0061] The acylation can also be performed starting from an ester derived from isonipecotic or nipecotic acid (Z=OR), when R is a good leaving group, such as p-nitrophenyl or ethyltrifluoroacetate using catalytic basic conditions
[0062] Before the reduction of the amido group, the deprotection of the amino group can be achieved by hydrolisis of the carbamate or by hydrogenation of the benzyl group using conventional methods. The reduction of the amido group can be performed in the presence of a hydride, such as LiAlH 4 or a borane in a dry polar aprotic solvent, such as tetrahydrofuran, as shown in Scheme 3.
[0063] Where convenient, compounds of Formula (II) from compounds of Formula (VI) can be obtained by a reduction of the amido group before the deprotection of the amino group.
[0064] Compounds of Formula (II) can also be obtained by reductive amination of compounds of Formula (IV) with amino protected piperidinecarboaldehydes (VIIIa) or (VIIIb) in the presence of a hydride, such as NaBH(OAc) 3 (Scheme 4). The commercially available aldehydes (VIIIa) and (VIIIb) with the amino group protected are those with a carbamate, such as BOC or CBZ or with a benzyl group. The deprotection of the amino group by conventional methods can lead to desired compounds of Formula (II).
[0065] Compounds of Formula (II) can also be prepared by the alkylation of compounds of Formula (IV) with hydroxymethyl piperidines with the amino group protected (IXa) or (IXb), after a derivatization of the hydroxy group into a good leaving group Y (Xa) or (Xb).
[0066] For example, the transformation of the hydroxy group into an alkyl or aryl sulfonate can be performed in the presence of a sulfonic anhydride, such as methanesulfonic anhydride in an organic aprotic solvent, such as dichloromethane or toluene and an organic base, such as triethylamine or diisopropylamine. The transformation can also be carried out with a sulfonic acid chloride in the presence of an aprotic solvent, such as dichloromethane in the presence of an organic base, such as diisopropylethylamine or triethylamine. Other transformations into a bromine, iodine or chlorine can be achieved by other conventional methods.
[0067] The alkylation of compounds of Formula (IV) with compounds of Formula (X) (Scheme 5) can be performed in the presence of an appropriate base and solvent. Useful bases include, but are not limited to, metal carbonates such as K 2 CO 3 or Cs 2 CO 3 , metal hydroxides, hindered alkoxides or tertiary organic amines. Typical solvents include polar aprotic liquids such as DMF or THF, or protic liquids such as alcohols. The deprotection of the amino group can be afford by conventional methods.
[0068] Some compounds of Formula (I) can also be prepared by the coupling of compounds of Formula (XIa) or (XIb) or their acid derivatives or by the coupling of compounds of Formula (XIc) or (XId):
[0069] in which W is as defined in Formula (I), Z can be as it was described for compounds (Va) or (Vb) and Y can be as it was described for compounds (Xa) or (Xb), with a compound of a Formula (IV):
[0070] in which R 1 -R 7 are as defined in Formula (I).
[0071] The coupling can be performed using the same methods and conditions described for the coupling of compounds of Formula (IV) with compounds of Formula (Va) or (Vb) and for the coupling of compounds of Formula (IV) with compounds of Formula (Xa) or (Xb).
[0072] Compound (IV) is prepared as it was described above. Compounds of Formula (XIa) and (XIb) can be synthesized by the coupling of isonipecotic and nipecotic acid with compounds of Formula (III) in an aprotic solvent, such as dichloromethane or toluene in the presence of an organic base, such as diisopropylethylamine or triethylamine. Compounds of Formula (XIc) and (XId) can be obtained from deprotected piperidines (Xa) and (Xb) by coupling with compounds of Formula (III) using similar conditions described above.
[0073] The obtained reaction products may, if desired, be purified by conventional methods, such as crystallisation, chromatography and trituration. Where the above described processes for the preparation of compounds of the invention give rise to mixtures of stereoisomers, these isomers may be separated by conventional techniques such as preparative chromatography. If there are chiral centers the compounds may be prepared in racemic form, or individual enantiomers may be prepared either by enantiospecific synthesis or by resolution.
[0074] One preferred pharmaceutically acceptable form is the crystalline form, including such form in pharmaceutical composition. In the case of salts and solvates the additional ionic and solvent moieties must also be non-toxic. The compounds of the invention may present different polymorphic forms, it is intended that the invention encompasses all such forms.
[0075] Another aspect of this invention relates to a method of treating or preventing an 5-HT 7 mediated disease which method comprises administering to a patient in need of such a treatment a therapeutically effective amount of a compound of formula (I) or a pharmaceutical composition thereof. Among the 5-HT 7 mediated diseases that can be treated are diseases caused by failures in central and peripheral serotonin-controlling functions, such as pain, sleep disorder, shift worker syndrome, jet lag, depression, seasonal affective disorder, migraine, anxiethy, psychosis, schizophrenia, cognition and memory disorders, neuronal degeneration resulting from ischemic events, cardiovascular diseases such as hypertension, irritable bowel syndrome, inflammatory bowel disease, spastic colon or urinary incontinence.
[0076] The present invention further provides pharmaceutical compositions comprising a compound of this invention, or a pharmaceutically acceptable salt, derivative, prodrug or stereoisomers thereof together with a pharmaceutically acceptable carrier, adjuvant, or vehicle, for administration to a patient.
[0077] Examples of pharmaceutical compositions include any solid (tablets, pills, capsules, granules etc.) or liquid (solutions, suspensions or emulsions) composition for oral, topical or parenteral administration.
[0078] In a preferred embodiment the pharmaceutical compositions are in oral form, either solid or liquid. Suitable dose forms for oral administration may be tablets, capsules, syrops or solutions and may contain conventional excipients known in the art such as binding agents, for example syrup, acacia, gelatin, sorbitol, tragacanth, or polyvinylpyrrolidone; fillers, for example lactose, sugar, maize starch, calcium phosphate, sorbitol or glycine; tabletting lubricants, for example magnesium stearate; disintegrants, for example starch, polyvinylpyrrolidone, sodium starch glycollate or microcrystalline cellulose; or pharmaceutically acceptable wetting agents such as sodium lauryl sulfate.
[0079] The solid oral compositions may be prepared by conventional methods of blending, filling or tabletting. Repeated blending operations may be used to distribute the active agent throughout those compositions employing large quantities of fillers. Such operations are conventional in the art. The tablets may for example be prepared by wet or dry granulation and optionally coated according to methods well known in normal pharmaceutical practice, in particular with an enteric coating.
[0080] The pharmaceutical compositions may also be adapted for parenteral administration, such as sterile solutions, suspensions or lyophilized products in the apropriate unit dosage form. Adequate excipients can be used, such as bulking agents, buffering agents or surfactants.
[0081] The mentioned formulations will be prepared using standard methods such as those described or referred to in the Spanish and US Pharmacopoeias and similar reference texts.
[0082] Administration of the compounds or compositions of the present invention may be by any suitable method, such as intravenous infusion, oral preparations, and intraperitoneal and intravenous administration. Oral administration is preferred because of the convenience for the patient and the chronic character of the diseases to be treated.
[0083] Generally an effective administered amount of a compound of the invention will depend on the relative efficacy of the compound chosen, the severity of the disorder being treated and the weight of the sufferer. However, active compounds will typically be administered once or more times a day for example 1, 2, 3 or 4 times daily, with typical total daily doses in the range of from 0.1 to 1000 mg/kg/day.
[0084] The compounds and compositions of this invention may be used with other drugs to provide a combination therapy. The other drugs may form part of the same composition, or be provided as a separate composition for administration at the same time or at different time.
[0085] The following examples are given only as further illustration of the invention, they should not be taken as a definition of the limits of the invention.
EXAMPLES
[0086] The starting materials of general formula (I) were prepared by means of conventional organic chemistry methods known to those skilled in the art. The preparation of some of the intermediates of general formulas (II), (IV), (VI) and (VII) is shown below:
Example A
[0087] This example illustrate the preparation of a compounds of general formula (IV).
6-methoxy-1,2,3,4-tetrahydroisoquinoline hydrochloride
[0088] This compound is well described in the literature in the Organic Reactions 1951, Vol. 6 (Chapter 3, pages 151-190).
[0089] A solution of 35% formaldehyde (2.49 g, 0.034 mol) was added dropwise to 2-(3-methoxyphenyl)ethanamine (5 g, 0.033 mol). The warm solution soon deposited an oil and the reaction was completed by heating the mixture for one hour at 100° C. The oil was extracted with toluene (25 ml) and washed with water (3×18 ml). The extract was dried over Na 2 SO 4 and the solvent was concentrated to yield a yellow oil. A solution of 20% hydrochloric acid (6 ml) was added to the crude and the mixture was stirred at 100° C. for 1 hour. After the evaporation to dryness, the residue was dissolved in a little water, made alkaline with concentrated potassium hydroxide, extracted with dichloromethane (3×90 ml) and dried over Na 2 SO 4 . After the evaporation of the solvent, the oil was dissolved in ethyl acetate and concentrated hydrochloric acid was added to form the hydrochloride, which was filtered to yield a white solid identified as 6-methoxy-1,2,3,4-tetrahydroisoquinoline hydrochloride (5.1 g, 80% yield).
[0090] 1 H NMR (300 MHz, CHLOROFORM-D) δ ppm 2.80 (t, J=6.01 Hz, 2H) 3.14 (t, J=6.01 Hz, 2H) 3.78 (s, 3H) 3.97 (s, 2H) 6.63 (d, J=2.50 Hz, 1H) 6.71 (dd, J=8.42, 2.56 Hz, 1 H) 6.93 (d, J=8.42 Hz, 1H)
[0091] MS (APCI (M+H) + ): 164
Example B
[0092] This example illustrate the preparation of a compound of general formula (VI).
4-(6,7-Dimethoxy-3,4-dihydro-1H-isoquinoline-2-carbonyl)-piperidine-1-carboxylic acid tert-butyl ester
[0093]
[0094] DCC (2.16 g, 0.011 mol), a catalytic amount of DMAP (0.098 g, 8 mmol) and 1-(tert-butoxycarbonyl)piperidine-4-carboxylic acid (2.04 g, 0.009 mol) were added to a solution of 6,7-Dimethoxy-1,2,3,4-tetrahydroisoquinoline (1.31 g, 0.008 mol) in dichloromethane (30 ml). The clear solution soon deposited a white solid corresponding to the cyclohexyl urea formation. The crude was stirred for 2 hours at room temperature. The solid was filtered and the crude was washed with water and dried over Na 2 SO 4 . The solvent was vacuum concentrated and the residue was purified by flash chromatography using a gradient consisting of different mixtures of dichloromethane/methanol to give pure tert-Butyl-4-(6,7-dimethoxy-1,2,3,4-tetrahydroisoquinoline-2-carbonyl)piperidine-1-carboxylate as yellow solid (3.8 g, 85% yield).
[0095] 1 H NMR (300 MHz, CHLOROFORM-D) δ ppm 1.45 (s, 9H) 1.62 (m, 4H) 1.70 (m, 4H) 2.78 (m, 3H) 3.72 (m, 1H) 3.86 (s, 6H) 4.16 (m, 2H) 4.64 (s, 1H) 6.62 (s, 2H)
[0096] MS (APCI (M+H) + ): 405
Example C
[0097] This example illustrate the preparation of a compound of general formula (VII).
(6,7-Dimethoxy-3,4-dihydro-1H-isoquinolin-2-yl)-piperidin-4-yl-methanone
[0098]
[0099] A solution of 5 N hydrochloric acid in ether (5 ml) was added to a solution of 4-(6,7-Dimethoxy-3,4-dihydro-1H-isoquinoline-2-carbonyl)-piperidine-1-carboxylic acid tert-butyl ester (3 g, 7.43 mmol) in ethyl acetate and the mixture was stirred for 2 hours at room temperature. The precipitate formed was collected by filtration and the white solid obtained was indetified as (6,7-dimethoxy-3,4-dihydroisoquinolin-2(1H)-yl)(piperidin-4-yl)-methanone (2.1 g, 95% yield).
[0100] MS (APCI (M+H) + ): 305
Example D
[0101] This example illustrate the preparation of a compound of general formula (II).
6,7-dimethoxy-2-(piperidin-4-ylmethyl)-1,2,3,4-tetrahydroisoquinoline
[0102]
[0103] A 1 M solution of LiAlH 4 in dry tetrahydrofuran (12 ml) was added dropwise to a solution of (6,7-dimethoxy-3,4-dihydroisoquinolin-2(1H)-yl)(piperidin-4-yl)methanone (2 g, 6.6 mmol) in dry tetrahydrofuran (60 ml) under argon atmosphere. The mixture was refluxed overnight. Water was added to the crude, made alkaline with 1 N NaOH and the salts formed was filtered over celite. Extraction with ethyl acetate yielded a solution that was dried with Na 2 SO 4 and concentrated in vacuo to give and oil that was purified by flash chromatography.
[0104] MS (APCI (M+H) + ): 291
Example E
[0105] This example illustrate the preparation of a compound of general formula (I).
2-((1-(2,5-dichlorophenylsulfonyl)piperidin-4-yl)methyl)-1,2,3,4-tetrahydroisoquino-line
[0106]
[0107] 2,5-dichlorobenzene-1-sulfonyl chloride (108.1 mg, 0.44 mmol) was added to a solution of 2-(piperidin-4-ylmethyl)-1,2,3,4-tetrahydroisoquinoline dihydrochloride (92.1 mg, 0.40 mmol) and N,N-diisopropylethylamine (206.9.2 mg, 1.60 mmol) in CH 2 Cl 2 (10 mL) and the mixture was stirred overnight at room temperature. The resulting solution was washed with water (3×10 mL), dried over Na 2 SO 4 , and evaporated to dryness. The free base was dissolved in ethyl acetate (1 ml). A 2.8 M solution of hydrogen chloride in ethanol (0.10 mL) was then added. The product was crystallized and collected by filtration, and vacuum dried to give a white solid (138 mg, 78%).
[0108] 1 H NMR (300 MHz, DMSO-D6) δ ppm 1.21 (m, 2H) 1.90 (m, 2H) 2.08 (m, 1H) 2.76 (m, 2H) 3.01 (m, 1H) 3.10 (m, 2H) 3.24 (m, 2H) 3.65 (m, 1H) 3.75 (d, J=12.45 Hz, 2H) 4.23 (dd, J=15.30, 7.83 Hz, 1H) 4.53 (d, J=14.94 Hz, 1H) 7.15 (m, 1H) 7.24 (m, 3H) 7.77 (m, 2H) 7.94 (m, 1H) 10.22 (br, 1H)
[0109] MS (APCI (M+H) + ): 439
[0110] The spectroscopic data for the identification of some of the sulfonamides compounds of the invention having general formula (I), prepared analogously to the methods described in the above examples, are shown in the following table 1:
MS (APCI No STRUCTURE Autonom 1 H-NMR (M + H) + ) 1 2-[1-(5-Chloro-2,4- difluoro-benzene sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.23 (m, 2H) 1.91 (m, 3H) 2.58 (t, J=11.57 Hz, 2H) 3.00 (m, 1H) 3.09 (m, 2H) 3.24 (m, 2H) 3.68 (m, 3H) 4.21 (m, 1H) 4.51 (d, J=14.06 Hz, 1H) 7.15 (m, 1H) 7.23 (m, 3H) 7.96 (m, 2H) 10.24 (br, 1H) 441 2 2-[1-(2-Chloro- benzenesulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.23 (m, 2H) 1.90 (m, 2H) 2.06 (m, 1H) 2.71 (m, 2H) 3.01 (m, 1H) 3.09 (m, 2H) 3.19 (m, 2H) 3.69 (m, 3H) 4.23 (m, 1H) 4.52 (d, J=16.11 Hz, 1H) 7.15 (m, 1H) 7.24 (m, 3H) 7.56 (m, 1H) 7.70 (m, 2H) 7.97 # (d, J=7.91 Hz, 1H) 10.19 (br, 1H) 405 3 2-[1-(2,5-Dichloro- benzenesulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.21 (m, 2H) 1.90 (m, 2H) 2.08 (m, 1H) 2.76 (m, 2H) 3.01 (m, 1H) 3.10 (m, 2H) 3.24 (m, 2H) 3.65 (m, 1H) 3.75 (d, J=12.45 Hz, 2H) 4.23 (dd, J=15.30, 7.83 Hz, 1H) 4.53 (d, J=14.94 Hz, 1H) 7.15 (m, 1H) # 7.24 (m, 3H) 7.77 (m, 2H) 7.94 (m, 1H) 10.22 (br, 1H) 439 4 2-(1-Benzenesulfonyl- piperidin-4-yl methyl)-1,2,3,4- tetrahydroisoquinoline hydrochloride 371 5 2-[1-(Toluene-3- sulfonyl)-piperidin- 4-ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.24 (m, 2H) 1.89 (m, 3H) 2.18 (t, J=11.27 Hz, 2H) 2.40 (s, 3H) 2.97 (m, 1H) 3.04 (m, 2H) 3.22 (m, 2H) 3.61 (m, 3H) 4.19 (m, 1H) 4.49 (d, J=12.01 Hz, 1H) 7.11 (m, 1H) 7.21 (m, 3H) 7.52 (m, 4H) 10.18 1H) 385 6 2-[1-(2-Chloro-4,5- difluoro-benzene- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.21 (m, 2H) 1.88 (m, 2H) 2.05 (m, 1H) 2.77 (m, 2H) 3.01 (m, 1H) 3.09 (m, 2H) 3.25 (m, 2H) 3.63 (m, 1H) 3.73 (d, J=12.30 Hz, 2H) 4.22 (dd, J=16.03, 7.10 Hz, 1H) 4.52 (d, J=13.62 Hz, 1H) # 7.15 (m, 1H) 7.23 (m, 3H) 8.05 (m, 2H) 10.26 (br, 1H) 441 7 2-[1-(5-Chloro-2,4- difluoro-benzene- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 441 8 2-[1-(2-Chloro- benzenesulfonyl)- piperidin-3-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 405 9 2-[1-(2,5-Dichloro- benzenesulfonyl)- piperidin-3-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 439 10 2-(1-Benzenesulfonyl- piperidin-3-ylmethyl)- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 371 11 2-[1-(Toluene-3- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4tetra- hydroiso- quinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.23 (m, 2H) 1.72 (m, 2H) 2.18 (m, 1H) 2.27 (m, 2H) 2.40 (s, 3H) 3.04 (m, 3H) 3.21 (m, 2H) 3.69 (m, 3H) 4.21 (m, 1H) 4.55 (m, 1H) 7.25 (m, 4H) 7.52 (m, 3H) 7.55 (m, 1H) 10.22 (br, 1H) 385 12 2-[1-(2-Chloro-4,5- difluoro-benzene sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 441 13 2-[1-(4-Chloro-2,5- dimethyl-benzene sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 433 14 2-[1-(3-Chloro-4- fluorobenzene- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.09 (m, 1H) 1.55 (m, 1H) 1.72 (m, 2H) 2.23 (d, J=8.64 Hz, 2H) 2.42 (m, 1H) 3.08 (m, 3H) 3.23 (m, 2H) 3.44 (m, 1H) 3.68 (m, 2H) 4.27 (dd, J=16.03, 7.39 Hz, 1H) 4.55 (m, 1H) 7.26 # (m, 4H) 7.75 (m, 2H) 7.95 (m, 1H) 10.32 (br, 1H) 423 15 2-[1-(5-Fluoro-2- methyl-benzene- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 403 16 2-[1-(4-Chloro-2,5- dimethyl-benzene sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.22 (m, 2H) 1.90 (m, 2H) 2.04 (m, 1H) 2.36 (s, 3H) 2.50 (s, 3H) 2.55 (m, 2H) 3.01 (m, 1H) 3.09 (m, 2H) 3.25 (m, 2H) 3.63 (m, 3H) 4.22 (dd, J=15.45, 7.83 Hz, 1H) 4.52 (d, J=15.67 Hz, 1H) 7.15 # (m, 1H) 7.24 (m, 3H) 7.57 (s, 1H) 7.75 (s, 1H) 10.28 (br, 1H) 433 17 2-[1-(3-Chloro-4- fluoro- benzenesulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4- tetrahydroisoquinoline hydrochloride 423 18 2-[1-(5-Fluoro-2- methyl-benzene- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 403 19 2-[1-(2-Bromo- benzenesulfonyl)- piperidin-3-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 449 20 2-[1-(Naphthalene-1- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 421 21 2-[1-(Thiophene-2- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 377 22 2-[1-(2-Bromo- benzenesulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.23 (m, 2H) 1.89 # (m, 2H) 2.06 (m, 1H) 2.74 (m, 2H) 3.02 (m, 1H) 3.10 (m, 2H) 3.26 (m, 2H) 3.69 (m, 3H) 4.24 (m, 1H) 4.53 (d, J=16.72 Hz, 1H) 7.16 (m, 1H) 7.23 (m, 3H) 7.58 (qd, J=7.10, 1.68 Hz, 2H) 7.88 (dd, J=7.82, 1.76 Hz, 1H) 7.99 (dd, J=7.47, 2.05 Hz, 1H) 10.13 (br, 1H) 449 23 2-[1-(Naphtalene-1- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.22 (m, 1H) 1.92 (m, 3H) 2.44 (m, 2H) 2.97 (m, 1H) 3.03 (m, 2H) 3.19 (m, 2H) 3.59 (m, 1H) 3.75 (m, 2H) 4.17 (dd, J=15.23, 5.86 Hz, 1H) 4.47 (d, J=17.28 Hz, 1H) 7.10 (m, 1H) 7.20 (m, 3H) 7.70 (m, 3H) 8.12 # (t, J=7.83 Hz, 2H) 8.29 (d, J=8.05 Hz, 1H) 8.68 (d, J=8.49 Hz, 1H) 10.13 (br, 1H) 421 24 2-[1-(Thiophene-2- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 377 25 2-[1-(2,4,5-Trichloro- benzenesulfonyl)- piperidin-3-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 473 26 2-[1-(2,4,5-Trichloro- benzenesulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 1H NMR (300 MHz, DMSO-D6) δppm 1.21 (m, 1H) 1.89 (m, 2H) 2.06 (m, 1H) 2.78 (m, 2H) 3.02 (m, 1H) 3.10 (m, 2H) 3.26 (m, 2H) 3.63 (m, 1H) 3.75 (d, J=12.45 Hz, 2H) 4.23 (dd, J=15.37, 6.74 Hz, 1H) 4.52 # (m, 1H) 7.16 (m, 1H) 7.24 (m, 3H) 8.10 (s, 1H) 8.18 (s, 1H) 10.13 (br 1H) 473 27 2-[1-(4-Fluoro- naphtalene-1- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline hydrochloride 439 28 2-[1-(Biphenyl-2- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 447 29 2-[1-(2,3-Dihydro- benzofuran-5- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline hydrochloride 413 30 2-[1-(Dibenzofuran-2- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 461 31 2-[1-(2-Methoxy-4- methyl-benzene- sulfonyl)-piperidin-4- ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 415 32 2-[1-(5-Isoxazol-5-yl- thiophene-2-sulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetrahydroiso- quinoline hydrochloride 444 33 2-[1-(4-Fluoro- naphtalene-1- sulfonyl)-piperidin-3- ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 439 34 2-[1-(Biphenyl-2- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 447 35 2-[1-(2,3-Dihydro- benzofuran-5- sulfonyl)-piperidin-3- ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 413 36 2-[1-(Dibenzofuran-2- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline 461 37 2-[1-(2-Methoxy-4- methyl-benzene- sulfonyl)-piperidin-3- ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 415 38 2-[1-(5-Isoxazol-5-yl- thiophene-2-sulfonyl)- piperidin-3-ylmethyl]- 1,2,3,4-tetrahydroiso- quinoline hydrochloride 444 39 6-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3H- benzooxazol-2-one 442 40 2-[1-(7-Methyl- benzo[1,2,5]- thiadiazole-4- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 443 41 5-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-2- fluoro-benzoic acid hydrochloride 433 42 2-[1-(3Cloro-4- methoxy-benzene- sulfonyl)-piperidin-4- ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 435 43 6-[4-(3,4-Dihydro-1H- 4isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3,4- dihydro-1H-quinolin- 2-one 440 44 6-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3H- benzothiazol-2-one 444 45 1{4-[4-(3,4-Dihydro- 1H-isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-phenyl}- ethanone hydrochloride 413 46 5-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-6-methyl- 1H-pyrimidine- 2,4-dione 419 47 7-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-1,5- dihydrobenzo[b][1,4]- diazepine-2-dione hydrochloride 469 48 6-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-1,4- dimethyl-1,4- dihydroquinoxaline- 2,3-dione 483 49 2-[1-(1H-Imidazole-4- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline 361 50 2-[1-(4-Fluoro-3- methyl-benzene- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydro- isoquinoline hydrochloride 399 51 6-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3H- benzooxazol-2-one hydrochloride 428 52 2-[1-(4-Cyclohexyl- benzenesulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 453 53 8-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-quinoline hydrochloride 422 54 2-[1-(4-Chloro- naphtalene-1- sulfonyl)-piperidin-4- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline hydrochloride 455 55 8-[4-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-quinoline hydrochloride 422 56 2-[1-(4-Chloro- naphtalene-1- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline hydrochloride 455 57 6-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3-methyl- 3H-benzooxazol-2-one hydrochloride 442 58 2-[1-(7-Methyl- benzo[1,2,5]- thiadiazole-4- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydroisoquinoline hydrochloride 443 59 5-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-2- fluoro-benzoic acid hydrochloride 433 60 2-[1-(3Chloro-4- methoxy-benzene- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline hydrochloride 435 61 6-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3,4- dihydro-1H-quinolin- 2-one 440 62 6-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3H- benzothiazol-2-one hydrochloride 444 63 1{4-[3-(3,4-Dihydro- 1H-isoquinolin-2- ylmethyl)-piperidine- 1-sulfonyl]-phenyl}- ethanone hydrochloride 413 64 5-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-6-methyl- 1H-pyrimidine- 2,4-dione 419 65 7-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-1,5- dihydrobenzo[b][1,4]diazepine-2-dione 469 66 6-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-1,4- dimethyl-1,4- dihydroquinoxaline- 2,3-dione 483 67 2-[1-(1H-Imidazole-4- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline 361 68 2-[1-(4-Fluoro-3- methyl-benzene- sulfonyl)-piperidin-3- ylmethyl]-1,2,3,4- tetrahydro-isoquinoline 403 69 6-[3-(3,4-Dihydro-1H- isoquinolin-2-yl- methyl)-piperidine-1- sulfonyl]-3H- benzooxazol-2-one hydrochloride 428 70 2-[1-(4-Cyclohexyl- benzenesulfonyl)- piperidin-3-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 453 71 6,7-Dimethoxy-2-[1- (toluene-3-sulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 481 72 6-Methoxy-2- [1(toluene-3-sulfonyl)- piperidin-4-ylmethyl]- 1,2,3,4-tetra-hydroiso- quinoline hydrochloride 415 73 2-[1-(2,3-Dihydro- benzofuran-5- sulfonyl)-piperidin-4- ylmethyl]-6,7- dimethoxy-1,2,3,4- tetrahydroisoquinoline hydrochloride 473 74 2-[1-(2,3-Dihydro- benzofuran-5- sulfonyl)-piperidin-4- ylmethyl]-6-methoxy- 1,2,3,4-tetrahydroiso- quinoline hydrochloride 443 75 2-[1-(4-Chloro-2,5- dimethylbenzene- sulfonyl)-piperidin-4- ylmethyl]-6,7- dimethoxy-1,2,3,4- tetrahydroisoquinoline hydrochloride 493 76 2-[1-(4-Chloro-2,5- dimethyl-benzene sulfonyl)-piperidin-4- ylmethyl]-6-methoxy- 1,2,3,4-tetrahydro- isoquinoline hydrochloride 463 77 2-[1-(2-Chloro- benzene-sulfonyl)- piperidin-4-ylmethyl]- 6,7-dimethoxy- tetrahydroisoquinoline hydrochloride 465 78 2-[1-(2-Chloro- benzene-sulfonyl)- piperidin-4-ylmethyl]- 6-methoxy-1,2,3,4- tetrahydro-isoquinoline hydrochloride 435
Biological Assays
Radioligand Binding
[0111] Radioligand binding assays were performed using the Cloned Human Serotonin Receptor, Subtype 7 (h5HT 7 ), expressed in CHO cells, coated on Flashplate (Basic FlashPlate Cat.: SMP200) from PerkinElmer (Cat.: 6120512). The protocol assay was essentially the recommended protocol in the Technical Data Sheet by PerkinEmer Life and Analytical Sciences. The Mass membrane protein/well was typically 12 μg and the Receptor/well was about 9-10 fmoles. The Flashplate were let equilibrate at room temperature for one hour before the addition of the components of the assay mixture. The binding buffer was: 50 mM Tris-HCl, pH 7.4, containing 10 mM MgCl 2 , 0.5 mM EDTA and 0.5% BSA. The radioligand was [ 125 I]LSD at a final concentration of 0.82 nM. Nonspecific binding was determined with 50 μM of Clozapine. The assay volume was 25 μl. TopSeal-A were applied onto Flashplate microplates and they were incubated at room temperature for 240 minutes in darkness. The radioactivity were quantified by liquid scintillation spectrophotometry (Wallac 1450 Microbeta Trilux) with a count delay of 4 minutes prior to counting and a counting time of 30 seconds per well. Competition binding data were analyzed by using the LIGAND program (Munson and Rodbard, LIGAND: A versatile, computerized approach for characterization of ligand-binding systems. Anal. Biochem. 107: 220-239, 1980) and assays were performed in triplicate determinations for each point. Results for representative compounds are given in the table 2 below:
TABLE 2 COMPOUND 5-HT7 IC-50 (nM) 1 70.2 2 28.4 ± 18.2 3 76.4 5 63 6 18.2 ± 3.7 16 36.1 ± 16.0 22 16.8 ± 8.0 23 83.4 | The invention relates to compounds having pharmacological activity towards the 5-HT7 receptor, and more particularly to some some tetrahydroisoquinoline substituted sulfonamide compounds, to processes of preparation of such compounds, to pharmaceutical compositions comprising them, and to their use for the treatment and or prophylaxis of a disease in which 5-HT is involved, such as CNS disorders. | 2 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a method of compensation in thermal recording. More particularly, it relates to a method of performing compensation in thermal recording with thermal recording apparatus by which the unevenness of a recorded image on a film is measured optically and compensated on the basis of the result of measurement.
[0002] Image recording apparatus that perform image recording on recording media with a thermal head are used extensively. In this type of image recording apparatus, a thermal recording material as a recording medium is pressed against a line thermal head having a multiple of heat-generating elements arranged in a 1D direction and as they are individually controlled in accordance with image data, the thermal recording material is transported in a direction perpendicular to the 1D direction, thereby recording the desired 2D gradation image.
[0003] The formation of various gradation images is depicted in FIG. 4A. An image with a gradation (D) of 1 is formed by heating the heat-generating elements for t seconds. An image with D=2 is formed by heating for 2t seconds. Similarly, images with D=3, 4 and 5 are formed by heating for 3t, 4t and 5t seconds.
[0004] As a result, pixels are formed on the thermal recording material and the area of color formation is gradation-dependent within the range of one pixel width in the direction of transport (see FIG. 4B), whereby a gradation image is recorded. While recording is performed by pulse-width modulation in the case under consideration, it should be noted that gradation images can also be recorded by pulse-number modulation in essentially the same manner.
[0005] If image is recorded using image data for the same specified recording density (gradation), so-called shading occurs from the thermal printer as unevenness in the recording density (a problem generally characterized in that image density is the highest in the center area of the thermal head in the direction in which the glaze extends but gradually decreases toward either end). So-called shading compensation is effected in order to correct this unevenness in density that occurs in the above-described type of image recording.
[0006] To perform shading compensation, image is recorded using image data for the same specified recording density and the density of the recorded image is measured optically and on the basis of the measured recording density, shading compensation data are preliminarily computed to enable subsequent compensation of the image data such that the actually recorded image will have a uniform density, and the image data for the recorded image is compensated using the computed shading compensation data.
[0007] Since the problem of shading in the thermal recording apparatus results from the thermal head, the site of occurrence of uneven densities in the recorded image does not change. On the other hand, the intensity of unevenness varies with many factors including the recording density of the image data, the temperature of the thermal head and the speed at which image recording is done (the transport speed of the heat-sensitive material relative to the thermal head) and it has been difficult to compensate shading with high precision.
[0008] This problem was previously addressed by the assignee and a solution has been proposed in Japanese Patent Application No. 8-42969“Thermal Recording Apparatus” (see JP 9-234899 A). Functionally, the proposed technology uses two essential portions, one being a correcting data storage portion which holds image data shading compensation data and weighting functions for weighting the correction coefficients for shading compensation, and the other being an image processing portion which weights the shading compensation data on the basis of the weighting functions, computes the correction coefficients for shading compensation and performs shading compensation on the image data.
[0009] As it turned out, however, this method of shading compensation based on optical measurements involves a new problem. That is, if the recorded image has uneven densities at high frequencies, they cannot be completely followed by the measuring optics and only “dull” results occur.
[0010] If the result of measurement is “dull”, it is clear that no further satisfactory result can be obtained by performing shading compensation on the thermal recording apparatus using the compensation data constructed on the basis of such “dull” result.
[0011] The present invention has been accomplished under these circumstances and its principal object is to improve the method of compensation in thermal recording with thermal recording apparatus of a type that performs optical measurement of the unevenness in the density of a recorded image on a film and which corrects the unevenness of image density on the basis of the result of the measurement. More particularly, the invention provides an improved method of compensation in thermal recording which is adapted to assure satisfactory compensation for uneven densities that occur at high frequencies in the thermal recording apparatus.
SUMMARY OF THE INVENTION
[0012] In order to attain the object described above, the present invention provides a method of compensation in thermal recording comprising the steps of: performing photoelectric reading of a recorded image on a thermal recording material to construct unevenness data; and using the unevenness data to perform unevenness compensation, wherein the unevenness data constructed by the photoelectric reading is used in the unevenness compensation after the unevenness data is subjected to filtering for frequency enhancement.
[0013] Preferably, the filtering for the frequency enhancement of the unevenness data is such that.
[0014] Preferably, the filtering for the frequency enhancement of the unevenness data is such that low-frequency component of the unevenness data is left as it is but high-frequency component of the unevenness data is enhanced and linear interpolation in a degree of the frequency enhancement in accordance with a frequency is effected between the low-frequency component and the high-frequency component.
[0015] Preferably, the filtering for the frequency enhancement of the unevenness data is performed by mathematical operations on digital data.
[0016] Preferably, the unevenness data is constructed by performing the photoelectric reading of the recorded image in which the thermal recording is performed on the thermal recording material using image data for an identical specified recording density.
[0017] Preferably, the unevenness compensation is shading compensation.
[0018] In order to attain the object described above, the present invention provides a method of compensation in thermal recording comprising the steps of: performing the thermal recording on a thermal recording material using image data representing an image having a uniform density; performing photoelectric reading of a recorded image on the thermal recording material to construct unevenness data; subjecting the unevenness data to filtering for frequency enhancement; and using the unevenness data subjected to the filtering to perform unevenness compensation of a thermal recording image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a process flowchart for an exemplary method of compensation in thermal recording according to the invention;
[0020] [0020]FIG. 2 shows schematically the construction of a recording section which is the essential part of a thermal recording apparatus which implements the method of the invention for compensation in thermal recording;
[0021] [0021]FIG. 3A is a diagram showing how data for a recorded image has become dull in the process of readout;
[0022] [0022]FIG. 3B is a diagram showing the original readout data;
[0023] [0023]FIG. 3C is a diagram showing the result of correcting the data in FIG. 3A by the method of the invention;
[0024] [0024]FIG. 4A illustrates drive signals for performing the conventional method of compensation by pulse-width modulation; and
[0025] [0025]FIG. 4B illustrates the pixels formed by application of those drive signals.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] A preferred embodiment of the present invention is described below in detail with reference to accompanying FIGS. 1 - 3 . The following description is directed to a case where the concept of the invention is applied to a thermal recording apparatus which performs thermal recording on a thermal film.
[0027] The thermal recording apparatus which implements the compensation method of the invention according to its preferred embodiment uses a thermal film F having a heat-sensitive recording layer formed on one side of a transparent base such as a transparent polyethylene terephthalate (PET) film. The apparatus consists basically of a loading section where a magazine containing a plurality of thermal films F is loaded, a feed/transport section which picks up one thermal film F from the magazine in the loading section and transports it to a recording section which performs thermal recording on the transfer film F by means of a thermal head to be described later, and an ejecting section through which the thermal film F with a recorded image is ejected to the outside of the apparatus.
[0028] The loading section has basically an inlet through which the magazine containing a plurality of thermal films A is inserted into the recording apparatus and a magazine guide mechanism. The feed/transport section takes thermal films F one by one out of the magazine in the loading section by such means as a sheet feeding mechanism using a sucker and sends each thermal film F to the recording section by the transport means.
[0029] The recording section is composed of a cleaning roller pair, a thermal head, and a platen roller and associated transport means (i.e., roller pairs and guides). As the platen roller rotates at a specified image recording speed while holding the thermal film F in a specified orientation, said thermal film F is transported in a so-called auxiliary scanning direction and subjected to image recording with the thermal head.
[0030] [0030]FIG. 2 shows the general layout of the recording section. The illustrated recording section 20 comprises basically a thermal head 32 , a platen roller 26 , a cleaning roller pair 22 , guides 24 and 28 and a transport roller pair 30 . The thermal head 32 is capable of thermal recording at a recording (pixel) density of, say, about 300 dpi on thermal films of, for example, up to B4 size. The thermal head 32 comprises a body 32 b having a glaze in which a multiple of heat-generating elements arranged in one direction (normal to the paper on which FIG. 2 is drawn) to effect thermal recording for one line, and a heat sink 32 c fixed to the body 32 b . The thermal head 32 is supported on a support member 34 that can pivot about a fulcrum 34 a either in the direction of arrow a or in the reverse direction.
[0031] As already mentioned, the platen roller 26 rotates at a specified image recording speed while holding the thermal film F in a specified orientation so that it is transported in a so-called auxiliary scanning direction (generally perpendicular to the direction in which the glaze extends). The cleaning roller pair 22 consists of an adhesive rubber roller 22 a and a non-adhesive roller 22 b.
[0032] Having described its layout, we now describe the recording operation of the thermal recording apparatus in the preferred embodiment. When a command for record START is issued, the thermal film F is taken out of the magazine and transported toward the recording section by the transport means until it reaches a regulating roller pair (not shown) provided just upstream of the cleaning roller pair 22 . At the regulating roller pair, the thermal film F stays for a moment and the temperature of thermal head 32 is checked. If it has reached a specified level, the thermal film F starts again to be transported by the regulating roller pair and moves into the recording section 20 .
[0033] Initially (before transport of the thermal head F starts), the support member 34 has pivoted to UP position (in the direction opposite to the direction of arrow a) so that the glaze 32 a of the thermal head 32 is not in contact with the platen roller 26 . When its transport by the regulating roller pair starts, the thermal film F is first pinched by the cleaning roller pair 22 and transported as it is guided by the guide 24 .
[0034] When the forward end of the thermal film F has reached the record START position (corresponding to the glaze 32 a of the thermal head 32 ), the support member 34 pivots in the direction of arrow a and the thermal film F becomes pinched between the glaze 32 a and the platen roller 26 such that the glaze 32 a is pressed onto the heat-sensitive recording layer of the thermal film F. Then, as already mentioned, the thermal film F is transported in the direction of arrow b by means of the platen roller 26 , the regulating roller pair, the transport roller pair 30 , etc. as it is held in a specified orientation by the platen roller 26 .
[0035] During this transport, the respective heat-generating elements in the glaze 32 a are heated in accordance with the data for the image to be recorded, thereby performing thermal recording on the thermal film F. In the embodiment under consideration, control of thermal recording in accordance with this image data involves shading compensation as outlined below with reference to the process flowchart shown in FIG. 1.
[0036] To begin with, thermal recording is performed with the thermal head 32 using image data representing the original image having a uniform density, that is, image data for an identical specified recording density (step 11 ). The density of the recorded image is measured with an optical instrument (step 12 ). The measured data is compensated by a predetermined filtering process (step 13 ).
[0037] In step 11 , thermal recording is performed with the thermal head 32 by an ordinary method. In step 12 , the density of the recorded image may be measured with a sensor comprising a light emitter in combination with a light receiver and the value of the resulting photocurrent is A/D converted to obtain digital readout data.
[0038] For the sake of convenience in explanation, an example of the result of density measurement in step 12 is shown in FIG. 3A as an analog value before A/D conversion. As already mentioned, the problem here with the result of density measurement is that its high-frequency component has been measured in a “dull” state.
[0039] Even if the actual recorded image as measured for density should provide the result shown in FIG. 3B, the result of an ordinary optical measurement is affected by several undesired phenomena such as the spread of reading light to produce so-called “dull” data as shown in FIG. 3A. In an extreme case, the degree of dullness is such that the peak value is reduced to about one half of what it should be.
[0040] To deal with this problem, the dull result of measurement has to be brought back to the initial state by performing the filtering process in step 13 (see FIG. 1). In the embodiment under consideration, the correct result of measurement is obtained by applying a predetermined digital filter to the result of A/D conversion and performing appropriate multiplications and additions.
[0041] Without dullness, the result of measurement should have been as shown in FIG. 3B but as it turned out, the actual result was “dull” as shown in FIG. 3A. In a case like this, the data shown in FIG. 3A is subjected to A/D conversion and a digital filter (0.0, −0.5, 2.0, −0.5, 0.0) is applied to the resulting digital data, whereby the data can be corrected as shown in FIG. 3C.
[0042] Needless to say, “2.0” in the digital filter corresponds to the peak value of the data shown in FIG. 3A. In the embodiment under consideration, the digital filter has the values 0.0, −0.5, 2.0, −0.5, 0.0. In principle, the values of the digital filter can appropriately be chosen from tables consisting of frequency-dependent settings.
[0043] To be more specific, the digital filter leaves low-frequency image data (low-frequency component of the digital readout data) as such whereas it enhances high-frequency image data (high-frequency component of the digital readout data). Intermediate image data between the low-frequency image data and the high-frequency image data is preferably processed by linear interpolation in a degree (level) of the frequency enhancement according to the frequency of the digital readout image data (in a frequency-dependent manner).
[0044] Described above is just one example of the configuration of the digital filter. Specific values of the digital filter may be determined on a trial-and-error basis. Alternatively, generalized or representative values may be chosen from the accumulation of the results of past measurements.
[0045] The foregoing embodiment has the advantage that even if data for a recorded image are measured with the high-frequency component becoming “dull” as shown in FIG. 3A due, for example, the spread of reading light, such “dull” data can be corrected to a state almost like the original data.
[0046] While the present invention has been described above with reference to the preferred embodiment, it should be understood that this is not the sole case of the invention and various improvements and modifications may of course be made without departing from the spirit and scope of the invention.
[0047] For instance, the aforementioned control of thermal recording in accordance with the data for the image to be recorded may include the various, image recording speed-dependent, control operations that are disclosed in commonly assigned JP 11-320933 A “Thermal Recording Apparatus”, for example, controlling the supply voltage to the thermal head, controlling the pressing force of the thermal head, controlling the position at which the thermal head is pressed, and controlling the number of groups into which the heat-generating elements to be energized are divided.
[0048] As described above in detail, the present inventions offers the advantage that it can realize a method of compensation in thermal recording which is adapted to assure satisfactory compensation for uneven densities that occur at high frequencies in the thermal recording apparatus.
[0049] Specifically, the invention offers the following practical advantage: the density of a recorded image is measured optically and the result is subjected to A/D conversion, followed by application of a digital filter to revert the dull portion of the digital data to the original state, thereby realizing correct shading compensation. | The thermal recording compensation method performs photoelectric reading of a recorded image on a thermal recording material to construct unevenness data and uses the unevenness data to perform unevenness compensation. The unevenness data constructed by said photoelectric reading is used in the unevenness compensation after the unevenness data is subjected to filtering for frequency enhancement. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of plant control and management information systems, and in particular to an integrated plant monitoring and diagnostic system for shared use by the operations, maintenance and engineering departments of a nuclear power plant. The system collects and monitors operating parameter data via sensors, generates prioritized condition reports including present conditions and anticipated impending conditions to be addressed by preventive maintenance or operational changes, and provides users with background technical and historical data that is ranked and cross referenced by related operational systems and related articles of equipment.
2. Prior Art
Various management information systems are known for monitoring and recording process parameters in connection with power generation as well as with industrial processes generally. These systems often are reactive in that they respond to present levels of monitored parameters, or at most respond to present trends to control generation of alarms and the like when a parameter exceeds preset values or threatens to do so. A typical process control system monitors sensed parameters to ensure that they remain within preset limits defined by the programmer of the system. Often the present levels can be displayed graphically to highlight trends.
Another form of management information system is known in connection with scheduling of maintenance procedures. By defining a useful life for each article of equipment among a number of articles which are related or inter-dependent, it is possible to schedule repair, replacement or preventive maintenance operations more efficiently so as to minimize downtime. The idea is to plan replacement or repair of articles of equipment for as late as practicable before an actual failure, preferably using intelligent scheduling procedures to minimize downtime by taking maximum advantage of any downtime. The scheduling system prompts or warns plant personnel to attend to each of the articles which may need attention at or soon after the time at which the maintenance of any particular article becomes critically important.
U.S. Pat. No. 4,908,775--Palusamy et al discloses a cyclic monitoring system which counts down a defined useful life expected for various structures in a nuclear power plant. This system is responsive to operating levels in the plant, and increases the predicted aging rate of plant structures to account for variations in usage including transient loading. A sampling module is provided to detect the current loading of monitored equipment periodically. Transient and steady state operating levels are determined from the sampled data and used to generate a usage factor. Equipment degradation due to fatigue and the like is anticipated by integrating the usage factor over time. Whereas operating levels and transient disturbances are taken into account in assessing the wear on plant equipment, the system can be used to plan maintenance and replacement activities or alternative plant operations, using a more accurate estimation of the useful life of the plant components.
The predictive maintenance system according to Palusamy '775 incorporates both operational data and a defined useful life data indexed to articles of equipment. However, the system is such that it primarily serves only maintenance functions. It would be advantageous to provide a system that benefits operational and engineering departments as well. The present invention is intended to accomplish this by integrating not only information regarding usage and expected useful life, but by further integrating design and technical specifications and historical data into a system that monitors operational levels as well as equipment conditions. This data is provided in a hierarchical data acquisition and processing system providing shared access by the different departments, especially operations, maintenance and engineering. The data is arranged and cross referenced for presentation of meaningful reports for each of the departments.
Nuclear reactors for generation of electric power are heavily instrumented to enable efficient plant operation and to ensure safety. U.S. Pat. No. 4,961,898 Bogard et al discloses a system operable to record and report neutron emission levels in and around the reactor as well as pressure and flow parameters, for accurately assessing the accumulation of stress on the operating structures. U.S. Pat. No. 4,935,195--Palusamy et al similarly attempts to factor corrosion of the coolant flow path structures for assessing the useful life of reactor components.
Typically, monitoring equipment for a nuclear power plant or similar process is associated specifically with a particular structure or operating system of the plant. For example, in Bogard et al the monitoring system is specifically associated with coolant flow structures. In Palusamy '195 the monitoring system is associated with the neutron emissions. For the most part, monitoring systems of this type are dedicated either to safety purposes (e.g., to detect an unsafe condition and to shut down and/or generate alarms automatically), or to operational control (e.g., to control the positions of valves and the like during ongoing plant operation). Routines which accumulate a usage factor for assessing the loading factor on a particular subsystem could use much of the same data which is collected by safety and control instrumentation. However, the prior art fails to provide a fully integrated system that can take full advantage of the available instrumentation.
It would be advantageous to provide such an integrated system which not only monitors various articles of plant equipment, but which also accounts for the interdependence of the subsystems, makes decisions or predictions in view of stored design criteria, and makes all this information available generally to plant personnel. In specifying the subsystems, design criteria and technical specifications were merged under the assumption that the subsystems would operate under certain conditions. Operational conditions such as equipment problems can change the loading level for a given article of equipment or subsystem, and also the loading levels of other articles and subsystems that are related to or interdependent with the given ones. Therefore, the interrelations of the articles or subsystems, their design specifications, their history and their current conditions should all be taken in account when assessing operational conditions and maintenance needs, or when evaluating operations on an engineering level.
It is generally advisable for plant management and/or maintenance personnel to collect any available data regarding the subsystems operating in a plant or in an area of the plant, to coordinate maintenance and repair activities. In this manner, a downtime for work on one or more articles or subsystems can be used for simultaneous work on others. However, a comprehensive calculation and analysis of relevant plant conditions can be lengthy and costly. In a monitoring system where information on operational conditions is only immediately available to the operators (e.g., for safety and/or control purposes), engineers, scientists, maintenance technicians, managers and headquarters staff must collect and analyze much of the same information in planning their activities. Each group tends to collect and analyze data in a manner that is best suited to their own area of concern. Nevertheless, an integrated arrangement is certainly more efficient and useful than one in which the various departments operate substantially independent information systems.
The present invention is intended to integrate diagnostic and predictive instrumentation for a number of interdependent plant systems, for taking advantage of available synergies. Furthermore, safety and control parameters are collected using a data network arrangement that is shared by primary and auxiliary system control and protection groups, plant maintenance groups, plant engineering and management. In order to accomplish this objective, the plant computerized information system is integrated generally with instrument data collection from a variety of sources, and stored design criteria information. The operational parameters are factored together in an integrated diagnostics and monitoring system with technical specifications for condition directed maintenance and aging management. Specific, actionable diagnostic information on equipment condition is developed, including cross referenced selection of background technical data, whereby operations and maintenance decisions can be made more effectively and from a greater base of knowledge.
The diagnostics and maintenance arrangement according to the invention puts control and safety parameter information to use by the engineering and maintenance departments rather than only the operations control personnel. Conversely, the system makes maintenance and engineering information available to operations and safety groups, thus providing various useful lines of communication and data access availability.
SUMMARY OF THE INVENTION
It is an object of the invention to integrate operational parameter data collection, evaluation based on stored design criteria, and plant information reporting, in a comprehensive plant information system useful for planning operational and maintenance decisions.
It is another object of the invention to make pertinent information readily available for use not only by plant operators, but also generally by engineers, scientists, maintenance technicians, managers and headquarters staff.
It is more particularly an object to collect a wide array of information respecting the character and operational conditions of functionally interdependent elements of a nuclear power generation plant, including design criteria applicable to the elements, and to process this information using intelligent monitoring and diagnostic routines that model operation of the plant to anticipate problems and enable efficient planning of operations and maintenance.
It is another object of the invention to define the overall architecture and operation of a plant information system according to these objects, which is best suited to take advantage of technology advancements as well as available data collection devices, processing apparatus, degradation types and diagnostic methodologies.
These and other objects are accomplished by an integrated information system for a plant with interactive processes running in functional equipment subsets, such as a nuclear power generation plant. Sensors are operatively coupled to monitor processes and equipment in the plant, collecting sample data for assessing operational conditions and for predicting maintenance requirements based on loading of the equipment. A processor accesses the sample data and compares present conditions to diagnostic specifications, technical specifications and historical data stored in memory and indexed to equipment subsets and functional operating groups. The processor generates prioritized reports to alert users to potential operational and/or maintenance problems. In addition to the prioritized reports, the processor accesses and outputs to the users reports of the diagnostic and technical specifications applicable to the process parameters exhibiting the potential problems. These specifications are provided in successive levels of detail and are cross referenced between related processes and related items of equipment. The information system integrates operations, maintenance, engineering and management interests in a common database of information via network-coupled data terminals.
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the specific examples, and is capable of variations within the scope of the appended claims. In the drawings,
FIG. 1 is a block diagram illustrating generally a plant information system integrating operation, control, protection, engineering and maintenance information according to the invention.
FIG. 2 is a block diagram of the invention showing modular elements of the invention and the data collection and communication links between the elements.
FIG. 3 is a plan view showing a layout for the data processing portions of the system.
FIG. 4 is a schematic illustration of data pathways for monitoring and control functions.
FIG. 5 is a schematic illustration of a networked installation of terminals sharing access to commonly collected and stored information.
FIG. 6 is a tabular display of actionable directives generated by a preferred embodiment in response to detected conditions.
FIG. 7 is a tabular display of exemplary cross referenced technical specifications referring to certain of the directives provided in FIG. 6.
FIG. 8 is a schematic illustration of an exemplary system architecture according to the invention, as applied to a nuclear power generation plant.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is applicable to a variety of industrial processes wherein data respecting process parameters is collected and reported to enable management decision making. A particularly apt application of the invention is to a nuclear power generation plant. A nuclear plant is normally highly instrumented for collecting information needed to operate at peak efficiency, as well as to tightly monitor operation for safety reasons. The signals developed by sensors for flow, temperature, pressure, valve status, nuclear particle flux levels and the like are to some extent coupled into operational circuits which are intended to effect control operations. According to the invention, sensor signals are coupled to a plant instrumentation control and monitoring center 20 that as shown in FIG. 1 is further coupled to a predictive maintenance and diagnostic center 24.
Information required for pertinent diagnostic information according to the invention includes design criteria applicable to the plant. For example, should a certain valve, flow element, heat transfer device or rotating machine be specified as having an estimated useful life when operated at a particular level of demand, pertinent diagnosis of the element requires that the remaining useful life be decremented as a function of the demand level. Accordingly, the predictive maintenance and diagnostic center is coupled to a diagnostic information center which makes such information available. In the embodiment shown in FIG. 1, the information center 20 is shown as a separate location in data communication with the plant-located predictive maintenance and diagnostic center 24. This is an efficient arrangement where the utility company may have a number of plants which share design aspects. However, the particular location of the respective data storage and computing systems can be varied provided the information is available to each of the processors which need the information.
Referring to FIG. 2, plant operational functions, maintenance functions and engineering functions are all integrated to a common network of information stored, collected and otherwise developed according to the invention. Both operational and safety related sensing and information collection are provided, and made available generally to operations, maintenance and engineering stations and/or users. The system can be physically arranged in a control center setup as shown, for example in FIG. 3, or can be accessed from distributed terminals in various areas of the plant or located remotely as in FIG. 4.
As shown in FIG. 2, the system preferably is based on a hierarchical system of data paths, including interconnections that allow data access without interfering with crucial operations. Safety related sensors 32 coupled to the plant operational elements 34 are sampled using a protective data acquisition system 42 and a control data acquisition system 44, which are separate and parallel. A process protection system 46 and operation control system 48 are coupled respectively to the protective and control data acquisition systems 42, 44. These elements are subject to certain inputs from the primary control and protection station(s) coupled to the protection and control systems through an integrated control system forming a kind of bus wherein operational and safety associated parameters are available to both the control and protection systems. However, the control and protection systems have a number of automatic aspects intended to control the plant to achieve process objectives such as efficient complementary setting of valves and the like as well as the capability of automated shutdown without operator intervention in the event of a safety threat.
Sensors 50 which are not directly safety related (but whose data may have implications with respect to operations, safety and control), are coupled to respective data processing units 54, which are coupled to data acquisition means 56 for collecting and reducing the data. The data processing units can collect sample data from one or a plurality of sensors 32, 50, reject data which is impossibly out of limits, and attend to numerical and/or graphical analyses such as average and standard deviation, peak level identification and the like. Data collected from the nonsafety related sensors 50 can be shared over a distributed processing communication path 58 such as the Westinghouse WDPF distributed processing family. In addition, the data processing units 54 are in communication with a number of monitoring systems 62 over the WDPF data pathway 58. Monitoring systems 62 selectively process available data in order to effect specific functions.
Proceeding from left to right over the WDPF 58 in FIG. 2, an interface or bridge element 64 couples the integrated safety/control system data pathway 66 with the WDPF data pathway 58. The bridge 64 permits data to pass between the integrated safety/control pathway 66 and the WDPF 58 in either direction, but is arranged to allow the integrated safety/control system bus 66 to operate regardless of the condition of the WDPF 58. For example, a failure of an element associated with the WDPF such as a power supply, data processing unit or even a line driver or similar element required for operation of the WDPF, cannot affect operation of the integrated safety/control system due to its isolation via the bridge interfacing element 64.
An auxiliary system control unit 68 is also coupled to the WDPF 58, enabling plant operations personnel to monitor data collected over the WDPF and preferably to control operation of the data processing units 54 from plant operations consoles 72. The auxiliary system control unit 68 is coupled to the data processing units 54 (and thus to the non-safety sensors 50) relatively directly through the WDPF 58. The WDPF data pathway is arranged for communication of data from the sensors 50, 32 to plant operations such that individual variables can be examined. However, in addition, the WDPF data is coupled through the intermediate processing systems 62 to a higher level data pathway identified in FIG. 2 as information highway 78. These intermediate processing systems 62 permit the application of higher level long and short term analysis for converting, e.g., a substantially database form of data collected by the data processing units 54 into more sophisticated statistical analyses, trend analyses and correlations that additionally use data stored in the respective intermediate processing systems 62. The modules of the intermediate processing systems 62 report to any and all of the plant operations consoles, plant maintenance personnel and plant engineering personnel. The same information highway 78 can be coupled to additional users via known networking arrangements, telephone line modem pathways and the like.
The intermediate modules 62 represent systems that can be arranged as processing terminals on a data communication network or concurrently operative routines in a larger and more sophisticated data processing system. The function of the intermediate processing units 62 is to select and analyze data available in a relatively less processed form on the WDPF 58, and to provide information which relies on the values and trends identified in the individual process parameters and in selected groups of related parameters. The output of the intermediate modules 62 is reported to users via diagnostic packages 82 tailored to the needs of the operations, maintenance and engineering departments, respectively. A given department such as maintenance or operations normally at least sometimes requires information from different ones of the intermediate modules 62, and the departments thus share the information relating to the process parameters.
A first intermediate processing module, identified in FIG. 2 as the beacon module 84, is arranged to monitor and report present operating parameters. Present operating parameter information affects not only operations decisions, but also is pertinent to maintenance (e.g., whether a subsystem is in use or available for mechanical work, whether a subsystem is being stressed, etc.). The same information is useful to engineering (e.g., to study the overall condition of the plant or interactions between process parameters). An operator diagnostic advisory unit 86 is coupled to the information highway for the primary purpose of collecting and usefully analyzing, storing and reporting upon operations. The operator diagnostic unit 86 can be arranged to run constantly, reporting information respecting diagnostic information and recommending or suggesting operational changes that may affect or alleviate operational problems or potential problems which may occur.
In addition to the beacon intermediate monitoring system 84 and the operations diagnostic unit 86, a corrosion monitoring system 88, a generator monitoring system ("GENAID") 90 and a transient/fatigue cycle monitoring system ("CMS") 92 operate to selectively analyze data collected by the data processing units and made available as process parameter data over the data highway. This information is also potentially useful in connection with operations, maintenance and engineering decisions. The intermediate processing units 62 are devoted to certain aspects of tasks which affect decisions in all these departments, but are organized in a manner that is not limited to one department. Instead, each of the intermediate processing units serves a particular data set. The data needed by the intermediate processing modules 62 may overlap with data needed by others of the intermediate processing modules, and preferably is broken down into the beacon 84 for present operational conditions, corrosion monitoring 88 for long term deterioration due to ambient conditions such as radiation and chemical conditions, generator analysis (GENAID) 90 for thermodynamic and coolant flow analysis, and transient pressure and flow variation monitoring 92, to assess fatigue.
A predictive maintenance and diagnostic unit 102 is also coupled to the information highway 78, for diagnosing and reporting maintenance problems, and a series of engineering diagnostic units 104 are included. The maintenance diagnostic system 102 is preferably organized in a manner that is most meaningful to maintenance personnel, for example referring to individual pieces of plant equipment instead of functional aspects of the process. However, the maintenance diagnostics are preferably arranged to group devices whose operation has an impact on other devices according to functional groupings as well. Preferably, the plant maintenance diagnostic systems are grouped to provide for analysis of categories such as mechanical devices including valves, rotating machines and the like (which may be subject to frictional problems), and pressure/flow conduits (for corrosion/erosion problems).
Similarly, the plant engineering departments use the information available on the information highway 78, as collected by the data processing units 54 and reduced by the intermediate processors 62. A variety of engineering and diagnostic routines 104 are preferably included, for example grouped for residual coolant system diagnosis, transient diagnosis of pressure, flow and/or electrical loading, generator diagnosis and chemical/nuclear diagnosis. These diagnostic processes are related to operational parameters (like the plant operations diagnostics) and also t specific apparatus (like the maintenance diagnostics), and are presented in a format which is tailored to engineering planning as opposed to operations or maintenance procedures.
A major benefit of integrating data collection and reporting according to the invention is that data need not be collected and analyzed redundantly. Nevertheless, the users of the system can retain the benefit of graphic user interfaces with which users may already using (e.g., in connection with analysis of the operation of subsystems having dedicated monitoring systems.). Although the data collection is common to each of the plant departments, specialized mathematical models, xpert "intelligent" analysis and neural networking are readily achieved.
The invention is particularly applicable to operational, maintenance and engineering functions in a nuclear power plant. Such a plant has a variety of apparatus which can be grouped functionally, and which affect one another in the operational and maintenance procedures and decisions undertaken in the plant. A key input to any decision related to life extension of a nuclear plant is the condition of the plant systems and components critical to the safe, reliable and economical operation of that plant. This means not only the current condition, but the condition predicted throughout the remainder of the plant operation. To establish this effectively, at least two things are needed:
Data on critical parameters related to equipment condition; and,
Engineering decision making capability in terms of evaluating available data, namely extraction, saving and use of monitored data to determine current conditions as well as to predict future conditions and make recommendations on actions needed to attain plant objectives.
Certain applications benefit from simply adding raw data to meet the first requirement. However a typical nuclear plant has extensive existing instrumentation providing abundant data. What is more lacking is an optimal means cohesively to use that data for the second requirement, i.e., engineering decision making. The emphasis in the data interface packages developed for nuclear power plants has been an the needs of the operator and his minute-by-minute needs for operations decisions.
The second requirement is met according to the invention by:
Accessing and supplementing the available plant data;
Establishing evaluation objectives (critical components, associated measures of degradation, criteria and limits, etc.); and,
Implementing a capability to evaluate the data and make recommendations.
Of course the system of diagnostics and monitoring must be cost justified. The relative costs of various maintenance approaches (corrective, preventive, predictive) over the plant life are such that a factor of two improvement in cost can be achieved by using a predictive approach to maintenance instead of traditional approaches.
It is an aspect of the invention that the diagnostic and monitoring functions are integrated, for example into a plant process computer and instrumentation system architecture. In this sense, the plant process computer can include one processor or any number of processors in data communication, for example over the network communication paths described. The architecture of the invention relates to the arrangements and interconnections which link inputs to the process, the defined or required characteristics of the process itself, and the resulting outputs from the process. For the case of a nuclear plant diagnostics and monitoring system, the types of data needed include process parameters, control and response data, and preferably accumulated historical data. This information is obtained from plant instrumentation, distributed plant computer systems, additional sensors which may be unrelated to safety and control systems, test and performance data (whether measured, stored from previous measurements or specified for the equipment) and mainframe data storage. Such data may be stored as to any appropriate frequency of measurement, from milliseconds to years, and may be reduced into the form of average and standard deviation over selected periods or may include raw samples.
The type of available data and the required output define the type and frequency of data processing steps needed to convert the available data into meaningful presentations, and to sift through the available data to detect conditions which should generate a diagnostic warning. One or more processors associated with the hierarchy provide the data processing power and data storage capabilities needed to effect timely calculations on a real-time, automated periodic and/or on-demand basis.
The calculations undertaken by the processor(s) are of the type used in monitoring subsystems for the respective plant components; however, according to the invention the calculations are not limited to input based upon current parameter values in an isolated subsystem. Accordingly, diagnostic routines applicable to a subsystem, as undertaken by the integrated diagnostic and monitoring system, are affected by the conditions in related subsystems. The specific calculations can be mathematical algorithms, logical rule based (as in fuzzy logic) or neural network processes involving a multidimensional chain of calculations and decisions. The calculations can also include statistical analyses and database management type processes.
Output data is to be used to alert operators to conditions which may become critical shortly or not for a long time, and preferably also enable general monitoring as to what is going on in the plant. Accordingly, the output is preferably generated in forms including on-screen graphic and tabular data displays, storage of data on disk, tape or hardcopy, as well as audio and/or video signalling. In addition to selection of data from the inputs or from first or second level information generated from the inputs, the output data includes diagnostic information for monitored devices and subsystems, recommendations for action which are selected based on the diagnostic information and plant conditions, and additional backup information about the devices and subsystems (such as their physical characteristics, ratings and the like), from which the operators can discern the basis of the diagnosis and recommendations.
The users of the output generated by the system include most types of plant personnel. General categories of users include the operations support staff, maintenance, engineering and scientific staff, and plant management. Outside of the plant, headquarters engineering and management staff preferably have access to the data, and it is even possible to allow vendors access in order to enable them to assess the conditions under which requested equipment is to operate, or to assess the present conditions applicable to equipment already supplied. Under such conditions the vendors may be aware of an aspect of the equipment that should be made known for diagnostic purposes.
Insofar as users remote from the processor generating the output data may be coupled to the processor, various high speed and low speed data communications links can be employed. Such users may be on-site or off-site, and are coupled in data communication with the processor by hardwire, modem, radio or fiber optic links, as required in view of the data capacity needed.
For output and display, utility personnel need specific diagnoses of critical aspects of plant condition. According to the invention, such critical aspects are ranked and prioritized in a tabular display 110 from which the user can select further information on the diagnosis, the recommended corrected action, and background information on the affected structural elements and/or plant subsystems. The current status of the plant must always be available and easily accessible. A sample of a tabular display of diagnostic considerations in summary form appears in FIG. 5.
In the example shown, there are a number of conditions 114 rated by priorities 116. The list includes conditions which represent reactor status or operational information, and some suggesting a need for maintenance. Based on preprogrammed relationships between components of the plant, operations and maintenance personnel can react as appropriate. FIGS. 6 and 7 are examples of backup information respecting the items mentioned in the diagnostic summary. In the example, a valve identified as 8701A is described as having an incorrect stem packing tightness. Based only on the information on the summary, the implications of incorrect stem packing tightness in the particular valve may be unclear. However, the diagnostics summary 110 is a gateway to additional information describing the valve, and in fact also includes reactor operational information which likewise identifies the valve as an element in need of attention.
Item 2 on the diagnostics summary states that thermal stratification in the residual heat removal (RHR) system exceeds level 1 limits, level 1 being a minimum warning threshold. By selecting item 2, the operator is provided with background information 120 on RHR thermal stratification conditions. The backup information as shown in FIG. 6, includes a longer explanation 124 of the problem, a description 126 of the consequences of inaction, and recommendations 128 for activities which may fix the problem. In the example, the explanation identifies valve 8701A as the likely culprit, suggesting that the valve may be leaking. In conjunction with the diagnostics summary, the user is led immediately to the cause of the problem and can readily assess the severity thereof.
The residual heat removal system is an operating subset of the reactor, and preferably a series of tabular, graphic and text screens can be selected by paging through the respective levels of diagnosis. FIG. 7 illustrates further informational screens 130 under the groupings of RHR Stratification Status, and also Valve Monitoring Status, which are alternative cross referenced paths leading to a resolution of the problem shown in the summary 110. The screens applicable to RHR Stratification include the subject valve, and the screens relating to valve monitoring mention the function of the subject valve. By proceeding through the screens and selecting cross referenced information it is possible to obtain a full picture of the situation.
Preferably, the diagnostic system includes means 132 for the user to acknowledge receipt of the recommendation. In this manner the system ensures that appropriate attention is paid by those people who can act on the recommendation, and one person does not assume that another is taking responsibility for attending to the recommendation. Acknowledgement, as well as moving between screens, can be effected using any convenient input means such as a keyboard, mouse, touch sensitive screen input or the like.
According to the invention, the recommendation reported to the responsible parties, permits access to detailed component data, historical operations and maintenance information, and other data that is readily accumulated due to the integration of the system. Any data that is helpful or necessary to effectively interpret the recommendation, to plan an implementation, and to interact with other affected plant groups can be included.
FIGS. 5-7, as an integrated whole, illustrate a graphic interface useful to plant users which enable the user to evaluate and act on a particular diagnosis at progressively deeper information levels, and with respect to cross referencing between component groupings and between operational and maintenance considerations. The example discussed above with respect to the RHR Stratification relates to diagnostic and monitoring functions. It will be appreciated that cross references between operational or maintenance functions and those of engineering or management can be organized in a similar manner. The specific calculations necessary to obtain the required output, and the required input to derive the calculations, are apparent to those skilled in the art.
The integrated input, output and display particulars useful to various plant and utility technical and managerial groups, are similar to an operational control center, and the predictive maintenance and diagnostic center of the invention uses an operational or control center approach to meet the needs of engineering, and operations and maintenance personnel. A difference is that the operational or control center for maintenance and diagnostics is linked not only to a wide variety of process inputs and sets of data generated from process inputs, but is also linked to information defining the plant and the design characteristics of the apparatus and processes employed in the plant. This linking is accomplished though the predictive maintenance and diagnostic routines that are integrated into the system as a whole.
The plant maintenance and diagnostic system can have a physical control center 150, as shown in FIG. 3, or the functions can be provided over a distributed network 154 as suggested by FIG. 4. An appropriate control center 150, for example, has a console 156 that displays current condition diagnoses, and has available recommendations and summary backup data. For increased flexibility, a distributed control embodiment includes individual terminals 158 (e.g., workstations or PC's) which can all access this data, or alternatively are devoted to analyzing specific degradations or diagnostics of specific components. Depending on need, certain networked stations can operate in a combination real-time and multi-tasking mode, in which data acquisition and report/diagnosis processing are divided into foreground and background processes. Certain such terminals can be set up to periodically process data, to process data on user demand, or to trigger processing based on the occurrence of some event.
A plant maintenance workstation 162 can also be located at or accessible as part of the plant maintenance and diagnostic system. Information developed from diagnostic functions is then used as a part of the overall plant maintenance planning and scheduling functions, as well as outage planning.
In data evaluation the specification of actual diagnostic calculations is undertaken, to provide the information required by plant decision makers. Factors affecting design of this part of the system include frequency of calculations to be performed, and the types of calculations themselves. For example, on demand requests for calculational updates may be appropriate for degradations that change slowly, such as fatigue accumulation. In other cases calculations may be run continuously, for example to assess the potentially rapid degradation of a piece of rotating equipment when oil flow is cut off.
Types of calculations can also vary widely. In some cases simple algorithmic calculations are performed on the input parameters directly; in others data transforms may be needed, either custom-made for a particular application, or with standard techniques such as various types of signal analysis. Finally, many diagnostic applications are well suited to artificial intelligence based calculational strategies, from simple rule-based methods for diagnosis of specific conditions, to more complex schemes based on neural networks typically applied to complex pattern recognition in signal analysis.
A comprehensive, functionally complete data acquisition capability for diagnostics and monitoring needs can rely in large part on the data obtainable from the plant process computer 170, shown in FIG. 8. The accessibility of this data for diagnostic purposes increases markedly when a plant computer upgrade, preferably using a data highway type setup, is implemented. With such an arrangement, it becomes possible to pass specific types of data at desired frequencies to numerous applications, simply by setting up a data transfer file and a node on the network. This eliminates difficulties in trying to access the signal output directly from the sensor, or trying to add a large number of wires to the process protection racks or plant computer, as had been done in the past. Such restrictions limited the potential applications and usability of the plant process computer data for uses other than operations and control.
Potential benefits of additional monitoring may justify the addition of sensors beyond the usual operational sensors in communication with the plant process computer. Data also may be needed at more frequent intervals than is typically provided for the plant process computer. In such cases, the number of containment penetrations available can become a limiting factor in the ability to add sensors. A highway concept as shown in FIGS. 2, 4 and 8 makes maximum use of existing sensors and decreases the need for adding containment penetrations. The sensors can be coupled to communicate directly with the PMDC 24 for use in diagnostic applications. In addition or instead, the raw analog signal data provided by the sensor 32, 50 can be processed, by such techniques as Fourier Analysis, and the resulting processed signal can be provided to the data highway.
Another method of data acquisition used at plants because of its cost effectiveness when data needs only to be obtained at infrequent intervals such as quarterly, or when conducting specific tests, is data obtained through portable analyzers. Previously, this data was manually transcribed for use in specific diagnostic and evaluative applications. With current technology, this data typically can be input directly to a computer disk, which can then be transferred automatically to a host computer 172 at the PMDC 24. The data and format are preferably standardized, so computer based application routines can be developed readily to utilize the data in diagnostic applications.
FIG. 4 shows a schematic of a preferred data processing layout for integrating diagnostics and monitoring over a monitoring data highway or network as described. This configuration is readily integrated with existing plant systems, and takes advantage of technology advancements in plant computer and data communication networks being implemented at many plants. The system can accept data both off-line and on-line. On-line data acquisition can occur either through the plant data highway or through smart devices that pre-process data (e.g., perform signal analysis) before sending the data over the system or plant data highway. The actual analyses are performed through a computer network distributed according to diagnostic function and located at the plant PMDC. In contrast to the plant control data highway, it would be possible to link these computers through a specific diagnostic data highway.
Preferably, the PMDC 24 is manned constantly during operation of the plant. In addition, communication capability exists to bring in various experts at the plant or utility headquarters. The outputs and displays of the PMDC, or selected subsets, can be provided to the various constituencies including engineering, scientific, maintenance, headquarters, or management for use in acting on diagnoses and recommendations. Short and long term data storage and retrieval capabilities are linked to the plant computer. Capability is also available to send selected diagnostic information over phone lines 174 or other data links, to other consultants or equipment vendors, to allow for rapid response and evaluation of critical conditions. Thus the D&M system itself is fully integrated into the total plant information system, and provides a means for plant people to function together effectively as a team to solve both short term difficulties, and to provide for long range planning to maximize efficiency of plant operation for life extension.
As applied to nuclear power generating plants, specific functional modules can be provided to address problems which are peculiar to such plants. Transient and fatigue monitoring is a first application. Operating transients cause thermal, pressure, and mechanical load fluctuations that contribute to fatigue accumulation in many pressure boundary components and systems over a plant operating period. Fatigue is considered in plant design through postulation and evaluation of specified number of occurrences of key normal and off-normal events, such as plant heatup, load changes, and reactor trips.
In the United States, nuclear power generation plants are required through their technical specifications to show continuing conformance of fatigue design and operation. Until recently, this was done by attempting to keep a log of the number of occurrences of certain of the design transients. This method has proved inadequate from design-operational conformance needs, because actual plant operating transients are different from design transients. Examples include thermal stratification that occurs in various places in horizontal piping, and additional at-power tests that cause fatigue. These are offset by the fact that many nuclear plants operate in a base load capacity, so events like load changes are fewer in number and less severe than may have been postulated in design and planning.
In addition to these considerations, to properly account for fatigue in justifying an extension of the predicted useful life of component structures or the plant as a whole, it is important to have as accurate a historical record of transients and fatigue over as much of the plant operation as possible. For these reasons, systems that automatically monitor plant process parameters and update fatigue on an ongoing basis are quite useful. In some cases it can be shown that the actual fatigue accumulation is less than predicted using design transients, even when accounting for the events not postulated in the original design. Additionally, the system according to the invention can help to identify and recommend operational changes to help slow the accumulation of fatigue.
The technology that makes automated fatigue monitoring practical and cost-effective is the Green's function based transfer function technology. This allows direct calculation of stress from available plant process parameters, without the need for repeated finite element calculations. Upon installing a transient and fatigue cycle monitoring systems in an operating plant, a review of records of past operating history is advisable. This information, along with plant design criteria, helps in selection of component regions to monitor for fatigue, and provides the means to establish an estimate of the fatigue accumulation up until the time of system installation, i.e., the fatigue baseline. This initial step also can provide insight into operating practices that may be enhanced to reduce the rate of transient and fatigue accumulation, and according to the invention the effectiveness of such operating practices can be monitored.
Another example specific to nuclear plant monitoring concerns monitoring the condition and performance of the reactor internals, as opposed to monitoring a particular mechanism (e.g., fatigue) that appears at various points throughout the plant system. In the case of reactor internals, the focus of data collection and analysis is a very specific component, or a part of a component, and the various degradation mechanisms and performance factors affecting it.
The reactor internals are of interest to at least two plant groups for different reasons. The reactor performance engineers are interested from the perspective of optimizing core life and fuel performance. The maintenance engineers are interested in the potential degradation mechanisms that affect the reactor internals such as loose parts, unwanted vibration, and material degradation. Both groups use similar input to make decisions, such as data from in-core temperature instrumentation, in-core and extra-core neutron flux detectors, loose parts accelerometers and other such process parameters, to evaluate current status. The performance engineers may use this data fairly frequently, e.g., to do on-line calculations of core performance. The maintenance engineers may analyze the data less frequently, and previously might take data manually only once per cycle for trend analysis. The integrated diagnostics and monitoring system of the invention provides information to both constituents through a common user interface utilizing a communication network.
Corrosion-erosion monitoring is another example of a system-wide degradation mechanism in nuclear power plants. It is tracked in at least two ways. Periodic wall thickness measurements can be taken at specific grid points on a component using a portable ultrasonic device. Permanent corrosion probes can be installed at strategic points in the system. The first approach monitors expected degradation and the second approach is used mainly in regions for which detailed information is desired about the corrosion process itself.
Turbine and generator diagnostics are a further example. In this case the requirements are again different from any of the previous examples. The turbine/generator arrangement is a high demand rotating machine that must reliably operate for months at a time. Failures can develop quickly, with potentially catastrophic consequences for the equipment, and may cause extended forced outages.
In such a case, the addition of sensors and monitoring devices can be easily cost-justified. The round-the-clock monitoring and evaluation capabilities of the invention are helpful to deal with failures that can develop quickly and unexpectedly. To monitor effectively under such conditions, the foregoing communication link back to the equipment vendor is useful, particularly where the vendor develops a diagnostic rule base and provides quasi-real time evaluation and diagnoses as needed. If several plants participate, all plants can benefit from ongoing enhancements to the diagnostic database with experience, and overall cost-effectiveness is increased.
FIG. 8 illustrates an architecture similar to that described above, applied specifically to a nuclear power generation plant and with the foregoing functional modules incorporated. Input comes from several real-time sources including the plant process computer and special application sensors, as well as through portable monitoring equipment. The sharing of common data between the various diagnostic modules is also illustrated. The individual diagnostic modules operate in modes ranging from on-demand to continuous real-time diagnostics, in two different locations including the PMDC and an off site location, and provide information on the plant information network to the plant people who need it.
The invention as described is especially adapted for production environments such as for nuclear plant diagnostics and monitoring. A wide range of other applications also are possible. Preferably, this wide range of diagnostic applications is based on flexible architecture, data acquisition, processing and display capabilities. An approach using a predictive maintenance and diagnostics center provides the flexibility, and a central focal point for effective use and integration of plant diagnostic capabilities.
The invention having been disclosed in connection with certain examples, a number of variations will now be apparent to persons skilled in the art. Whereas the invention is not intended to be limited to the embodiments disclosed as examples, reference should be made to the appended claims rather than the foregoing discussion of examples, in order to assess the scope of the invention in which exclusive rights are claimed. | An integrated information system is provided for a plant with interactive processes running in functional equipment subsets, such as a nuclear power generation plant. Sensors are operatively coupled to monitor processes and equipment in the plant, collecting sample data for assessing operational conditions and for predicting maintenance requirements based on loading of the equipment. One or more processors access the sample data and compares present conditions to diagnostic specifications, technical specifications and historical data stored in memory and indexed to equipment subsets and functional operating groups. The processor(s) generate prioritized reports to alert users to potential operational and/or maintenance problems. In addition to the prioritized reports, the processor accesses and outputs to the users reports of the diagnostic and technical specifications applicable to the process parameters exhibiting the potential problems. These specifications are provided in successive levels of detail and are cross referenced between related processes and related items of equipment. The information system integrates operations, maintenance, engineering and management interests in a common database of information via network-coupled data terminals. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-166041, filed on Jun. 1, 2001, the entire contents of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a semiconductor memory device having floating gates. Particularly, this invention relates to a semiconductor memory device having floating gates formed on a device-isolation region and a method of producing this type of semiconductor memory device.
[0003] A device-isolation region with a shallow trench, a shallow-trench isolation (termed STI hereinafter) region, is provided in device isolation process to meet the demands for scaling-down under a specific design rule for miniaturization of highly integrated semiconductor memory devices.
[0004] A known method of producing a semiconductor memory device is described with reference to FIGS. 1A to 1 G, focusing on forming memory-cell sections.
[0005] As shown in FIG. 1A, STI regions 101 are formed in a semiconductor substrate 100 , and then gate oxide films 102 are formed on the semiconductor substrate 100 . Formed next are floating gates 103 , each formed on a part of the corresponding gate oxide film 102 and STI region 101 . A CVD silicon oxide film 104 is then formed on a part of each floating gate 103 by chemical vapor deposition (termed CVD hereinafter). Formed on each side wall of the CVD silicon oxide film 104 in the same way is a CVD silicon-oxide-film side wall 105 .
[0006] Next, as shown in FIG. 1B, reactive ion etching (termed RIE hereinafter) is applied to provide a groove 106 in each STI region 101 , having 50 nm in depth from the upper surface of each STI region 101 and makes thin films of the CVD silicon oxide films 104 and CVD silicon-oxide-film side walls 105 .
[0007] The CVD silicon oxide films 104 and CVD silicon-oxide-film side walls 105 formed on the floating gates 103 are removed by HF paper cleaning, as shown in FIG. 1C.
[0008] Next, as shown in FIG. 1D, a gate-to-gate insulating film 107 of an ONO film having 20 nm in entire thickness is deposited over the entire device surface by low-pressure chemical vapor deposition (termed LP-CVD hereinafter). The ONO film is an insulating film having a three-layer structure of a silicon oxide film (O), a silicon nitride film (N) and another silicon oxide film (O), termed an inter-poly insulating film.
[0009] Deposited over the entire device surface by LP-CVD, as shown in FIG. 1E, is a P-type-impurity-doped polycrystalline silicon layer 108 having about 100 nm in thickness, followed by a tungsten silicide film 109 having about 50 nm in thickness deposited by sputtering. The polycrystalline silicon layer 108 and the tungsten silicide film 109 function as control gates for this semiconductor memory device. Deposited next on the tungsten silicide film 109 by LP-CVD is a silicon nitride film 110 having thickness in the range from 200 nm to 230 nm, for example.
[0010] The silicon nitride film 110 is made thin, as shown in FIG. 1F, by removing the film 110 by a certain thickness.
[0011] A structure of such semiconductor memory device and a method of producing such semiconductor memory device are shown for example in FIGS. 117 to 25 in Japanese Patent Application No. 11-350841 (Japanese Unexamined Patent Publication No. 2001-168306).
[0012] The known semiconductor memory device described above has the following drawbacks:
[0013] Metallic substances, if attached on an exposed surface of the semiconductor memory device during the process in FIG. 1C, could cause crystal defects, low reliability, and so on. The buried surface under the gate-to-gate insulating film 107 should be cleaned for preventing such phenomena to enhance insulating property. This is usually performed with dilute hydrofluoric acid effective for metal removal.
[0014] The dilute-hydrofluoric-acid cleaning etches a silicon oxide film equally in all directions. In detail, as shown in FIG. 1 G, an enlarged view of a block Q in FIG. 1F, etching has advanced in a lateral direction over the exposed surface of the STI region 101 under the floating gate 103 .
[0015] The advancement of etching forces the floating gate 103 to face the polycrystalline silicon 108 at two corners R and S via the gate-to-gate insulating film 107 . Electric flux lines will converge at the corners R and S of the floating gate 103 toward the polycrystalline silicon layer 108 to increase electric field locally in accordance with the curvature radius of each corner.
[0016] Increase in electric field locally converged at the corners R and S of the floating gate 103 and applied to the gate-to-gate insulating film 107 while the memory cell is operating for writing or erasing could cause a low insulating property. This leads to a high probability of memory-cell writing/erasing property lowering or memory-cell threshold-level variation.
[0017] Dielectric breakdown or increased leak current could also be caused under stresses due to electric field applied and converged on the gate-to-gate insulating film 107 in memory-cell writing, erasing or charging.
SUMMARY OF THE INVENTION
[0018] A semiconductor memory device having at least one floating gate according to the first aspect of the present invention includes: a semiconductor substrate; at least one device-isolation region buried in the semiconductor substrate, having a top surface protruding from a top surface of the semiconductor substrate, the top surface of the device-isolation region having a concave section that has a depression thereon; at least one gate-insulating film formed on the semiconductor substrate; a first gate formed on the gate-insulating film, the device-isolation region and the depression; a gate-to-gate insulating film formed on the first gate and in the concave section and the depression of the device-isolation region; and a second gate formed on the gate-to-gate insulation film, the depression being filled with the second gate.
[0019] Moreover, a semiconductor memory device having floating gates according to the second aspect of the present invention includes: a semiconductor substrate; at least one device-isolation region buried in the semiconductor substrate, having a top surface protruding from a top surface of the semiconductor substrate, the top surface of the device-isolation having a concave section that has a depression thereon; at least one gate-insulating film formed on the semiconductor substrate; a plurality of first gates formed on the gate-insulating film, the device-isolation region and the depression, the first gates being isolated from each other on the device-isolation region; a gate-to-gate insulating film formed on the first gates and in the concave section and the depression of the device-isolation region, the first gates being isolated from each other by the gate-to-gate insulating film; and a second gate formed on the gate-to-gate insulation film, the depression area being filled with the second gate.
[0020] Furthermore, a method of producing a semiconductor memory device having floating gates according to the third aspect of the present invention forms at least one device-isolation region and a gate-insulating film on a semiconductor substrate; forms a first gate material on the device-isolation region and the gate-insulating film; forms first gate electrodes by separating the first gate material into two gate materials, the separated materials being left on the device-isolation region; provides a concave section on the device-isolation region, the concave section being narrower than a distance between the separated first gate electrodes; provides a depression in the device-isolation region under the first gate electrodes and at edges of the concave section on the device-isolation region; forms a gate-to-gate insulating film on the concave section on the device-isolation region and the first gate electrodes, the depression in the device-isolation region being filled with the gate-to-gate insulating film; and forms a second gate electrode on the gate-to-gate insulation film.
[0021] Moreover, a method of producing a semiconductor memory device having floating gates according to the fourth aspect of the present invention forms a gate-insulating film and then a first gate material on a semiconductor substrate; provides at least one groove through the first gate material, the gate-insulating film and a part of the semiconductor substrate; fills the groove with an insulating material to form a device-isolation region having a top surface higher than a top surface of the first gate material; forms a second gate material on the first gate material and the device-isolation region; forms second gate electrodes by separating the second gate material into two gate materials, the separated materials being left on the device-isolation region; provides a concave section on the device-isolation region, the concave section being narrower than a distance between the separated second gate electrodes; provides a depression in the device-isolation region under the second gate electrodes and at edges of the concave section on the device-isolation region; forms a gate-to-gate insulating film on the concave section on the device-isolation region and the second gate electrodes, the depression in the device-isolation region being filled with the gate-to-gate insulating film; and forms a third gate electrode on the gate-to-gate insulating film.
BRIEF DESCRIPTION OF DRAWINGS
[0022] [0022]FIGS. 1A to 1 F are sectional views each illustrating a process of a method of producing a known semiconductor memory device, FIG. 1G being an enlarged sectional view of a block Q in FIG. 1F;
[0023] [0023]FIG. 2 is a plan view illustrating memory cells in semiconductor memory device of a first and a second embodiment according to the present invention;
[0024] [0024]FIG. 3A is a sectional view taken on line “A-B” of FIG. 2, illustrating the memory cells in the semiconductor memory device of the first embodiment according to the present invention, FIG. 3B being an enlarged sectional view of a block E in FIG. 3A;
[0025] [0025]FIG. 4 is a sectional view taken on line “C-D” of FIG. 2, illustrating the memory cells in the semiconductor memory device of the first embodiment according to the present invention;
[0026] FIGS. 5 to 24 are sectional views, taken on line “A-B” of FIG. 2 illustrating the memory cells, each illustrating a process of a method of producing the semiconductor memory device of the first embodiment according to the present invention;
[0027] [0027]FIG. 25 is an enlarged sectional view of a block I in FIG. 24;
[0028] [0028]FIG. 26 is an enlarged sectional view of an etched region of the block I in FIG. 24;
[0029] [0029]FIGS. 27 and 28 are sectional views, taken on line “A-B” of FIG. 2 illustrating the memory cells, each illustrating a process of a method of producing the semiconductor memory device of the first embodiment according to the present invention;
[0030] FIGS. 29 to 32 are sectional views, taken on line “C-D” of FIG. 2 illustrating the memory cells, each illustrating a process of a method of producing the semiconductor memory device of the first embodiment according to the present invention;
[0031] [0031]FIG. 33 is a sectional view taken on line “A-B” of FIG. 2, illustrating the memory cells in the semiconductor memory device of the second embodiment according to the present invention;
[0032] [0032]FIG. 34 is a sectional view taken on line “C-D” of FIG. 2, illustrating the memory cells in the semiconductor memory device of the second embodiment according to the present invention;
[0033] FIGS. 35 to 54 are sectional views, taken on line “A-B” of FIG. 2 illustrating the memory cells, each illustrating a process of a method of producing the semiconductor memory device of the second embodiment according to the present invention;
[0034] [0034]FIG. 55 is an enlarged sectional view of a block P in FIG. 54;
[0035] [0035]FIGS. 56 and 57 are sectional views, taken on line “A-B” of FIG. 2 illustrating the memory cells, each illustrating a process of a method of producing the semiconductor memory device of the second embodiment according to the present invention; and
[0036] FIGS. 58 to 61 are sectional views, taken on line “C-D” of FIG. 2 illustrating the memory cells, each illustrating a process of a method of producing the semiconductor memory device of the second embodiment according to the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0037] Several embodiments of semiconductor memory device having floating gates and method of producing the semiconductor memory device according to the present invention will be disclosed with reference to the attached drawings. There is disclosed below focus on memory cells of a non-volatile semiconductor memory device as a representative of application of the present invention.
First Embodiment
[0038] The planer structure of memory cells is shown in FIG. 2. Several device-isolation regions 1 are formed in stripe at a constant interval in the vertical direction. Several control gates 2 are also formed in stripe at a constant interval in the horizontal direction orthogonal to the device-isolation regions 1 . The regions with no device-isolation regions 1 formed are device regions.
[0039] Formed under a part of each control gate 2 at a constant interval are several floating gates 3 . The length of each floating gate 3 in the vertical direction in FIG. 2 is equal to that of each control gate 2 . The length of the floating gate 3 in the horizontal direction in FIG. 2 is, however, shorter than the control gate 2 . A device width X between adjacent device-isolation regions 1 is, for example, in the range from about 100 to 150 nm. Another device width Y for the device-isolation regions 1 is, for example, in the range from about 200 to 250 nm. A length Z between adjacent floating gates 3 in the horizontal direction in FIG. 2 is, for example, in the range from about 70 to 100 nm.
[0040] Shown in FIG. 3A is a sectional view taken on line “A-B” of FIG. 2. The device-isolation regions 1 are formed in a semiconductor substrate 5 . The depth of each device-isolation region 1 buried in the semiconductor substrate 5 is, for example, in the range from about 200 to 250 nm. The device-isolation regions 1 are made of a HDP (High Density Plasma)-CVD oxide film. Each device-isolation region 1 has a protruding section higher than the top surface of the semiconductor substrate 5 . The protruding section has a concave section 6 on the center. Moreover, the concave section 6 has a depression 7 at the upper edges.
[0041] Gate oxide films (tunnel oxide films) 8 , gate-insulating films of, for example, oxynitride are formed on the semiconductor substrate 5 , in the range from about 5 to 10 nm in thickness.
[0042] Each of several floating gates 9 is formed on a gate oxide film 8 and a part of the protruding section of the device-isolation region 1 , in the range from about 150 to 200 nm in thickness. The floating gates 9 are isolated from each other on the device-isolation regions 1 . The floating gates 9 are formed on the gate-insulating films 8 and device-isolation regions 1 , with almost the same thickness, thus the top surface of each floating gate 9 is irregular depending on the height of the bottom surface thereof.
[0043] A gate-to-gate insulating film 10 is formed on each floating gate 9 and in the concave section 6 and depression 7 . The gate-to-gate insulating film 10 is made, for example, of an ONO film with thickness of, for example, about 5 nm for a silicon oxide film, about 7 nm for a silicon nitride film formed thereon and about 5 nm for another silicon oxide film formed thereon. Every depression 7 formed between the lower edge of each floating gate 9 and the upper edge of the protruding section of each device-isolation region 1 is filled with the gate-to-gate insulating film 10 . The top surface of the gate-to-gate insulating film 10 is irregular depending on the height of the bottom surface thereof.
[0044] Formed on the gate-to-gate insulating film 10 is a polycrystalline silicon layer 11 with which the concave section 6 of each device-isolation region 1 is filled. The top surface of the polycrystalline silicon layer 11 is irregular depending on the height of the bottom surface thereof.
[0045] The thickness of the polycrystalline silicon layer 11 formed on the gate-to-gate insulating film 10 but not filled in the concave section 6 is, for example, in the range from about 70 to 100 nm.
[0046] A tungsten silicide layer 12 is then formed on the polycrystalline silicon layer 11 , having the thickness, for example, in the range from about 40 to 60 nm. The top surface of the tungsten silicide layer 12 is irregular depending on the height of the bottom surface thereof. The polysilicon layer 11 and the tungsten silicide layer 12 function as the control gates 2 . A silicon nitride film 13 is formed on the tungsten silicide layer 12 , having the thickness of about 100 nm, for example.
[0047] For example, the width of the protruding section 6 in each device-isolation region is about 100 nm, the thickness of the gate-to-gate insulating film 10 is about 20 nm and the width of the polysilicon layer 11 filled in the protruding section 6 is about 60 nm.
[0048] The enlarged sectional view of a block E indicated by a dot line in FIG. 3A is shown in FIG. 3B. Illustrated in this figure with an arrow is electric filed generated in a block F indicated by a dot line at an upper edge of each floating gate 9 . On the contrary, no electric filed is generated in a block G indicated by a dot line at a lower edge of each floating gate 9 . This is because the floating gate 9 has been covered with the thick gate-to-gate insulating film 10 at the corner of the lower edge. In detail, the gate-to-gate insulating film 10 has been formed of the lower silicon oxide film 14 , a silicon nitride film 15 formed thereon and the upper silicon oxide film 16 formed thereon. Firstly, the silicon oxide film 14 has been filled in the exposed depression 7 followed by the silicon nitride film 15 on the silicon oxide film 14 , as if the nitride film being folded.
[0049] No electric filed will be generated in the direction indicated by a straight line H, or the center line on the lower corner of each floating gate 9 . This is because the gate-to-gate insulating film 10 exists twice from the lower corner of the floating gate 9 toward the polycrystalline silicon layer 11 along the straight line H. The gate-to-gate insulating film 10 lies as inclined to the depression 7 in the direction of the straight line H. The thickness of the gate-to-gate insulating film 10 at lower corner of the floating gate 9 in the direction of the straight line H is thus thicker than that formed on the other regions. This serves to generate no electric fields.
[0050] Shown in FIG. 4 is a sectional view taken on line “C-D” of FIG. 2. The gate-insulating film 8 has been formed over the semiconductor substrate 5 . Formed on gate-forming regions on the gate-insulating film 8 are multi-layered gate electrodes 4 , each made of the floating gate 9 , the gate-to-gate insulating film 10 , the polycrystalline silicon layer 11 , the tungsten silicide layer 12 and the silicon nitride film 13 . Although not shown, source/drain impurity regions for each transistor have been formed near the surface of the semiconductor substrate 5 between adjacent multi-layered gate electrodes 4 .
[0051] A gate width M for each multi-layered gate electrode 4 is, for example, in the range from about 150 to 170 nm. A space N between adjacent multi-layered gate electrodes 4 is also, for example, in the range from about 150 to 170 nm.
[0052] The first embodiment of semiconductor memory device has the gate-to-gate insulating film formed as if folded in the depression at the lower corner G etched further under each floating gate, thus not suffering convergence of electric field at the corner G. The first embodiment therefore achieves decrease in convergence of electric field to the gate-to-gate insulating film almost half of the known device, to restrict lowering of reliability which could otherwise occur such as low memory-cell writing and erasing property, variation in memory-cell threshold levels and low charge conservation.
[0053] In detail, this device configuration restricts convergence of electric field to the gate-to-gate insulating film at the floating-gate corners, to relieve voltage breakdown and leak current which could otherwise occur to the gate-to-gate insulating film due to convergence of electric field, for enhanced reliability of the semiconductor memory device. This is because convergence of electric field is restricted at the lower edge of each floating gate in the first embodiment, whereas which occurs to both upper and lower edges of each floating gate of the known device. Moreover, the first embodiment enhances reliability of the semiconductor memory device by preventing each floating gate from being not capable of charging electrons which could otherwise occur due to voltage breakdown or high leak current to the gate-to-gate insulating film under stresses due to frequent writing/erasing operations.
[0054] Disclosed next is a method of producing the semiconductor memory device of the first embodiment according to the present invention. The disclosure starts with FIGS. 15 to 28 for the semiconductor memory device in section taken on line “A-B” of FIG. 2.
[0055] As shown in FIG. 5, a silicon thermal oxide film 20 of about 20 nm in thickness for example, is formed by dry oxidation on the semiconductor substrate 5 , for example, a silicon substrate. A silicon nitride film 21 of about 300 nm in thickness for example, is deposited by LP-CVD on the silicon thermal oxide film 20 . The silicon nitride film 21 will function as a masking material for forming trenches on the semiconductor substrate 5 and also as a CMP stopper.
[0056] Next, as shown in FIG. 6, the entire device surface is covered with a photoresist 22 of about 600 nm in thickness for example. The photoresist 22 is then processed, by lithography, into a specific device-isolation pattern.
[0057] The silicon nitride film 21 and the silicon thermal oxide film 20 are processed as shown in FIG. 7 by RIE with the photoresist 22 as a mask. The photoresist 22 is then removed by ashing, as shown in FIG. 8. The semiconductor substrate 5 is processed as shown in FIG. 9 by RIE with the silicon nitride film 21 as a mask, to provide grooves 23 of about 250 nm in depth for example, as device-isolation regions. The depth of each groove 23 is defined as the length from the top surface of the semiconductor substrate 5 to the bottom of the groove 23 .
[0058] Next, as shown in FIG. 10, the grooves 23 are filled with a CVD silicon oxide film 24 deposited over the entire device surface at about 700 nm in thickness for example, followed by STI to form the device-isolation regions.
[0059] The CVD silicon oxide film 24 is polished into flat by CMP, as shown in FIG. 11. In detail, CMP is performed with the silicon nitride film 21 as a stopper, followed by thermal processing in nitrogen ambient to provide dense CVD silicon oxide films 24 . The CPM procedure leaves the silicon nitride film 21 of about 100 nm in thickness for example. The thermal processing is performed in nitrogen ambient, for example, for about one hour at about 900° C. How each CVD silicon oxide film 24 becomes dense is expressed in wet-etch selectivity as follows: The CVD silicon oxide film 24 is dense about 1.3 times the silicon thermal oxide film 20 , just after formed. The thermally-processed CVD silicon oxide film 24 will, however, be dense about 1.2 times the silicon thermal oxide film 20 .
[0060] The silicon nitride film 21 is removed as shown in FIG. 12 and further the silicon thermal oxide film 20 is removed as shown in FIG. 13, by wet etching. The wet etching for both films is isotropic etching so that the CVD silicon oxide films 24 will have round corners at upper edges 25 . In detail, etching is usually performed for thickness about 1.5 times the silicon thermal oxide film 20 so that each CVD silicon oxide film 24 will be removed by about 40 nm at its surface and corners.
[0061] Next, as shown in FIG. 14, a silicon thermal oxide film 8 is formed over the entire device surface at about 10 nm thickness by dry oxidation. The silicon thermal oxide film 8 will function as a tunnel oxide film for memory cells.
[0062] A polycrystalline silicon layer 26 doped with phosphorous as impurities is deposited, by LP-CVD, over the entire device surface at about 100 nm for example, as shown in FIG. 15. The polycrystalline silicon layer 26 will be processed into floating gates in later process stage. Deposited further by LP-CVD over the entire device surface is a CVD silicon oxide film 27 of about 200 nm in thickness for example. The CVD silicon oxide film 27 will be used as a masking material for processing the polycrystalline silicon layer 26 .
[0063] Next, as shown in FIG. 16, the entire device surface is covered with a photoresist 28 of about 600 nm in thickness for example. The photoresist 28 is then processed, by lithography, into a specific floating-gate pattern.
[0064] The CVD silicon oxide film 27 is processed as shown in FIG. 17 by RIE with the photoresist 28 as a mask and the polycrystalline silicon layer 26 as a stopper. The photoresist 28 is removed by ashing as shown in FIG. 18. A CVD silicon oxide film 29 is then deposited by LP-CVD over the entire device surface at about 50 nm in thickness for example, as shown in FIG. 19.
[0065] Next, as shown in FIG. 20, the CVD silicon oxide film 29 is processed by RIE with the polycrystalline silicon layer 26 as a stopper to form a CVD silicon-oxide-film side wall 30 at each side face of the CVD silicon oxide film 27 so that the polycrystalline silicon layer 26 will be exposed. The width of the CVD silicon-oxide-film sidewall 30 is about 30 nm, for example, at each side face of the CVD silicon oxide film 27 .
[0066] The polycrystalline silicon layer 26 is processed by RIE with the CVD silicon oxide films 24 as a stopper. In detail, RIE is performed at a relatively high etch selectivity in relation to the silicon oxide films so that almost no lateral etching will advance with almost no variation in width for the CVD silicon-oxide-film side walls 30 . The space between adjacent floating gates is for example about 100 nm.
[0067] Next, as shown in FIG. 22, a CVD silicon oxide film 31 is deposited over the entire device surface at about 20 nm for example. The CVD silicon oxide films 31 , 24 and 27 , and also the CVD silicon-oxide-film side walls 30 are processed to provide a groove 32 in each CVD silicon oxide film 24 . The width of each groove 32 is about 100 nm for example. The thickness of each CVD silicon oxide film 31 left on the CVD silicon oxide film 24 and above each groove 32 is about 3 nm for example. This thickness corresponds to the gap between an edge of each groove 32 and an edge of the corresponding polycrystalline silicon layer 26 .
[0068] The CVD silicon oxide films 27 and 31 , and also the CVD silicon-oxide-film side walls 30 are selectively removed by HF paper cleaning to provide a concave section 6 above each CVD silicon oxide film 24 , as shown in FIG. 24. This process is performed for later stages to electrically shield adjacent memory cells to relieve parasitic capacitance to be generated therebetween for less variation in cell-writing threshold levels, with the polysilicon layer, which will become control gates in later stage, filled in the STI grooves 32 . In detail, the groove provided in each CVD silicon oxide film 24 will extend the passage for static capacitance passing through the film 24 , for less parasitic capacitance to be generated between adjacent floating gates.
[0069] Variation in cell-writing threshold level depends on the behavior of charges in floating gates of adjacent memory cells, which varies due to parasitic capacitance generated between adjacent cells during a reading operation.
[0070] HF paper cleaning allows selective etching to silicon oxide films depending on moisture density therein. In this embodiment, the CVD silicon oxide films 27 and 31 , and also the CVD silicon-oxide-film side walls 30 , the films with no thermal processing applied, are only selectively removed whereas the thermally processed CVD silicon oxide films 24 with a low moisture density remain, by HF paper cleaning. The width of each groove is about 100 nm.
[0071] Shown in FIG. 25 is an enlarged sectional view of a block I indicated by a solid line for the peripherals of an edge of each of polycrystalline silicon layer 26 in FIG. 24. FIG. 25 shows a distance J between each groove 32 and the corresponding polycrystalline silicon layer 26 due to pre-existence of the CVD silicon oxide film 31 . The distance J is obtained at a rate higher than an etching rate K for the CVD silicon oxide film 24 in a hydrofluoric-acid applying process.
[0072] The distance J allows a dilute hydrofluoric-acid applying process to be performed before deposition of the gate-to-gate insulating films, as shown in FIG. 26. This process restricts isotropic etching by the etching rate K within a block 35 indicated by a dot line. The block 35 is removed by the dilute hydrofluoric-acid applying process to provide the depression 7 due to etching advanced on the upper edge of the CVD silicon oxide film 24 in the lateral direction.
[0073] Metallic substances, if attached on an exposed part of the semiconductor memory device could cause crystal defects, low reliability, and so on. The buried surface is cleaned for preventing such phenomena by the hydrofluoric-acid applying process effective for metal removal, to enhance insulating property for the gate-to-gate insulating film 10 . The hydrofluoric-acid applying process is performed with oxide-film etching by thickness in the range from about 1 to 2 nm. The hydrofluoric-acid applying process promotes etching on the exposed surface of the CVD silicon oxide film 24 and also a region of the polycrystalline layer 26 , which faces the groove.
[0074] Next, as shown in FIG. 27, an ONO film is deposited by LP-CVD in each depression 7 , as if being folded, as the gate-to-gate insulating film 10 of about 20 nm in total thickness.
[0075] The distance J for the floating gate to provide the depression 7 is set, before ONO-film deposition, at a rate higher than the etching rate for the hydrofluoric-acid applying process. The ONO film is then filled in between the floating gate and the top surface of device-isolation region.
[0076] Next, as shown in FIG. 28, the polycrystalline silicon layer 11 with phosphorous as impurities is deposited by LP-CVD over the entire device surface at about 100 nm in thickness for example. The tungsten silicide layer 12 having about 50 nm, for example, in thickness is then formed by sputtering on the polycrystalline silicon layer 11 , followed by the silicon nitride film 13 deposited thereon by LP-CVD, at about 200 nm in thickness.
[0077] The polycrystalline silicon layer 11 may be formed in the range from about 5 to 500 nm for example. Polycide or metal may be used instead of the polycrystalline silicon layer 11 . The polycide may be WSi, NiSi, MOSi, TiSi or CoSi, for example. Mono-crystal silicon with no impurities doped may be used at first, which is then doped with phosphorous, arsenic or boron by ion implantation with thermal treatment in later stages to be changed into the polycrystalline silicon layer 11 .
[0078] One of the purposes of the processes illustrated in FIGS. 18 to 20 is to obtain an enough alignment margin for the patterns of device-isolation regions and device regions in FIG. 6 and the patterns of floating gates in FIG. 16. Another purpose is to gain a large floating-gate surface area, or a high memory-cell coupling ratio to achieve efficient voltage transfer to the gate oxide films which will function as a tunnel oxide film.
[0079] Disclosed next is a method of producing the semiconductor memory device with respect to FIG. 4 and also FIGS. 129 to 32 , the sectional views taken on line “C-D” of FIG. 2. FIG. 29 shows a sectional view taken on line “C-D” of FIG. 2, in the process illustrated in FIG. 28, the sectional view taken on line “A-B” of FIG. 2.
[0080] Illustrated in FIG. 29 are the gate oxide film 8 , the floating gate 9 , the gate-to-gate insulating film 10 , the polycrystalline silicon layer 11 , the tungsten silicide layer 12 and the silicon nitride film 13 , laminated in order on the semiconductor substrate 5 .
[0081] As shown in FIG. 30, a photoresist 40 is applied over the entire device surface at about 600 nm thickness for example, and then processed into a specific gate pattern by lithography. The silicon nitride film 13 is processed by RIE with the photoresist 40 as a mask to expose the tungsten silicide layer 12 to the openings, as shown in FIG. 31. The photoresist 40 is then removed by ashing to expose each silicon nitride film 13 , as shown in FIG. 32.
[0082] The tungsten silicide layer 12 , the polycrystalline silicon layer 11 , the gate-to-gate insulating film 10 and the floating gate 9 are processed by RIE with the silicon nitride films 13 as a mask to form a specific gate structure.
[0083] The floating gate 9 is etched at a high selectivity to the gate oxide film 8 to leave the film 8 on the semiconductor substrate 5 . Oxidation is then performed for device recovery from damages due to attacks of plasma and ion injected into the semiconductor substrate and gate oxide film edges and also crystallization of the tungsten silicide layer 12 for lowering resistance.
[0084] Although not shown for the subsequent process stages, a diffusion layer is formed and then a inter-layer film is deposited over the entire device surface, followed by contact and wiring formation, to produce a MISFET.
[0085] The method of producing the semiconductor memory device according to the first embodiment allows further advancement of etching, before formation of the gate-to-gate insulating film, on the exposed STI grooves after formation of the floating gate over the device-isolation regions formed by STI.
[0086] This configuration restricts electric-field convergence to the gate-to-gate insulating film at the floating-gate corners and also prevents low withstand voltages and increased leak currents which may otherwise occur due to electric-field convergence, thus achieving high yielding and reliability for semiconductor memory devices.
[0087] Moreover, this production method protects the semiconductor memory devices against voltage brake down or high leak current to the gate-to-gate insulating film, that could cause less floating-gate chargeability, during writing/erasing operations to be performed several times just after production, thus achieving high yielding.
[0088] This production method further protects semiconductor memory devices against voltage brake down or high leak current to the gate-to-gate insulating film, which could cause less floating-gate chargeability, due to stresses after writing/erasing operations performed many times, thus achieving high yielding.
Second Embodiment
[0089] Disclosed with respect to FIGS. 133 and 34 is the configuration of semiconductor memory device in this embodiment. The planer structure of this semiconductor memory device is also shown in FIG. 2, like the first embodiment. FIG. 33 is a sectional view taken on line “A-B” of FIG. 2.
[0090] Formed in the semiconductor substrate are several device-isolation regions 1 . The depth of each device-isolation region 1 buried in the semiconductor substrate 5 is for example in the range from about 200 to 250 nm. Each device-isolation region 1 is made of a HDP-CVD oxide film. Each device-isolation region 1 has a protruding section higher than the top surface of the semiconductor substrate 5 . The protruding section has a concave section 6 on the center. Moreover, the concave section 6 has a depression 7 at the upper edges.
[0091] Gate oxide films (tunnel oxide films) 42 of, for example, oxynitride are formed on the semiconductor substrate 5 in the range from about 5 to 10 nm.
[0092] A floating gate formed on each gate oxide film 42 and a part of each protruding section of the device-isolation region 1 is made of a first polycrystalline silicon layer 43 and a second polycrystalline silicon layer 44 formed thereon, having thickness in the range from about 150 to 200 nm for example. There are several floating gates, made of the first and second polycrystalline silicon layers 43 and 44 , adjacent floating-gate regions being isolated from each other on each device-isolation regions 1 .
[0093] Each first polycrystalline silicon layer 43 is formed on the gate oxide film 42 . Each second polycrystalline silicon layer 44 is formed on the corresponding first polycrystalline silicon layer 43 and device-isolation region 1 . The second polycrystalline silicon layer 44 has almost the same thickness, thus the top surface thereof being irregular depending on the height of the bottom surface thereof.
[0094] A gate-to-gate insulating film 45 is formed on the second polycrystalline silicon layers 44 and in the concave sections 6 and the depression 7 . The gate-to-gate insulating film 45 is made, for example, of an ONO film with thickness of, for example, about 5 nm for a silicon oxide film, about 7 nm for a silicon nitride film formed thereon and about 5 nm for another silicon oxide film formed thereon.
[0095] All of the depressions 7 each formed between the lower edge of the second polycrystalline silicon layer 44 and the upper edge of the protruding section of the device-isolation region 1 are filled with the gate-to-gate insulating film 45 . The top surface of the gate-to-gate insulating film 45 is irregular depending on the height of the bottom surface thereof.
[0096] Formed on the gate-to-gate insulating film 45 is a polycrystalline silicon layer 46 with which the concave sections 6 of the device-isolation regions 1 are filled. The top surface of the polycrystalline silicon layer 46 is irregular depending on the height of the bottom surface thereof. The thickness of the polycrystalline silicon layer 46 formed on the gate-to-gate insulating film 45 but not filled in the concave sections 6 is, for example, in the range from about 70 to 100 nm.
[0097] A tungsten silicide layer 47 is then formed on the polycrystalline silicon layer 46 , having the thickness, for example, in the range from about 40 to 60 nm. The top surface of the tungsten silicide layer 47 is irregular depending on the height of the bottom surface thereof. The polysilicon layer 46 and the tungsten silicide layer 47 function as control gates. A silicon nitride film 48 is formed on the tungsten silicide layer 47 , having the thickness of about 100 nm, for example.
[0098] For example, the width of each concave section 6 in the device-isolation region is about 100 nm, the thickness of the gate-to-gate insulating film 45 is about 20 nm and the width of the polysilicon layer 46 filled in each concave section 6 is about 60 nm. The structure at the floating-gate lower corners shown in FIG. 33 is the same as the first embodiment shown in FIG. 3B.
[0099] Shown in FIG. 34 is a sectional view taken on line “C-D” of FIG. 2, in this embodiment. The gate oxide film 42 has been formed over the semiconductor substrate 5 . Formed on gate-forming regions on the gate oxide film 42 are multi-layered gate electrodes 49 , each made of the floating gate made of the first and the second polycrystalline silicon layers 43 and 44 , the gate-to-gate insulating film 45 , the polycrystalline silicon layer 46 , the tungsten silicide layer 47 and the silicon nitride film 48 . Although not shown, source/drain impurity regions of each transistor have been formed near the surface of the semiconductor substrate 5 between adjacent multi-layered gate electrodes 49 .
[0100] A gate width M for each multi-layered gate electrode 49 is, for example, in the range from about 150 to 170 nm. A space N between adjacent multi-layered gate electrodes 49 is also, for example, in the range from about 150 to 170 nm.
[0101] This embodiment of semiconductor memory device has the same advantages as the first embodiment.
[0102] Disclosed next is a method of producing the semiconductor memory device of this embodiment according to the present invention. A feature of this method lies in a process to form a tunnel oxide film and a polycrystalline silicon film becoming a part of each floating gate, before formation of device-isolation regions. This process is called a floating-gate forming-in-advance process hereinafter.
[0103] The disclosure starts with FIG. 33 and FIGS. 35 to 57 for the semiconductor memory device in section taken on line “A-B” of FIG. 2.
[0104] As shown in FIG. 35, a silicon thermal oxide film 50 of about 10 nm in thickness for example, is formed by dry oxidation on the semiconductor substrate 5 , for example, a silicon substrate. The silicon thermal oxide film 50 will be processed into the gate oxide film 42 functioning as a tunnel oxide film in later stage. A first polycrystalline silicon layer 51 of about 50 nm in thickness for example, is deposited by LP-CVD on the silicon thermal oxide film 50 . The first polycrystalline silicon layer 51 has been doped with phosphorous as impurities and will be processed into a part of each floating gate.
[0105] A silicon nitride film 52 of about 300 nm in thickness for example, is deposited by LP-CVD on the first polycrystalline silicon layer 51 . The silicon nitride film 52 will function as a masking material for forming trenches on the semiconductor substrate 5 and also as a CMP stopper.
[0106] Next, as shown in FIG. 36, the entire device surface is covered with a photoresist 53 of about 600 nm in thickness for example. The photoresist 53 is then processed, by lithography, into a specific device-isolation pattern, to expose a part of the silicon nitride film 52 .
[0107] The silicon nitride film 52 is processed as shown in FIG. 37 by RIE with the photoresist 53 as a mask and the first polycrystalline silicon layer 51 as a stopper, to expose a part of the first polycrystalline silicon layer 51 . The photoresist 53 is then removed by ashing, as shown in FIG. 38, to expose the first polycrystalline silicon layer 51 .
[0108] The first polycrystalline silicon layer 51 is processed as shown in FIG. 39 by RIE with the silicon nitride film 52 as a mask and the silicon thermal oxide film 50 as a stopper. Likewise, the silicon thermal oxide film 50 is processed by RIE with the silicon nitride film 52 as a mask and the semiconductor substrate 5 as a stopper, to expose a part of the semiconductor substrate 5 .
[0109] The semiconductor substrate 5 is processed as shown in FIG. 40 by RIE with the silicon nitride film 52 as a mask, to provide grooves 55 of about 250 nm in depth for example, as device-isolation regions. Next, as shown in FIG. 41, the grooves 55 are filled with a CVD silicon oxide film 56 deposited over the entire device surface at about 700 nm in thickness for example, thus the silicon thermal oxide film 50 being processed into the gate oxide film 42 .
[0110] The CVD silicon oxide film 56 is polished into flat by CMP, as shown in FIG. 42. In detail, CMP is performed with the silicon nitride films 52 as a stopper, followed by thermal processing in nitrogen ambient to provide dense CVD silicon oxide films 56 .
[0111] The silicon nitride films 52 are removed by wet etching as shown in FIG. 43, to expose the first polycrystalline silicon layers 51 . Next, as shown in FIG. 44, the CVD silicon oxide films 56 are etched by isotropic wet etching at about 20 nm in thickness, for example, in both vertical and horizontal directions, to have round corners at upper edges 57 , with the first polycrystalline silicon layers 51 being processed into the first polycrystalline silicon layers 43 . This process is to minimize the steps of the CVD silicon oxide films 56 , which have been formed due to removal of the silicon nitride film 52 in the former stage.
[0112] A second polycrystalline silicon layer 58 doped with phosphorous as impurities is deposited, by LP-CVD, over the entire device surface at about 100 nm for example, as shown in FIG. 45. The second polycrystalline silicon layer 58 and the first polycrystalline silicon layer 43 will be processed into floating gates in later stage. Deposited further by LP-CVD over the entire device surface is a CVD silicon oxide film 59 of about 200 nm in thickness for example. The CVD silicon oxide film 59 will be used as a masking material for processing the second polycrystalline silicon layer 58 .
[0113] Next, as shown in FIG. 46, the entire device surface is covered with a photoresist 60 of about 600 nm in thickness for example. The photoresist 60 is then processed, by lithography, into a specific floating-gate pattern, to expose a part of the CVD silicon oxide film 59 .
[0114] The CVD silicon oxide film 59 is processed as shown in FIG. 47 by RIE with the photoresist 60 as a mask and the second polycrystalline silicon layer 58 as a stopper. The photoresist 60 is removed by ashing to expose the CVD silicon oxide films 59 , as shown in FIG. 48.
[0115] A CVD silicon oxide film 61 is then deposited by LP-CVD over the entire device surface at about 50 nm thickness for example, as shown in FIG. 49. Next, as shown in FIG. 50, the CVD silicon oxide film 61 is processed by RIE with the second polycrystalline silicon layer 58 as a stopper to form CVD silicon-oxide-film side walls 62 on the side faces of the CVD silicon oxide films 59 .
[0116] Next, as shown in FIG. 51, the second polycrystalline silicon layer 58 is processed by RIE with the CVD silicon oxide films 56 as a stopper to expose a part of each CVD silicon oxide film 56 .
[0117] Next, as shown in FIG. 52, a CVD silicon oxide film 63 is deposited at about 20 nm in thickness for example by LP-CVD over the exposed entire surface of the CVD silicon oxide films 56 , the second polycrystalline silicon layers 58 , the CVD silicon oxide films 59 and the CVD silicon-oxide-film side walls 62 .
[0118] The CVD silicon oxide films 63 and 56 and also the CVD silicon-oxide-film side walls 62 are processed by RIE to provide grooves 64 at about 50 nm in depth and about 80 nm in width for example, as shown in FIG. 53. The bottom surface of each groove 64 is lower than the bottom surface of each first polycrystalline silicon layer 43 . The remaining CVD silicon oxide film 63 has about 10 nm in thickness for example. The CVD silicon oxide films 59 , 62 and 63 are selectively removed by HF paper cleaning.
[0119] Illustrated in FIG. 55 is an enlarged sectional view of a block P indicated by a solid line for the peripherals of the edge of each second polycrystalline silicon layer 58 in FIG. 54. FIG. 55 shows a distance J between each groove 64 and the corresponding second polycrystalline silicon layer 58 due to the existence of the CVD silicon oxide film 63 in the former stage.
[0120] As shown in FIG. 55, the enlarged sectional view of each second polycrystalline silicon layer 58 on the top of the CVD silicon oxide film 56 , the second polycrystalline silicon layer 58 is formed so that the distance J is larger than a width K of a region to be subjected to a hydrofluoric-acid applying process. The distance J is obtained at a rate higher than an etching rate K for the CVD silicon oxide film 56 with the hydrofluoric-acid applying process.
[0121] The distance J allows a dilute hydrofluoric-acid applying process to be performed before deposition of the gate-to-gate insulating films, as shown in FIG. 55. This process restricts isotropic etching by the etching rate K within an etched region, or a block 65 indicated by a dot line. The etched region 65 is removed by the dilute hydrofluoric-acid applying process to form the device-isolation region 1 and provide the depression 7 due to etching advanced on the upper edge of the region 1 in the lateral direction.
[0122] Metallic substances, if attached on an exposed part of the semiconductor memory device could cause crystal defects, low reliability, and so on. The buried surface is cleaned for preventing such phenomena by the hydrofluoric-acid applying process to enhance insulating property for the gate-to-gate insulating film 45 .
[0123] The hydrofluoric-acid applying process is performed with oxide-film etching by thickness in the range from about 1 to 2 nm. The hydrofluoric-acid applying process promotes etching on the exposed surface of the CVD silicon oxide film 56 and also a region of the second polycrystalline layer 58 , that faces the groove 64 .
[0124] Next, as shown in FIG. 56, an ONO film is deposited by LP-CVD in each depression 7 , as if being folded, as the gate-to-gate insulating film 45 of about 20 nm in total thickness. The gap for the floating gates is set, before ONO-film deposition, at a rate higher than the etching rate in the hydrofluoric-acid applying process. The ONO film is then filled in between the floating gates and the top surface of device-isolation region.
[0125] Next, as shown in FIG. 56, an ONO film is deposited by LP-CVD as the gate-to-gate insulating film 45 of about 20 nm in total thickness. Next, as shown in FIG. 57, the polycrystalline silicon layer 46 with phosphorous as impurities is deposited by LP-CVD over the entire device surface at about 100 nm in thickness for example. The tungsten silicide layer 47 having about 50 nm, for example, in thickness is then formed by sputtering on the polycrystalline silicon layer 46 . The polycrystalline silicon layer 46 and the tungsten silicide layer 47 will be processed into control gates in later stages. The silicon nitride film 48 of about 200 nm in thickness is deposited by LP-CVD on the tungsten silicide layer 47 .
[0126] Disclosed next is a method of producing the semiconductor memory device with respect to FIG. 34 and also FIGS. 158 to 61 , the sectional views taken on line “C-D” of FIG. 2. FIG. 58 shows a sectional view taken on line “C-D” of FIG. 2, in the process illustrated in FIG. 57.
[0127] Illustrated in FIG. 58 are the gate oxide film 42 , the first polycrystalline silicon layer 43 , the second polycrystalline silicon layer 44 , the gate-to-gate insulating film 45 , the polycrystalline silicon layer 46 , the tungsten silicide layer 47 and the silicon nitride film 48 , laminated in order on the semiconductor substrate 5 .
[0128] As shown in FIG. 59, a photoresist 66 is applied over the entire device surface at about 600 nm in thickness for example, and then processed into a specific gate pattern by lithography. The silicon nitride film 48 is processed by RIE with the photoresist 66 as a mask to expose the tungsten silicide layer 47 to the openings, as shown in FIG. 60. The photoresist 66 is then removed by ashing to expose the silicon nitride films 48 , as shown in FIG. 61.
[0129] The tungsten silicide layer 47 , the polycrystalline silicon layer 46 , the gate-to-gate insulating film 45 , the second polycrystalline silicon layer 44 and the first polycrystalline silicon layer 43 are processed by RIE with the silicon nitride film 48 as a mask to form each specific gate structure, as shown in FIG. 34.
[0130] The the second polycrystalline silicon layer 44 and the first polycrystalline silicon layer 43 are etched at a high selectivity to the gate oxide film 42 to leave the film 42 on the semiconductor substrate 5 .
[0131] Oxidation is then performed for device recovery from damages due to attacks of plasma and ion injected into the semiconductor substrate and gate oxide film edges and also crystallization of the tungsten silicide layer 47 for lowering resistance.
[0132] Although not shown for the subsequent process stages, a diffusion layer is formed and then a inter-layer film is deposited over the entire device surface, followed by contact and wiring formation, to produce a MISFET.
[0133] This embodiment of production method has advantages the same as the first embodiment. Moreover, this embodiment allows formation of floating gates before device-isolation regions, preventing generation of depressions, which may otherwise occur between device regions and device-isolation regions, for enhanced reliability.
[0134] The first and second embodiments can be applied to non-volatile semiconductor memory devices having floating gates, such as flash memories.
[0135] As disclosed above, the present invention provides semiconductor memory devices and their production methods, which can restrict convergence of electric field to the gate-to-gate insulating film at the floating-gate corners, to relieve voltage breakdown and leak current which otherwise occur to the gate-insulating film due to convergence of electric field, for enhanced reliability and yielding. | A semiconductor memory device having at least one floating gate includes a semiconductor substrate; at least one device-isolation region buried in the semiconductor substrate, having a top surface protruding from a top surface of the semiconductor substrate, the top surface of the device-isolation region having a concave section that has a depression thereon; at least one gate-insulating film formed on the semiconductor substrate; a first gate formed on the gate-insulating film, the device-isolation region and the depression; a gate-to-gate insulating film formed on the first gate and in the concave section and the depression of the device-isolation region; and a second gate formed on the gate-to-gate insulation film, the depression being filled with the second gate. A method of producing a semiconductor memory device having floating gates, forms at least one device-isolation region and a gate-insulating film on a semiconductor substrate; forms a first gate material on the device-isolation region and the gate-insulating film; forms first gate electrodes by separating the first gate material into two gate materials, the separated materials being left on the device-isolation region; provides a concave section on the device-isolation region, the concave section being narrower than a distance between the separated first gate electrodes; provides a depression in the device-isolation region under the first gate electrodes and at edges of the concave section on the device-isolation region; forms a gate-to-gate insulating film on the concave section on the device-isolation region and the first gate electrodes, the depression in the device-isolation region being filled with the gate-to-gate insulating film; and forms a second gate electrode on the gate-to-gate insulation film. | 7 |
FIELD OF INVENTION
This invention relates to ammunition wherein the projectile thereof has a muzzle velocity of less than the speed of sound, i.e. subsonic, as the projectile leaves the weapon and during its free flight to a target. Particularly the invention relates to subsonic rifle ammunition.
BACKGROUND OF INVENTION
Most commonly, the projectile from a fired weapon, particularly a rifle, leaves the muzzle of the weapon at a speed that is greater than subsonic speed, i.e. at a muzzle velocity of greater than approximately 1086 ft/sec. at sea level under standard conditions of temperature and pressure. The faster a projectile travels, the flatter is its trajectory to its target. Also faster speeds of projectiles tend to reduce the effects of lateral wind forces upon the path of the projectile to its target. Therefore, for accuracy of delivery of the projectile to a desired target, commonly it has been the practice to maximize the quantity of powder used to project a given weight projectile to its target consistent with the permissible pressure for a given weapon. Supersonic muzzle velocities, therefore, are the norm for rifles.
Projectiles traveling at supersonic speeds generate an audible sound during their free flight to the target. This sound, and/or the sound generated by the projectile breaking the sound barrier, can be used to locate the source of the weapon from which the projectile was fired. Under certain circumstances of military operations and/or police operations, it is desirable that the source of the weapon firing a projectile not be identifiable by the sound generated by the traveling projectile. One partial solution to this problem is to restrict the speed of travel of the projectile to a subsonic speed.
A round of ammunition (often synonymously termed a "bullet" or a "cartridge") normally includes a case which includes a primer, a quantity of powder contained within the case, and a projectile held in the open end of the case. Upon the striking of the primer by the firing pin of the weapon there is generated a flame which serves to ignite the powder within the case, generating gases which expand and propel the projectile from the muzzle of the weapon. Normally, the case is geometrically shaped and sized to be contained within the chamber of the weapon, and the projectile is of a diametral dimension which allows it to fit in the breech end of the barrel, and to eventually pass through the barrel upon firing of the round. For many rifles, for example, it is common to make the case of the round of ammunition of a size which will provide for the maximumization of the force with which the projectile is propelled from the weapon to the target. Thus, it is common, for a round for a given caliber weapon, to employ a case which will contain a maximum amount of powder, hence the case has a large diameter relative to the diameter of the projectile employed. This case then becomes the "standard" case for a particular caliber weapon and weapons of this caliber are chambered to accept this standard case. Standards for the shape and size of a cartridge for a given weapon, e.g. a rifle, of a given caliber are established and published by Sporting Arms and Ammunition Manufacturers Institute (SAAMI).
In the many instances where the standard cartridge case is of a diameter which is substantially larger than the diameter of the bore of the weapon, that end of the case which receives and holds the projectile of the cartridge is "necked down" to a diameter suitable to engage and hold the projectile in the case. For example, the outer diameter of the case for a 0.224 caliber cartridge commonly is 0.360 inch, and the outer diameter of the projectile thereof is 0.224 inch. In any event, at least a portion of the projectile projects from the end of the case and is received within the breech end of the bore of the weapon. In this situation, the circular shoulder developed on the case by the necking-down operation serves as a point of reference for the insertion of the cartridge in the chamber of the weapon. Specifically, the chamber of the weapon is sized and shaped such that, when the cartridge is fully and properly inserted into the chamber, at least the juncture of the necked-down length of the case with the circular base of the shoulder engages the breech end of the barrel. With the cartridge in this position within the chamber, that portion of the projectile which projects outwardly from the end of the case is disposed within the bore of the weapon. Through adjustment of the length of that portion of the projectile which extends from the end of the case, it is possible to select the distance by which the projectile extends into the bore of the weapon. In all cartridges, the distal end of the projectile terminates at or short of the commencement of the rifling lands of the bore of the weapon.
Heretofore, it has been proposed to produce subsonic ammunition which comprises the "standard" case and projectile for a given weapon, e.g. a rifle, and to merely reduce the quantity of powder required to propel the projectile to that volume of powder which provides only sufficient energy to propel the projectile at a subsonic muzzle velocity. The round of ammunition thus produced looks and feels like a standard round of ammunition for its intended weapon, but it is only about 50% or less filled with powder, leaving a substantially portion of the interior volume of the case void of powder.
A major problem with this prior practice for the manufacture of subsonic ammunition relates to the reduced volume of powder within the case and the void volume within the case. Specifically, when the weapon is pointed (aimed) at a downward angle, relative to the horizontal, the powder within the case moves toward the leading end of the round and adjacent to that end of the projectile which is inserted into the case. This serves to form an air gap between the primer and the powder so that when the primer is struck by the firing pin, there is a finite time before the flame from the primer reaches and ignites the powder within the leading end of the case, and a finite time elapsing before the burning powder generates sufficient gases to propel the projectile from the weapon. Conversely, if the weapon is aimed upwardly, relative to the horizontal, the powder within the case moves toward the primer so that upon the firing of the primer there is instantaneous ignition of the powder and relatively quicker build up of the gases which propel the projectile from the weapon. At intermediate angles of aiming of the weapon, relative to the horizontal, there are corresponding intermediate delays in the time required for the projectile to be propelled from the weapon after the firing pin has struck the primer. These degrees of delay are extremely detrimental to the accuracy of delivery of the projectile to an intended target. In some circumstances, the delays in "firing" or "hang-fires" of the weapon have been sufficiently long as to deceive the shooter firing the weapon into believing that they have experienced a misfire. Suspecting a misfire, the shooter may open the bolt of the weapon to eject the suspected faulty round, whereupon the round may explode with obvious serious endangerment to the shooter.
In accordance with another aspect of the prior art subsonic ammunition, it has been the practice to use fast-burning powders, e.g. pistol powders. These powders exacerbate the problem of erratic propulsion of a projectile from the weapon by reason of the rapid build up of pressure within the case and the rapid fall-off of the pressure once the projectile leaves the case. As a consequence, the prior art subsonic ammunition fails to provide the energy needed to operate the bolt in a semiautomatic or automatic weapon and/or to lock the bolt in an open position upon the firing of the last round in the magazine.
Further, in the prior art subsonic ammunition, there has been no way for the shooter to differentiate between subsonic and supersonic rounds of ammunition for a given weapon aside from printed information on the container for the ammunition. As a result, subsonic ammunition has been fired when supersonic ammunition was intended, and vice versa.
SUMMARY OF INVENTION
The present invention comprises subsonic ammunition which fires with consistency from round to round, and which is identifiable by visual observation and/or tactilely. In accordance with one aspect of the present subsonic ammunition, there is provided a case having a rear end within which there is received a primer, and an opposite leading end which is open to receive therein a projectile. For a given caliber weapon, the projectile of the present invention is not materially changed from that which is commonly used with the weapon. However, the case of the present ammunition is provided adjacent its leading (open) end with a plurality of stepped stages, each of which reduces the effective diameter of the case, in stages, from the maximum outer diameter of the case to that diametral dimension which is adapted to accommodate the entry into, and proper anchoring of a projectile in the case. In short, there are multiple stages of reduction of the diameter of the case from its maximum outer diametral dimension to its minimum outer diametral dimension at its open, and leading, end. In this manner, a first one of the stages of diameter reduction reduces the outer diameter of the case, adjacent its open end, from its maximum value to a minimum reduced diametral dimension within which the projectile is received. The inner diameter of this first stage is determined by the outer diameter, i.e. caliber, of the projectile. A second one of these stages reduces the maximum outer diametral dimension of a portion of the length of the case to an intermediate diametral dimension. The effect of these multiple stages of reduced diameter of the case adjacent the open end thereof, is multi-fold. First, at least two of the diameter reductions are performed over approximately that length of the case which surrounds that length of the projectile which is disposed within the case. In the first stage reduction, the inner wall of the case and the outer wall of the projectile are in engaging relationship. In the second stage reduction, the inner wall of the case is disposed adjacent to, but not in engagement with, the outer wall of the projectile, thereby defining an annular space therebetween. The thickness of this annular space is chosen to preclude or limit the entry of powder into this space, thereby effectively reducing the amount of interior volume of the case which is available to receive powder therein. Thus, a given quantity of powder more nearly fills the available interior volume of the case and does not shift within the case as a function of the position of the weapon with respect to the horizontal. Second, the multiple stage diameter reductions impart a distinctive outer geometry to the case which is readily identifiable visually or tactilely.
In accordance with one aspect of the present invention, the powder employed in the present ammunition is a relatively slow burning type of powder. This powder provides a rapid peak in pressure build up within the case, but contrary to fast burning powders, the pressure build up produced by the present powder does not fall off sharply, but rather it platforms, so that there is available sufficient energy at the proper gas port location for operating the bolt of a semiautomatic or automatic weapon.
Still further, the circular shoulders that are formed internally of the case of the present invention have been found to function to buffer the peaking of the build up of pressure within the case upon firing to thereby cause the energy peak in the pressure build up within the case to be partially consumed in the deformation of the stepped portions of the case back to the geometry of the chamber. This results in a more uniform distribution of the pressure within the case such that there is a uniform thrust applied to the projectile, yielding consistency of projectile propulsion between rounds and a more lengthy column of uniform pressure in the barrel to enter the gas port and operate the bolt of a semiautomatic or automatic weapon.
Specifically, in accordance with one aspect of the present invention, in total, desirably, the staged diameter reductions effect a total reduction in available interior volume of the case by about 20%. Thereupon, the case is loaded with that quantity of powder which substantially fills the case with powder (i.e., that volume of the case which is not occupied by the projectile). The cartridge thus provided is of the same effective length as the cartridge heretofore employed with the given weapon, contains that quantity of powder therein so that it fires a projectile subsonically, fits within the existing chamber and barrel of the weapon, and exhibits consistency in powder ignition and burn, uniform and controlled pressure distribution and build up, hence consistency of accuracy of delivery of the projectile to a target, and functioning of a semiautomatic or automatic weapon which heretofore has not been possible. The interior open space of the cartridge is filled with sufficient gunpowder such that the cartridge fires uniformly at substantially all angles of fire relative to the horizontal. Only if the weapon is held substantially vertically downward when fired is there a possibility of the gunpowder in the present cartridge not being in immediate contact with the primer. "Hang-fires" are essentially eliminated. Additionally, the multiple stepped geometry of the case provides a means for ready visual or tactile identification of the round as being subsonic.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic representation, partly in section, of a prior art subsonic cartridge;
FIG. 2 is a schematic representation, in section, depicting a prior art subsonic cartridge when oriented with its longitudinal centerline parallel with the horizontal;
FIG. 3 is a schematic representation, in section, of the cartridge of FIG. 2 when oriented with its longitudinal centerline angularly downwardly from the horizontal;
FIG. 4 is a schematic representation, in section, of the cartridge of FIG. 2 when oriented with its longitudinal centerline angularly upwardly from the horizontal;
FIG. 5 is a schematic representation, partly in section, of a subsonic cartridge embodying various of the features of the present invention;
FIG. 6 schematically depicts one embodiment of a case having no stepped stage;
FIG. 7 schematically depicts a case having a single stepped stage;
FIG. 8 schematically depicts a case having two stepped stages in accordance with the present invention;
FIG. 9 schematically depicts a case having three stepped stages in accordance with the present invention;
FIG. 10 schematically depicts a typical projectile employed in a subsonic cartridge of the present invention; and,
FIG. 11 is a schematic representation, in section of one embodiment of a round of ammunition having three necked-down stages and depicting the directionality of the forces internally of the case created by burning of powder within the case.
DETAILED DESCRIPTION OF INVENTION
With reference to the accompanying Figures, a subsonic cartridge 10 of the prior art is depicted in FIG. 1 and includes a case 12 having an open end 14 within which there is received an elongated projectile 16 and having a closed end 18 within which there is received a primer 20. The depicted case includes a single "necked down" stage 22 wherein the maximum diametral dimension,d, of the case is reduced to a diametral dimension, d 1 . The stage 22 includes a straight cylindrical section 24, and a bell-shaped end section which includes a circular wall (i.e., shoulder) 26 that defines the transition of the cylindrical section 24 to the maximum (original) diametral dimension of the case. In the prior art, the height,h, of this wall equals the difference between the maximum outer diameter of the case and the outer diameter of the cylindrical section 24. The inner diameter of this stage 22 is such as permits the snug fit therein of the outer diameter of the projectile 16. In practice, the trailing end 28 of the projectile extends into the interior of the case. In a preferred embodiment of the present invention, all of the length of the projectile except a rounded blunt nose portion is disposed within the interior 30 of the case. The rounded blunt nose portion of the projectile length projects from the open end 14 of the case.
Within the prior art case depicted in FIG. 1 there is provided a quantity of powder 32 which is sufficient only to propel the projectile from the weapon at a subsonic muzzle velocity. As noted in FIG. 1, this quantity of powder does not completely fill the interior volume of the case which is available to receive powder after the projectile has been disposed within the case. Commonly, in the prior art, approximately 60% or less of the available interior volume of the prior art case is filled with powder, leaving a void volume 33 interiorly of the case. Accordingly, when the cartridge of FIG. 1 is tilted relative to the horizontal, the powder within the case flows toward one or the other ends of the case, depending upon the angle of tilt relative to the horizontal. FIGS. 2-4 depict a prior art subsonic cartridge when oriented with its longitudinal centerline parallel to the horizontal (FIG. 2) and at various angles relative to the horizontal (FIGS. 4 and 5). When the cartridge is tilted downwardly (FIG. 3), the powder within the case flows toward the projectile, and away from the primer, thereby requiring that the primer flame travel through open space within the case before igniting the powder. When the cartridge is tilted upwardly as in FIG. 4, the powder flows to the primer end of the cartridge so that when the primer is fired, the powder is ignited without delay. These circumstances create inconsistent ignition of the powder, inconsistent build up of pressure within the case and barrel, and inconsistency in the accuracy of delivery of the projectile, among other problems.
With specific reference to FIG. 5, in the depicted embodiment of the present invention, there is provided an improved subsonic round 48 of ammunition including an elongated substantially cylindrical case 50 having a longitudinal centerline 49 an open end 52 within which there is received an elongated projectile 54, and having a closed end 55 within which there is received a primer 56. In contrast to the case depicted in FIG. 1, the case 50 of FIG. 5 includes a plurality of "necked down" stages, namely a first stage 58, a second stage 60 and a third stage 62. Referring to FIGS. 6-8, the outer maximum diametral dimension,d, of the case is reduced to a first reduced diametral dimension, d 1 , to define the first "necked-down" stage 58. The length,l, of this first stage, measured along the longitudinal centerline 49 of the round is a function of the standard sizing of the chamber of a particular caliber weapon. In a 0.223 caliber weapon, the length of the first stage will be about 0.18 inch. The case is further "necked-down" by reducing its diametral dimension, d, to a second reduced diametral dimension, d 2 , to define the second "necked-down" stage 60. The length of this second stage is generally a function of the length of that portion of the projectile which is disposed within the case. Desirably, the length of the second stage extends along at least a major portion of the trailing end of the projectile within the case. In those instances where there is an inordinate length of the projectile disposed within the case, as desired, one or more further "necked down" stages may be employed, each such stage serving to further reduce the internal volume of the case which is available to receive powder. In the instance where the trailing end of the projectile extends beyond the combined lengths of the first and second stages, a third "necked down" stage may be employed to define a further annulus between the inner wall of the third stage and that portion of the outer wall of the projectile which is encircled by the inner wall of the third stage. It is understood that there may be provided third, fourth, etc., stages irrespective of the length of the projectile. In the instance of a third stage, the case is further "necked-down" by reducing its diametral dimension, d, to a third diametral dimension, d 3 , to define the third "necked-down" stage 62. The individual length of this third stage, and the individual length of any further stage, preferably is substantially equal to the length of the second stage to provide uniform geometry of the second and third, and any further, stages. Of course, each stage is larger in size than its preceding stage.
The inner diameter of the first stage 58 is such a permits a snug fit therein of the outer circumference of the projectile 16. As noted, in practice, almost all of the projectile extends into the interior of the case, with only the rounded blunt nose of the projectile projecting from the open end of the case.
The second stage 60 defines an annulus 70 between the inner diameter 72 of the case and the outer diameter,d 4 ,of that portion of the projectile which is surrounded by the second stage 60 of the case. Importantly, the inner diameter of the second stage 60 of the present case is established at a value which will distance the interior wall 74 of the case apart from the outer circumference of that portion of the projectile which is surrounded by the second stage 60 such that there is no engagement of the case wall of the second stage with the projectile. Preferably the thickness of the annulus is such that essentially no powder particles can move into the annulus 70 formed between these inner and outer diameters, or the quantity of powder which might enter the annulus is of no material effect upon the pressure build up upon firing of the powder within the case.
The overall length of the case 50 of the present invention is equal to the overall length of the case 12 of the prior art cartridge, for the same caliber weapon. Linear extension of a standard case may occur by the action of forming the stages of reduced diameters. This increase in overall length of the case, if it occurs, is readily rectified by trimming the open end of the case to a proper overall length prior to inserting a projectile into the case.
The projectile of the present invention is essentially identical to the projectile employed in the prior art subsonic cartridge for the same caliber weapon. In this manner, the case of the present invention is received within the chamber of the weapon with its first "necked-down" stage 58 and the exposed end of the projectile being received in the breech end of the chamber of the weapon. To utilize the present cartridge in a weapon, therefore, requires no modification of the weapon. The shoulder 80 formed at the juncture of the first and second stages 58 and 60 serves to engage the breech end of the chamber of the weapon to indicate and ensure that the cartridge has been properly received within the chamber.
On the other hand, the interior volume of the case 50, when the projectile is mounted in the open end thereof, which is available to receive powder, is between about 10% and about 20% less than the available interior volume of the prior art cartridge. In this manner, the present inventor has found that the case of the present invention can be made to be substantially filled with powder and still obtain subsonic velocity of the projectile. By this means, the present round will fire consistently from round to round, the powder will ignite and burn uniformly, and the projectile will be propelled from the barrel at a subsonic muzzle velocity.
By reason of the stepped exterior geometry of the present cartridge, a shooter may readily distinguish the present subsonic cartridge from the normal supersonic cartridge for a given weapon. This recognition is possible merely by visually examining the exterior of the present cartridge or by tactile examination of the exterior of the cartridge, this latter identification method being of importance in low light or dark shooting conditions.
Referring to FIGS. 6-8, in one example of a subsonic round of ammunition manufactured in accordance with the present invention, a case 50 of the type available commercially and comprising a substantially straight cylinder having a longitudinal centerline 49 and an open end 52 (FIG. 6) preferably is provided with a first "necked down" stage 58 (FIG. 7) employing a first forming die, and thereafter provided with a second "necked down" stage 60 employing a second forming die. As desired the case may further thereafter be provided with a third "necked-down" stage 62, employing a third forming die. The procedures for forming a single "necked down" stage are well known in the shooting art and involve placing the case in a forming die and applying pressure in a direction substantially parallel to the longitudinal centerline of the case to force the case into the die and form a "necked down" stage. Heretofore, it has been the practice only to form a single "necked down" stage adjacent the open of the case for the sole purpose of receiving and holding a projectile within the open end of the case. As desired, a single forming die having internally stepped stages may be employed to form the first, second and third stages in a single die forming operation.
As noted, the inner diameter of the second "necked down" stage 60 is greater than the inner diameter of the first "necked down" stage 58. The combined lengths of the first and second stages commonly, and preferably, substantially equals that length of the projectile 16 which is received in the open end 52 of the case. That is, that end of the second stage nearest the rear end of the case is substantially coterminal with the trailing end of the projectile within the case. Recalling that the inner diameter of the first "necked down" stage of the case is substantially equal to the outer diameter of the projectile, it will be recognized that the second "necked down" stage, having an inner diameter that is greater than the outer diameter of the projectile, in cooperation with the projectile encompassed by the second stage of the case, forms an annulus 70 (FIG. 5) surrounding that portion of the length of the projectile which is surrounded by the second stage. The extent of reduction of the diameter of the case at the second stage is chosen such that the annulus 70 has a thickness which is not materially greater than, and preferably less than, the average particle size of powder employed in the cartridge, thereby preventing any material amount of the powder from entering the annulus. This set of conditions effectively reduces the available interior volume of the case by a first amount. Importantly, the inner wall 74 of the second stage 60 does not engage the outer wall of the projectile so as to inhibit the movement of the projectile from the case upon firing of the weapon.
The interior volume of the first stage is occupied by the projectile and therefore is not available to receive powder. The diameter of any third stage is chosen to be less than the original diameter of the case, but greater than the diameter of the second stage. In this manner, the interior volume of the case which is available to receive powder therein is reduced by a second amount. The combined first and second amounts of reduction in the available interior volume of the case are designed to reduce the overall available interior volume of the case to between about 80% and about 90% of its original available volume, the available volume being defined as the original volume of the case less the volume within the first stage.
In the formation of the several stepped stages of the case of the present invention, it is preferred that the extent of diameter reduction per each of the second and third stages be uniform over the number of stages. For example, if the maximum outer diameter of the case is to be reduced, in two stages, to a minimum diameter, then the overall reduction in diameter of the case to be accomplished by the second and third stages would be divided by two to determine the amount of diameter reduction per stage. In this manner, there is provided uniformity of reduction of the case diameter from stage to stage (disregarding the first stage which is filled by the projectile). This factor is of importance in controlling the build up of gas pressure within the case prior to and/or after the projectile has been propelled from the case and/or the barrel of the weapon. More specifically, the present inventor has found that upon the ignition of the slow burning powder by the fired primer, the gas build up within the case commences adjacent the primer and progresses along the length of the case and eventually along the length of the barrel 92. Referring to FIG. 11, as this pressure build up reaches the internal circular shoulder 80 formed by the third stage of diameter reduction, the pressure commences deformation of the shoulder toward the inner wall 82 of the chamber 84 of the weapon in the direction of the arrows 86 of FIG. 11. Substantially instantaneously, the build up of pressure within the case also commences deformation of the internal circular shoulder 88 formed by the second stage of diameter reduction in the direction of the arrows 90 of FIG. 11. This deformation of the case in these areas consumes energy in a gradual manner, thereby causing the internal shoulders to function in the nature of pressure buffers that reduce the rate of pressure build up within the case and thereby tend to make the pressure build up more uniform. This uniformity of pressure build up enhances the control over the propulsion of the projectile from the weapon, thereby ensuring that the projectile does not exceed subsonic velocity. This control over the pressure build up not only has been found to eliminate pressure excursions within the case 50 and weapon barrel 92 which could propel the projectile supersonically, but also permits one to maximize the amount of powder employed for a given round of ammunition to thereby have available adequate pressure for operation of the bolt of a semiautomatic or automatic weapon. Successful control over the pressure build up as noted, is enhanced by selecting the extent of diameter reduction per stage to be uniform between stages as described herein.
In one example of a cartridge embodying the present invention, a 5.56 mm (0.223 caliber) cartridge for the M16 rifle was prepared. In this cartridge, the original outer diameter of the case was 0.36 inch. This case, as received from the manufacturer, was 1.76 inches long overall, had a wall thickness adjacent its open end of 0.012 inch, and included a first "necked down" stage which had an outer diameter of 0.244 inch and an inner diameter of 0.22 inch. This first stage extended from the open end of the case along the length of the case a distance of about 0.18 inch. This case was die formed to produce a second "necked down" stage which had an outer diameter of about 0.264 inch, and which extended from the first stage along the length of the case a distance of about 0.35 inch. Thereafter the case was further die formed to produce a third "necked down" stage having an outer diameter of 0.320 inch. This third stage extended from the second stage along the length of the case a distance of about 0.35 inch. All cartridges cases were chosen for uniformity of construction. All projectiles were crimped in their respective cases employing a uniform crimping procedure and pressure.
The case was provided with a primer and loaded with 10.2 grains of N540 gunpowder from Vihta Vuori Oy. Thereafter, a 126 grain projectile formed from a mixture of tungsten and lead powders, cold-compacted to a density of between 11.6 and 12.4 and encased in a copper jacket, was inserted into the open end of the case. This projectile possessed a flat end 25 which was inserted into the case and a rounded blunt end 27 which projected from the open end of the case. The projectile was 0.85 inch in length, had an outer diameter of 0.224 inch, and substantially all of the projectile was received within the case, aside from the blunt rounded nose (about 0.015 inch length) of the projectile which was disposed within the barrel 92 to a terminus just short of the breech ends of the lands 94 of the barrel when the cartridge was disposed within the chamber 84 in position for firing. After the projectile had been inserted into the case, approximately 80% to 90% of the interior volume of the case that was not occupied by the projectile was filled with the powder. This powder had an average particle size such that essentially no powder was able to enter the 0.008 inch thick annular space between the internal diameter of the second stage of the case and the outer diameter of the projectile.
Multiple ones of the cartridge of the above example were produced and fired using an unmodified M16-M4 military rifle. Firing was conducted in semiautomatic mode and in automatic mode employing various barrel lengths. In both modes of operation, the projectiles of the present cartridges left the muzzle of the weapon at subsonic speeds and, in both modes of operation, at the end of a firing cycle (i.e. all cartridges in the magazine were fired), the bolt of the weapon was locked in the open position. There were no failures of proper bolt operation during either of these modes of operation. | An ammunition cartridge for producing subsonic flight of a projectile therefrom at substantially all angles of fire relative to the horizontal, including an elongated, generally cylindrical case including a closed end containing a primer therein, a body portion suitable for the receipt of a quantity of gunpowder therein, and an open end suitable for receiving an elongated projectile therein. The case further includes a first stepped down stage at the open end thereof wherein the outer diameter of thereof is reduced by an amount sufficient to encircle at least a portion of the length dimension of the elongated projectile to thereby temporarily retain the projectile disposed in the open end of said case means prior to the firing of said cartridge, and at least one further stepped down stage disposed contiguous to said first stepped down stage and extending from said first stepped down stage in the direction of the closed end of said case means, the reduced diameter of said second stepped down stage being greater than the diameter of said first stepped down stage. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/881,443, filed Jul. 27, 2007, which is a continuation of U.S. patent application Ser. No. 11/411,261, filed Apr. 26, 2006, U.S. patent application Ser. No. 10/756,437, filed Jan. 13, 2004, now U.S. Pat. No. 7,094,235, which is a continuation of U.S. patent application Ser. No. 10/016,297, filed Dec. 12, 2001, now U.S. Pat. No. 6,699,240, incorporated herein by reference in their respective entireties. This application also claims priority from U.S. Provisional Patent Application No. 60/286,953, filed Apr. 26, 2001, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to surgical tools and procedures generally and relates more particularly to the use of ablation to treat atrial fibrillation and other disorders.
[0003] In patients with chronic atrial fibrillation having tachycardia that resistant to medical treatment, the Maze procedure has been employed. This procedure controls propagation of the depolarization wavefronts in the right and left atria by means of surgical incisions through the walls of the right and left atria. The incisions create blind or dead end conduction pathways, which prevent re-entrant atrial tachycardias from occurring. While the Maze procedure is successful in treating atrial fibrillation, the procedure is quite complex and is currently practiced by only a few very skilled cardiac surgeons in conjunction with other open-heart procedures. The procedure also is quite traumatic to the heart, as in essence the right and left atria are cut into pieces and sewn back together, to define lines of lesion across which the depolarization wavefronts will not propagate.
[0004] It has been suggested that procedures similar to the Maze procedure could be instead performed by means of electrosurgical ablation, for example, by applying RF energy to internal or external surfaces of the atria to create lesions across which the depolarization wavefronts will not propagate. Such procedures are disclosed in U.S. Pat. No. 5,895,417, issued to Pomeranz, et al., U.S. Pat. No. 5,575,766, issued to Swartz, et al., U.S. Pat. No. 6,032,077, issued to Pomeranz, U.S. Pat. No. 6,142,944, issued to Swanson, et al. and U.S. Pat. No. 5,871,523, issued to Fleischman, et al, all incorporated herein by reference in their entireties. Hemostat type electrosurgical or cryo-ablation devices for use in performing such procedures are described in U.S. Pat. No. 5,733,280 issued to Avitall, U.S. Pat. No. 6,237,605 issued to Vaska, et al, U.S. Pat. No. 6,161,543, issued to Cox, et al., PCT published Application No. WO99/59486, by Wang and in pending U.S. patent application Ser. No. 09/747,609 filed Dec. 22, 2000 by Hooven, et al., all incorporated herein by reference in their entireties. In order for such procedures to be effective it is desirable that the electrosurgically created lesions are continuous along their length and extend completely through the tissue of the heart. In order for such procedures to be effective it is desirable that the electrosurgically created lesions are continuous along their length and extend completely through the tissue of the heart. Analogous issues arise when attempting to create continuous lines of lesion through the walls of other heart chambers or other organs.
SUMMARY OF THE INVENTION
[0005] According to the present invention elongated lesions as might be desired in a maze type procedure or other procedure may be produced using a set of two elongated ablation components carrying means (e.g. an electrode or electrodes) for applying ablation energy (e.g. RF energy) along its length. The ablation components are adapted to be arranged on opposite sides of the walls of the atria or other hollow organs, on either side of the organ walls and to ablate or create lesions in the tissue between the components. The ablation components may also be arranged along opposing external surfaces of an organ, for example opposite sides of an atrial appendage or along opposite sides of the tissue adjacent the bases of the right or left pulmonary veins.
[0006] The ablation components are provided with a magnetic system for drawing the components toward one another to compress the wall or walls of an atrium or other hollow organ therebetween, along the length of the components. In these systems, at least one of the components is provided with a magnet or series of magnets extending along the component. The other component is provided with a ferromagnetic member or preferably another magnet or series of magnets extending along its length, having polarity chosen to assure attraction between the two components. The magnet or magnets may be rigid or flexible and may be formed of magnetic material, e.g. rare earth magnets, or may alternatively be electromagnets.
[0007] In one preferred embodiment of the invention, the two components comprise opposing jaws of an electrosurgical hemostat, provided with elongated RF electrodes and having straight or curved configurations. In some of these embodiments, the jaws of the hemostat are both rigid and the magnets are present primarily to assure good contact and alignment between the jaws, along their length. In other embodiments, one jaw may be rigid and the other flexible, for example to allow it to be temporarily deformed to access desired locations. In these embodiments, magnetic system also assists the flexible jaw in returning to a configuration corresponding to the rigid jaw, as the jaws are brought into proximity to one another. In some embodiments, one jaw may be shapeable, so that the physician can select a desired configuration, with the other jaw being flexible. In these embodiments, the magnetic system allows the flexible jaw to automatically assume a configuration corresponding to the shapeable jaw. In other embodiments, both jaws might be flexible.
[0008] Similar sets of embodiments may be provided wherein the two components are separate from one another, for example mounted to separate handles. Alternatively, a first, external component might be mounted to a handle, to he held by the physician, while a second, internal component may be located on a percutaneously introduced catheter. In these embodiments, the internal component would typically be quite flexible, while the external component would be either rigid or shapeable. In these embodiments the magnetic system allows the internal component to automatically assume a configuration corresponding to the external component, after introduction of the internal component to the interior of the hollow organ.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a plan view of hemostat of the type in which the present invention may be embodied.
[0010] FIGS. 2A through 2G illustrate alternative configurations for the jaws of the hemostat of FIG. 1 , illustrating alternative embodiments of the present invention in cross section and longitudinal section.
[0011] FIG. 3 is a perspective view of a hemostat of a second type, in which the present invention may be usefully practiced.
[0012] FIG. 4 is an illustration of a system employing the invention, including a first external component and a separate second internal component.
[0013] FIGS. 5A through 5D illustrate alternative embodiments of the distal portion of the internal component illustrated in FIG. 4 , in cross section and longitudinal section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] FIG. 1 is a plan view illustrating a bipolar electrosurgical hemostat of a type in which the present invention may usefully be practiced. The hemostat is provided with handles 14 and 12 , coupled to pivoting jaws 16 and 18 , respectively. Located along jaws 16 an 18 are ablation electrodes 20 and 22 , which, as discussed below, take the form of RF electrodes. In alternative embodiments, electrodes 20 and 22 may be employed to apply microwave radiation, or might be replaced by elongated heating or cooling elements to provide for thermal or cryo-ablation along their length. In the embodiment illustrated, the electrodes are irrigated RF electrodes, allowing for delivery of saline or other conductive fluid along their lengths, generally according to the mechanism as described in U.S. Pat. No. 6,096,037 issued to Mulier, incorporated herein by reference in its entirety. Each electrode is provided with a fluid delivery lumen 30 , 32 , through which the saline or other conductive fluid is delivered to the electrodes. Lumens 30 and 32 are coupled to a luer fitting 34 , which may be coupled to a source of conductive fluid. Separate luer fittings for each of lumens 30 , 32 might alternatively be provided. Similarly, each electrode is provided with conductors 24 , 26 allowing the electrodes to be coupled to a source of ablation energy via electrical connector 28 , as noted above. The source of ablation energy may provide RF energy or microwave energy. In alternative embodiments in which electrodes 20 and 22 are replaced by heaters, the fluid delivery lumens may not be provided, and instead, electrical conductors 24 and 26 may be coupled to two elongated resistive heaters arranged along jaws 16 and 18 , and coupled to an electrical power source via connector 28 . In alternative embodiments in which elongated cooling elements are substituted for electrodes 20 and 22 , cooling fluid might be delivered to electrodes via fluid lumens 30 and 32 or alternatively, in the event electrical cooling devices are provided, electrical power might be delivered to the cooling devices via connectors 24 and 26 through electrical connector 28 .
[0015] While the discussion below focuses on ablation systems in which the particular ablation energy delivered is RF energy, delivered via irrigated electrodes, it should be understood that the present invention can usefully be practiced in conjunction with the other forms of ablation energy referred to above. As such, for purposes of the following discussion, the illustrated and described irrigated RF electrodes should be taken as exemplary of a mechanism for applying ablation energy according to the present invention, rather than as limiting.
[0016] Jaws 16 and 18 may have a straight configuration as illustrated, or may be curved. Jaws 16 and 18 are preferably manufactured of a non-ferromagnetic material such a biocompatible plastic, and, as discussed below, carry an elongated magnet or series of magnets, extending along the electrodes 20 and 22 , in order to assist in aligning the electrodes relative to one another on opposite sides of tissue to be ablated and to assist in compressing tissue between the electrodes to assure good contact along their length. As described in more detail, jaws 16 and 18 may be rigid, shapeable, or flexible, depending on the particular embodiment of the invention being practiced.
[0017] FIGS. 2A through 2G illustrate various alternative embodiments of the invention, employing different types of magnetic alignment systems and different configurations for the first and second components (in this case the jaws 16 and 18 ), along which ablation energy is to be applied. FIG. 2A illustrates a cross sectional view through jaws 16 and 18 of the hemostat of FIG. 1 , in which the electrodes 20 and 22 take the form of elongated electrode coils 100 , 102 , respectively, carrying internal porous tubes 104 and 106 . Tubes 104 and 106 may be fabricated, for example, of porous polytetrafluoroethylene (PTFE), and have their internal lumens coupled to the fluid lumens 30 and 32 illustrated in FIG. 1 . By this mechanism, delivery of conductive fluid such as saline solution along the length of the electrode coils 101 and 102 may be accomplished. While as described, the electrodes 20 and 22 each include a single elongated electrode coil embodiments in which the components (jaws 16 and 18 ) are provided with multiple electrodes arranged along their length are also within the scope of the present invention.
[0018] As illustrated, jaws 16 and 18 are each provided with a pair of magnets or a series of magnets 108 , 110 , 112 , 114 , which extend along the jaws 16 and 18 . These magnets, shown in cross section, may either be individual elongated magnets or may be a series of shorter magnets, extending along the jaws. The polarities of magnets correspond to the “N” and “S” markings as illustrated, arranged such that the jaws 16 and 18 are attracted to one another along their lengths. Provision of magnets on both sides of the electrodes 18 and 20 assist in assuring that the electrodes will center themselves with respect to one another so that the electrodes will be located directly across from one another when placed on opposite sides of tissue to be ablated. The magnets also assist in compressing the jaws of the hemostat along their length, assuring good contact with the tissue along the length of the jaws.
[0019] Jaws 16 and 18 are preferably fabricated of a non-ferromagnetic material, such as a plastic, so that the magnets and electrode coils as illustrated may be insulated from one another. In some embodiments, both jaws 16 and 18 may be rigid and may be pre-formed with the same configuration so that they are parallel to one another. Alternatively, one of jaws 16 and 18 may be rigid, while the other of the two jaws may be quite pliant or flexible, so that upon placement of the jaws on either side of the wall of a hollow organ to be ablated, the magnetic force provided by the magnets causes the flexible jaw to assume a configuration parallel to the rigid jaw and to compress the wall of the hollow organ between the jaws. In additional alternative embodiments, one of the two jaws 16 and 18 may be shapeable by the physician, to assume a desired configuration, with the other of the two jaws being flexible. In this embodiment as well, the flexible jaw is aligned and configured parallel to the shapeable jaw when the two jaws are brought towards one another on either side of the wall of the hollow organ to be ablated. The shapeable jaw may be shapeable by virtue of the material chosen to fabricate the jaw, or means of a shapeable insert, for example, a longitudinally extending rod of nitinol, stainless steel, or other shapeable metal, not illustrated in FIG. 2A .
[0020] FIG. 2B illustrates an alternative embodiment of an invention according to the present invention, similarly showing a cross section through jaws 16 and 18 of the hemostat of FIG. 1 . All elements correspond to identically numbered elements in FIG. 2A . In this embodiment, only a single elongated electrode or line of electrodes 116 , 118 is provided for each of the two jaws 16 , 18 respectively. This configuration allows for a reduction in the overall size of the jaws, but otherwise functions as described in conjunction with FIG. 2A . In FIG. 2B , an optional metallic shaping wire 120 is shown, mounted adjacent to the magnet or magnets 118 , to allow the physician to shape jaw 18 . In embodiments in which this shaping wire is present, it is to be expected that jaw 16 would be flexible, and would conform to the configuration provided to jaw 18 by the physician, after placement of the jaws on opposite sides of tissue to be ablated.
[0021] FIG. 2C illustrates a third alternative embodiment of the present invention, also taking the form of a cross section through jaws 16 and 18 of the hemostat of FIG. 1 . Identically, numbered components correspond to those illustrated in FIG. 2A . In this embodiment, elongated magnets or series of magnets 122 and 124 are located within the porous fluid lumens 106 and 104 , so that magnetic force applied to draw the jaws 16 and 18 toward one another is applied centered with respect to the electrode coils 100 and 102 . The various alternative embodiments discussed above in conjunction with FIGS. 2A and 2B may correspondingly be provided in conjunction with the jaws having the general configuration illustrated in FIG. 2C .
[0022] As illustrated in 2 A, 2 B and 2 C, the magnets are arranged so that the south pole(s) of the magnet(s) of one jaw are adjacent to the north pole(s) of the magnet(s) of the other jaw. This configuration will be most desirable in conjunction with embodiments in which single, elongated magnets extend essentially along the length of the jaws, and also in embodiments in which a series of shorter, closely spaced magnets extending along the jaws is provided. In embodiments in which magnets extend along the jaw but are more substantially spaced from one another, the polarity of the magnets may be altered, so that along one jaw, the north poles of the magnets may be located at the distal ends of the magnets and the south poles located at the proximal ends wherein on the other jaw, the south poles of the magnets will be located at their distal ends and north poles of the magnets will be located at proximal ends. Alternative magnetic configurations such as this may be employed in any of the embodiments illustrated in FIGS. 2A , 2 B and 2 C in which the magnets take the form of series of spaced, magnets, running along the lengths of the jaws.
[0023] The magnets themselves may be of any appropriate magnetic material. One particularly desirable set of magnetic materials for use in the present invention may be rare earth magnets, due to their extraordinary strength for relatively small sizes and weights. However, elongated flexible magnets might be substituted, as well as ceramic magnets. In addition, as discussed in more detail below, the magnets may be replaced with electromagnetic coils. In further alternative embodiments, it may be possible to employ magnets located in only one of the jaws, substituting a ferromagnetic material such as magnetic stainless steel for the other of the two magnets. For example, in the embodiment illustrated in FIG. 2A , magnets 108 and 110 might be replaced be elongated magnetic stainless steel members. In such an embodiment, the elongated stainless steel members would be attracted to the magnets 112 and 114 as described below and might also be employed to provide the ability to shape the jaw 116 to a desired configuration. Similar substitutions of non-magnetized ferromagnetic materials for the magnets illustrated in FIGS. 2B and 2C are also believed within the scope of the present invention.
[0024] FIG. 2D is a longitudinal sectional view through jaw 18 of the hemostat of FIG. 1 . In this embodiment, the magnets 112 and 114 take the form of a series of magnets, mounted within the body of jaw 18 . Electrode coil 102 and fluid lumen 106 are also illustrated in longitudinal section.
[0025] FIG. 2E illustrates an alternative longitudinal sectional view through jaw 18 , otherwise as illustrated in FIGS. 1 and 2A . Components corresponds to identically numbered components in FIG. 2A . In this embodiment, however, jaw 18 is provided with indentations 126 in between the individual magnets 114 and 112 . These indentations, in conjunction with fabrication of the jaw 18 of the flexible material, define hinge points, facilitating bending of the jaw 18 . Such a configuration will be particularly desirable in the event that jaw 16 as illustrated in FIGS. 1 and 2A were to be made rigid or shapeable, with jaw 18 being flexible enough to adapt to the configuration of jaw 16 , when placed on the opposite side of tissue to be ablated.
[0026] FIG. 2F is a longitudinal sectional view through a hemostat having a jaw configuration as illustrated in FIG. 2C . Components correspond to identically numbered components in FIG. 2C . In this view, the magnet 122 takes the form of a series of magnets located within fluid lumen 104 .
[0027] FIG. 2G illustrates a longitudinal section through an embodiment of the present invention having a jaw configuration as illustrated in FIG. 2B . In this embodiment, the magnet 118 take the form a series of magnets 118 , located along side the shaping wire 120 . Electrode coil 102 and fluid lumen 104 are also visible.
[0028] In the embodiments of FIGS. 2D , 2 F and 2 G, it should be understood that elongated continuous magnets, flexible or rigid might be substituted for a series of individual magnets as illustrated. In addition, it should also be understood that in some embodiments, the magnets as illustrated might be more widely spaced from another, and arranged so that their north/south magnetic access extends longitudinally along the lengths of the jaws, as described above in conjunction with FIGS. 2A through 2C . In such embodiments, the north/south magnetic axes of the magnets in one jaw would be opposite those of the magnets in the other jaw. Jaws employing this arrangement of magnets might also be used in conjunction with a jaw or other ablation component taking the form of a series of electro magnets, for example, coils having their axes extending along the axes of the jaws or other ablation components.
[0029] FIG. 3 is a perspective view of a bipolar electrosurgical hemostat of a second type, appropriate for use in conjunction with the present invention. In this embodiment the hemostat is provided with handles 212 and 214 and elongated jaws 216 and 218 . In this case, jaw 218 carries a circular ablation component 238 , along which an electrode 220 is arranged. Jaw 216 is provided with a hook shaped ablation component 236 , carrying a corresponding electrode facing electrode 220 . The instrument of FIG. 3 is particularly adapted for ablations and circling the bases of the pulmonary veins, in the context of an electrosurgical procedure analogous to a maze procedure as discussed above. In this embodiment, it may be desirable that the circular ablation component 238 is either rigid or shapeable by the physician, to allow adaptation of the configuration of the component to this particular anatomy of the patient involved. Component 236 is preferably at least flexible enough to be spread open slightly to facilitate placing of the jaw around the basis of the pulmonary veins and may be quite flexible, relying on the magnetic attraction between components 236 and 238 and to cause component 236 to assume a configuration parallel to component 238 . As in conjunction with the hemostat illustrated in FIG. 1 , fluid lumens 230 and 232 are provided to allow delivery of a conductive fluid to the electrodes, via luer fitting 234 . Electrical conductors 224 and 226 are provided to conduct electrical energy to the electrodes, via electrical connector 228 . As discussed above in conjunction with the hemostat of FIG. 1 , alternative means for applying ablation energy such as microwave antenna or heaters or coolers to provide thermal or cryo-ablation may be substituted for the electrodes.
[0030] FIG. 4 illustrates an additional alternative embodiment of the invention, in which the two ablation components are separate from one another rather than being joined as in the hemostats of FIGS. 1A and 3 . In this embodiment, the first component corresponds generally to jaw 216 of the hemostat of FIG. 3 , provided in this case with a handle 312 allowing the physician to manipulate the device. An electrode 320 extends around the curved ablation component 318 , and may be, as discussed above, an irrigated electrosurgical electrode, provided with fluid via lumen 332 and luer fitting 334 and provided with electrical power via conductors 326 and electrical connector 328 . In use, the curved ablation component 318 will be placed on the exterior surface of the organ to be ablated, for example, placed around the bases of a patient's pulmonary veins. In this particular embodiment, the curved ablation component 318 is preferably rigid or malleable, as the internal ablation component 304 , as discussed below, will be quite flexible.
[0031] The internal ablation component 304 takes the form of a catheter having an elongated catheter body 414 carrying an electrode along its distal portion 420 . Distal portion 420 may have a structure corresponding generally to the illustrated structures for the jaws of the hemostats as illustrated in FIGS. 2A through 2G , with the caveat that the structure of a distal portion 420 of the catheter should be fabricated of a sufficiently flexible material that it may be introduced percutaneously and navigated to the desired location within the organ to be ablated. For example, the catheter might be advanced through the vascular system to the interior of the left atrium, to a position adjacent the openings into the pulmonary veins. Alternatively, as illustrated in FIGS. 5A through D below, the distal portion 420 of the catheter may be specifically optimized for location at the distal portion of a catheter. As illustrated, the proximal end of the catheter is provided with a fitting 416 carrying a fluid coupling 434 allowing delivery of saline or other conductive fluid to the electrode located along the distal portion 420 of the catheter. Electrical power is provided to the electrode by means of conductors 426 and connector 428 in a fashion analogous to that described above for the other embodiments.
[0032] FIGS. 5A-5D illustrate various alternative configurations for the distal portion 4120 of the catheter 304 illustrated in FIG. 4 . The embodiments of the invention as illustrated in FIGS. 5A-5D may also be employed in external ablation components as illustrated in FIG. 4 or in hemostat type devices as illustrated in FIGS. 1 and 3 .
[0033] FIG. 5A is cross sectional view through the distal portion 420 of the catheter illustrated in FIG. 4 , showing a first embodiment of invention particularly optimized for use as part of a percutaneously introduced catheter. In this embodiment, the outer surface of the distal portion comprises a porous tube 404 , which may be made of PTFE as discussed above, surrounding an electrode coil 402 . A magnet or series of magnets 406 is mounted within the lumen of the electrode coil 402 . In this embodiment, fluid is delivered through the lumen of the electrode coil 402 , permeates through the porous wall of tube 404 , and electrical energy provided by electrode 402 is coupled to the tissue to be ablated via the conductive fluid in the wall and on the surface of tube 404 . As illustrated, the electrode is shown having its magnetic polarity such that its north/south axis runs transverse to the axis of the catheter. However, alternative embodiments employing a series of spaced magnets having their north/south axis running along the axis of the catheter are also within the scope of the invention.
[0034] FIG. 5B shows an alternative cross section through the distal portion 420 of the catheter FIG. 4 . Numbered elements correspond to identically numbered elements in FIG. 5A . In this embodiment, however, a shaping wire 410 is shown, allowing the physician to provide a desired configuration to the distal portion 420 of the catheter. For example, the catheter may be biased to assume a generally circular configuration, which is straightened during the passage of the catheter through the vascular system, with shaping wire 410 allowing it to resume its desired configuration when no longer retrained by vascular system.
[0035] FIG. 5C shows an additional alternative cross section through the distal portion 420 of the catheter FIG. 4 . Numbered elements correspond to identically numbered elements in FIG. 5A . In this embodiment, coil 412 , however is not an ablation electrode but instead is employed as an electromagnet to attract the catheter to an associated external ablation component. Delivery of ablation energy, e.g. RF or microwave, is accomplished by central wire 418 .
[0036] FIG. 5D shows a longitudinal sectional view through the distal portion 420 of a catheter having a cross section as illustrated in FIG. 5C . Numbered elements correspond to identically numbered elements in FIG. 5C . In this view it can be seen that coil 412 is one of a series of spaced electromagnet coils spaced along the distal portion 420 of the catheter. As illustrated, coils 412 are wired in series, however, in alternative embodiments they may be wired for individual activation. | A method for ablation in which a portion of atrial tissue around the pulmonary veins of the heart is ablated by a first elongated ablation component and a second elongated ablation component movable relative to the first ablation component and having means for magnetically attracting the first and second components toward one another. The magnetic means draw the first and second components toward one another to compress the atrial tissue therebetween, along the length of the first and second components and thereby position the device for ablation of the tissue. | 0 |
SUMMARY OF THE INVENTION
This invention is concerned with a so-called dual-fuel engine which is an engine that is supplied with a mixture of gaseous fuel and air that is ignited by the injection of so-called pilot oil which is a small quantity of diesel fuel.
A primary object of the invention is to more efficiently operate dual-fuel engines.
Another object is to operate such an engine in a more efficient manner so that it is specifically applicable to over-the-road engines, such as trucks.
Another object is to electronically control the pilot oil injector in an engine of the above type.
Another object is to delay the time of injection as the speed of the engine decreases.
Another object is an injection procedure whereby the pilot oil starts to burn at the same piston position regardless of speed.
Another object is a method of operating an engine of the above type in which the same quantity of pilot oil is injected over the entire speed range.
Other objects will appear from time to time in the ensuing specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of an engine in accordance with my invention; and
FIG. 2 is a control diagram.
DETAILED DESCRIPTION
In the drawing an engine is indicated generally at 10 which is a cross section through one cyliner and piston. It should be understood that the engine may have a number of cylinders and pistons, for example six or eight. The cylinder 12 may have a water jacket for cooling purpose and the cylinder head 14 is mounted thereon by conventional head bolts not shown. The cylinder head has an inlet valve 16 and an exhaust valve 18. An inlet manifold is indicated generally at 20 which supplies air through an inlet passage controlled by the inlet valve 16. A conventional butterfly valve 22 controls the air flow to the engine in the case of a normally aspirated engine. For a highly turbocharged engine a wastegate (not shown) would be employed. The gaseous fuel is supplied from a manifold 24 through a metering valve 26 to a gas inlet pipe 28 in the inlet passage with a gas-air mixture beig formed at or around the inlet valve.
The engine has a diesel fuel injector 30 which is shown mounted between the inlet and exhaust valves. And it should be understood that the injector supplies a small quantity of pilot oil after the air-gas mixture is in the cylinder to initiate combustion. A diesel fuel supply 32 of any suitable type provides pilot oil through a filter 34 to a fuel pump 36 and thereafter to a pressure relief valve 38, then to a fuel pressure regulator 40 and thereafter through a supply line 42 to the pilot fuel injector 30. A return line 44 returns excess pilot oil to the supply 32.
The inlet and exhaust valves are camshaft operated in the usual manner. However, the pilot fuel injection is electronically controlled and may have a microprocessor 46 which is an electronic engine control unit with various input and output signals. For example, the inputs on the left side may be the governor position 48, the fuel pressure 50, the speed of the engine 52 and the timing of the engine crankshaft at 54. On the right side typical inputs may be the operating mode, i.e. whether the engine is being operated as a full diesel engine or on the dual-fuel cycle at 56, the air and fuel temperatures and pressures for air-fuel ratio calculations at 58 and other suitable sensors as at 60. Three outputs are shown on top, the first being a diesel rail pressure regulator 62, the diesel injector control 64 for injector 30 and a control to the gas metering valve at 66 which controls gas metering valve 26. These various inputs and outputs may be conventional, for example as explained in U.S. Pat. No. 4,628,818, issued Dec. 16, 1986. The crank angle position or position of the piston may be determined by a crank angle sensor indicated generally at 68 and a similar cam sensor 70 may be used to determine the position of the cams on the crankshaft.
The use, operation, and function of the invention are as follows:
One of the reasons for converting diesel engines to the dual-fuel mode is that there is a significant difference in the cost between diesel fuel and natural gas, the natural gas being the cheaper on an energy basis. The ability, therefore, to reduce the amount of diesel fuel used as pilot oil adds materially to the economics backing the conversion to dual-fuel.
It is well known that the delivery from a jerk type fuel pump is not linear with speed. If, on the one hand, the pump has been adjusted to deliver the minimum required amount of pilot oil at the rated speed the fuel pump will fail to deliver enough oil to cause the injector to open when the engine slows down. If, on the other hand, the pump has been adjusted to deliver the minimum requirement for the injector to work properly at the minimum required speed (idling) the engine, when speed is increased toward the rated RPM, will knock violently due to the additional ignition points throughout the combustion space.
In addition to the problem caused by the variation in fuel delivery with speed discussed above, most jerk pumps are also cam driven and the pump timing is therefore difficult to change. The need to change the injection timing arises when there is a major change in speed. If, to accommodate the ignition delay common for diesel fuels, the timing of injection is advanced this advance will cause the engine to lose efficiency due to early firing when speed is reduced. To save fuel and avoid other troubles with the engine it is therefore desirable that timing should be able to be altered when major changes in speed takes place.
Both the variable delivery problem and the inability to readily change timing can be overcome by the use of an electronic engine control unit in conjunction with unit injectors powered hydraulically.
The injectors may comprise a high-speed solenoid, pressure intensifier, and accumulator nozzle. The fuel quantity received by the injectors is governed by the variable common rail pressure. The microprocessor can be programmed to vary injection timing in consonance with speed and to hold the pilot oil quantity constant regardless of speed changes.
Besides the functions described above, the microprocessor has the capacity to control other functions such as air-fuel ratio, speed control, etc., necessary for good dual-fuel engine operation.
The recommended system for a carbueretted or port-injected dual-fuel engine operates on natural gas with diesel fuel pilot oil injection. As the engine senses speed changes, the microprocessor will change the timing of injection to what it should be dependent upon the speed involved. There will be a certain time of injection when the engine is running at its rated speed. As the engine slows down, the time of pilot oil injection will be retarded so that the injection will start at approximately the same time interval prior to TDC. The quantity of pilot oil will not change but rather will be set constant and will be set by the microprocessor. Thus, injection and the resulting ignition will vary depending upon engine speed. In either case, the length of the time that it takes the fuel to react is the same. The amount of pilot oil injected is set in accordance with low speed and will be generally constant throughout speed changes so that at the high speeds, excess pilot oil is not being injected.
The engine shown on the drawings may be assumed to be either two cycle or four cycle, naturally aspirated or supercharged. And if supercharged it may be either an exhaust driven turbo charger or a crankshaft driven unit.
While the preferred form and several variations of the invention have been shown and suggested, it should be understood that suitable additional modifications, changes, substitutions, and alterations may be made without departing from the invention's fundamental theme. | This is concerned with a method of operating a dual-fuel engine, meaning an engine that is supplied with a mixture of gaseous fuel and air which is ignited by an injection of a small amount of so-called pilot oil which is diesel fuel. Additionally the invention is concerned with a method of operation that injects an approximately constant amount of pilot oil regardless of speed variations so as to save fuel at the higher speeds and is specifically applicable or useful with over-the road dual fuel engines, meaning mobile units on trucks, tractors, etc. | 8 |
This application corresponds to Korean patent application No. 97-3580 filed Feb. 5, 1997 in the name of Samsung Electronics Co., Ltd., which is herein incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of fabricating a semiconductor memory device, and more particularly, to a method for etching a Pt film or layer which is used as a storage node of a capacitor of a semiconductor memory device.
2. Description of the Related Art
In general, as semiconductor memory devices (such as a dynamic random access memory (DRAM)) become more highly integrated, they require capacitors of high capacitance which occupy only a small area. To satisfy this integration requirement, a trench type or cylinder type capacitor has been developed which offers high capacitance with a relatively small surface area. Unfortunately, however, the trench type or cylinder type capacitor is difficult to form correctly and requires a complicated fabrication process. Therefore, using conventional technology, there are severe, practical limits to the realization of the desired high capacitance and high integration of the semiconductor memory device.
To solve the problems of fabrication difficulty and inconsistency, a method for forming a capacitor has been developed and widely utilized which uses barium strontium titanate (BST) as a dielectric of the capacitor. BST has a dielectric constant approximately 400 times higher than that of a conventional dielectric. When the capacitor is formed using a material having a high dielectric constant, such as BST, a platinum (Pt) layer is usually used as plate and storage nodes of the capacitor. Pt is used because it is a stable material and therefore does not oxidize at the surface of the dielectric during the high-temperature heat treatment required for forming the BST dielectric film. Moreover, Pt has excellent conductivity and therefore less leakage current is generated from the dielectric electrode of the capacitor than when other conductive films such as iridium (Ir), ruthenium (Ru), or polysilicon are used. One drawback of Pt, however, is that because it is a non-reactive metal, it does not react easily with other chemicals and is therefore very difficult to pattern using dry etching.
Due to this difficulty, halogen is usually used for etching the Pt layer in a process known as "reactive ion etching" (RIE). Unfortunately, because halogen reacts only weakly with Pt ions, the Pt layer is etched primarily by a physical reaction called "ion sputtering" rather than by a chemical reaction. As the Pt layer is etched by ion spluttcrinig, etchingy residues are generated which reduce the etching slope of the Pt layer and thereby result in Pt electrodes which do not have a fine pattern. A fine pattern of Pt electrodes is desirable because the BST capacitor will be used increasingly in fine pattern DRAM devices. Also, because of the difficulty in etching the Pt layer, the etch rate is generally low. A low etch rate is undesirable because it results in low throughput. In order to improve the low etch rate during reactive ion etching, an etching gas containing chlorine or fluorine is used because of the possibility of Pt compound formation.
A conventional method for etching the Pt layer, using chlorine gas as an etching gas, is disclosed in U.S. Pat. No. 5,515,984 "Method for etching Pt layer," issue date May, 14, 1996. According to this conventional method, chlorine and oxygen are used as an etching gas. Etching residues platinum chloride (PtCl) and platinum monoxide (PtO) arc correspondingly formed on the sidewalls of an etching resist film and the Pt layer is etched using the etching resist film and the etching residues as an etching mask. The etching residues are then removed by a process known as "wet etching." Despite the improvements offered by this technique over the other processes described above, the etching residues left by this process require appropriate removal, and the etching slope of the Pt layer is still less than desirable. As for the etching residue, it was revealed from experiments that most of the residue is pure aluminum rather than platinum compounds, so most of the residues cannot be removed by wet etching. The industry is therefore in need of a method for etching a Pt layer of a semiconductor device which results both in an improved etching slope of the Pt layer and in Pt electrodes having a finer pattern.
SUMMARY OF THE INVENTION
To solve the problems experienced in the prior art, it is an object of the present invention to provide a method for etching a Pt layer of a semiconductor device which results in an improved etching slope of a sidewall of the Pt layer.
According to this invention, a method for etching a Pt layer of a semiconductor device is provided in which a semiconductor substrate, where a Pt layer is formed, is heated to a predetermined temperature during an etching process of the Pt layer. An adhesive layer containing titanium (Ti) is used as an etching mask on the Pt layer in order to improve the etching slope of the Pt layer and to improve the electrode pattern.
Specifically, the method for etching a Pt layer of a semiconductor device includes forming a barrier layer, a Pt layer, an adhesive layer containing Ti, and a mask layer on the semiconductor substrate, in sequence. The semiconductor substrate includes a bottom layer in which the trench or cylinder type capacitors arc formed. The mask layer is then patterned to form a mask pattern, following which the adhesive layer is patterned using the mask pattern. Patterning is performed by dry etching, using a mixture of argon and chlorine as an etching gas.
The resultant structure is heated to a temperature of approximately between 120˜300° C., in a plasma etching apparatus, without exciting the plasma of the etching apparatus. The Pt layer is then etched using a patterned mask layer and a patterned adhesive layer formed on the semiconductor substrate. The mask layer is preferably composed of one or more layers including at least one oxide layer. It is also preferable for the adhesive layer to contain Ti and to have the barrier layer formed of titanium nitride (TiN) or a material containing TiN. The bottom layer of the semiconductor substrate includes a first insulating layer having contact holes formed on the semiconductor substrate, each of which is filled with a polysilicon plug.
The Pt layer is patterned using mixtures of oxygen and chlorine (O 2 /Cl 2 ), oxygen and hydrogen bromide (O 2 /HBr), oxygen and bromine (O 2 /Br 2 ), or oxygen and argon (O 2 /Ar) as etching gases. Preferably, the Pt layer is patterned using an etching method known as "magnetically enhanced reactive ion etching" (MERIE), and using O 2 /Cl 2 as the etching gas, where oxygen is 50% or more of the total O 2 /Cl 2 mixture by flow rate (sccm). The mask pattern on the Pt layer is then removed by overetching.
Overetching to remove the mask pattern is performed by extending the total etching time by about an additional 0.5˜1.5 times the etching time required to etch up to an etching end point of the Pt layer. The adhesive layer and the barrier layer are patterned using a mixture of argon and chlorine (Ar/Cl 2 ) as the etching gas.
In summary, according to the present invention, the semiconductor substrate where the platinum (Pt) layer is formed is heated to a predetermined temperature and the platinum (Pt) layer is overetched using an etching gas. An adhesive layer containing titanium (Ti) is used as an etching mask on the platinum (Pt) layer. The Ti etching mask increases protection of the Pt layer from erosion during the etching process and the etching slope of the sidewall of the platinum (Pt) layer is thereby improved.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the present invention will become more readily apparent from the following detailed description of a preferred embodiment made with reference to the attached drawings in which:
FIGS. 1 through 5 are sectional views of a semiconductor device illustrating a method for etching a Pt layer of a semiconductor device according to the present invention.
FIG. 1 is a sectional view of a semiconductor device following the formation of a bottom layer including trench or cylinder type capacitors and a Pt layer according to the present invention.
FIG. 2 is a sectional view of the semiconductor device of FIG. 1 following the formation of an adhesive layer on the Pt layer and a mask layer on the adhesive layer according to the present invention.
FIG. 3 is a sectional view of the semiconductor device of FIG. 2 following an etching process of the Pt layer according to the present invention.
FIG. 4A is a sectional view of the semiconductor device of FIG. 3 following an overetching process performed at a high temperature to remove the mask layer according to the present invention.
FIG. 4B is a sectional view for comparison of the semiconductor device of FIG. 3 following an overetching process performed at a low temperature to remove the mask layer.
FIG. 5 is a sectional view of the semiconductor device of FIG. 4A after the mask pattern is overetched, the adhesive layer mask pattern is removed from the Pt layer, and a barrier layer is patterned under the Pt layer.
DETAILED DESCRIPTION
FIG. 1 is a sectional view of a semiconductor device following the formation of a bottom layer 102, plug 104, a barrier layer 106, and a Pt layer 108 according to the present invention. Referring to FIG. 1, a bottom layer 102 is formed on a semiconductor substrate 100 where a lower structure such as a transistor (not shown) is formed. The bottom layer 102 is created by forming a first insulating layer (i.e., an interlayer dielectric) on the semiconductor substrate 100, patterning the first insulating layer to form a contact hole, and filling the contact hole with a polysilicon plug 104. The semiconductor substrate is subsequently planarized through a planarization process such as etchback or chemical mechanical polishing performed on the bottom layer 102.
A barrier layer 106 is then formed over the entire surface of the substrate where the planarization process has been performned in order to prevent deterioration of capacitor performance due to inter-diffusion of the polysilicon plug 104 and a Pt layer 108, formed on the barrier layer 106. The barrier layer 106 is formed to a thickness of approximately 300˜700 Å using titanium nitride (TiN) or a material containing TiN. Pt is deposited on the barrier layer 106 in a conventional manner, such as sputtering or chemical vapor deposition (CVD), to form the Pt layer 108. In a preferred embodiment of the present invention, the Pt layer 108 is a conductive layer used as a storage node of a capacitor in a semiconductor memory device and is formed to a thickness of approximately 2000 ű500 Å.
FIG. 2 is a sectional view of the semiconductor device of FIG. 1 following the formation of an adhesive layer on the Pt layer and a mask layer on the adhesive layer according to the present invention. Referring to FIG. 2, an adhesive layer 110, for enhancing the adhesion of a mask layer to the Pt layer 108, is formed by depositing titanium (Ti) on the same structure where the Pt layer 108 is formed. The adhesive layer 110 in the present embodiment is formed to a thickness of approximately 400˜800 Å. Subsequently, the mask layer 112 is formed on the adhesive layer 110 to a thickness of approximately 3000˜6000 Å, and at least includes an oxide layer. The mask layer according to the present invention is not necessarily formed of a single layer, however. For example, although the mask layer may consist of only a single oxide layer, as in this embodiment, the mask layer may also be formed of a plurality of layers, at least one of which is an oxide layer. In other words, the mask layer may be a composite layer containing one or more oxide layers.
Following formation of the mask layer, the mask layer is coated with photoresist, and a conventional photolithographic process is performed on the mask layer to form a mask pattern 112. The adhesive layer 110 is then patterned using the mask pattern 112 as an etching mask in order to form an adhesive layer mask pattern 110 contacting the mask pattern 112. At this time, the adhesive layer is patterned using a dry etching process such as magnetically enhanced RIE (MERIE), for example, using a mixture of argon and chlorine Ar/Cl 2 as an etching gas.
FIG. 3 is a sectional view of the semiconductor device of FIG. 2 following an etching process of the Pt layer according to the present invention. Referring to FIG. 3, following the formation of the mask pattern 112 and the adhesive layer mask pattern 110, the semiconductor substrate is heated to a temperature of approximately 120˜300° C., without exciting a plasma of the MERIE equipment. The Pt layer 108 is then etched using an etching gas containing O 2 (i.e., O 2 /Cl 2 , O 2 /HBr, O 2 /Br 2 or O 2 /Br) until a portion of the barrier layer 106 is exposed. The mask pattern 112 and the adhesive layer mask pattern 110 are used during this process as an etching mask. It is preferable that the O 2 content of the etching gas is at least 50% by flow rate (sccm) for the etching process. In the most preferred embodiment, the etching gas consists of a mixture of oxygen and chlorine in the ratio of 4:1 by flow rate (sccm). Accordingly, ions and radicals of the O 2 gas are species for the sputtering of the Pt layer. Furthermore, the O 2 gas increases an etching selection ratio of the Pt layer 108 with respect to the mask pattern 112 (formed of an oxide layer), and changes the Ti layer of the adhesive layer mask pattern 110 into TiO x . TiO x acts as an additional etching mask pattern during the etching of the Pt layer. That is, a portion of O 2 ions and radicals partially oxidize the Ti layer into a TiO x layer, thereby reducing an erosion velocity of the mask.
FIG. 4A is a sectional view of a Pt layer 108A having an enhanced etching slope resulting from overetching of the Pt layer 108 (see FIG. 3) under the same etching conditions as those discussed with reference to FIG. 3. The mask pattern 112 (see FIG. 3) is eroded away completely and thereby removed during the overetching process. The overetching process is preferably performed by extending the total etching time by approximately 0.5˜1.5 times the etching time required to expose the barrier layer 106 (i.e., an etching end point as shown in FIG. 3). When an etching gas containing oxygen, chlorine and Argon (O 2 /Cl 2 /Ar) is used, the etching slope of the Pt layer 108A, having a pitch of 0.58 μm and a thickness of 2000 Å, is 65° or less. This is because the Pt does not react with oxygen and chlorine. However, when the Pt layer 108A is etched using an etching gas containing significant amounts of oxygen, the Ti of the adhesive layer mask pattern 110A formed on the Pt layer is converted into TiO x and acts as an additional mask pattern (i.e., in addition to the mask pattern 112 containing the oxide layer).
The TiO x adhesive layer mask pattern 110A is eroded at a high temperature of approximately 120˜300° C. at a rate equivalent to that at which it is eroded at room temperature. Accordingly, because the high temperature hastens the oxidation of Ti, and thus the formation of a TiO x layer, and because the erosion rate of the TiO x layer is relatively slow, erosion by oxygen ions or sputtering of a radical is relatively reduced according to this invention. Damage of the adhesive layer mask pattern 110A is therefore prevented at high process temperatures. Because the adhesive layer mask pattern 110A has relatively little erosion, the adhesive layer mask pattern 110A therefore acts as a factor for improving the etching slope of the Pt layer 108A. An etching slope of the Pt layer as close to vertical as possible is desired.
FIG. 4B is a sectional view of a semiconductor substrate after etching at less than 120° C. to provide a comparison with the results of overetching at a high temperature as shown in FIG. 4A. Referring to FIG. 4B, when etching is performed at a temperature below 120° C., the mask pattern 112 is eroded and removed, and the edges of the adhesive layer mask pattern 110B are also eroded, causing the sidewall slope thereof to be degraded to an angle of approximately 45°. Accordingly, when the Pt layer is etched through sputtering at a low temperature, the adhesive layer mask pattern 110B cannot improve the etching slope. For example, when the overetching is performed with the chamber at a temperature of 130° C. and the semiconductor substrate surface at a temperature of 120° C., the etching slope O 2 of the Pt layer 108B is 72° or less.
In summary, referring to both FIGS. 4A and 4B, when overetching is performed at a temperature below 120° C., the adhesive layer mask pattern 110B containing Ti is rapidly eroded at its edges by ion sputtering. However, when the overetching is performed at a temperature of 120° C. or more (preferably above 160° C.), the adhesive layer mask pattern 110A is not eroded, even after the mask pattern 112 (see FIG. 3) is removed, and thus the etching slope of the sidewall of the Pt layer 108A is close to vertical (90°). This is because the Ti of the adhesive layer pattern 110A is converted to TiO x more rapidly than that of the adhesive layer mask pattern 110A etched at below 120° C. Specifically, when the temperature of the MERIE chamber is set at 160° C. and the surface temperature of the semiconductor substrate is set at 140° C., the etching slope θ1 of the Pt layer 108A is improved to an angle of approximately 80°. The temperatures described above of approximately 120˜300° C. refer to the temperature of a semiconductor substrate surface. Accordingly, the overetching of the Pt layer 108A and the controlled etching temperature may improve the etching slope of the Pt layer.
FIG. 5 is a sectional view of the semiconductor device after the mask pattern 112 is overetched, the adhesive layer mask pattern 110A (see FIG. 4A) is removed from the Pt layer 108A, and a barrier layer 106A is patterned. Referring to FIG. 5, A mixture of argon and chlorine (Ar/Cl 2 ) is used as the etching gas for removing the adhesive layer mask pattern 110A and for patterning the barrier layer 106A. Therefore, the etching of the Pt layer 108A, including the barrier layer 106A on a polysilicon plug 104, is completed by this process.
The following examples explain the relationship between an etching chamber temperature and the etching slope of a Pt layer. To obtain the following information, Pt layers were overetched at etching chamber temperatures of 100° C., 130° C. and 160° C., and the etching slope of the sidewall of each Pt layer was measured. The Pt layer in each case was 2000 Å thick, the adhesive layer on the Pt layer was 600 Å thick, and the mask pattern formed of an oxide layer was 5000 Å thick. When the temperature of the etching chamber was 100° C., 130° C. and 160° C. during the etching and overetching processes, the resulting etching slopes of the Pt layer sidewalls were 71°, 72° and 80°, respectively. As evidenced by this data, when the temperature of the etching chamber was increased from 100° C. to 130° C., the characteristics of the etching slope were not significantly enhanced. However, when the temperature of the etching chamber was increased to 160° C., the etching slope of the Pt layer was remarkably enhanced.
These results are explainable on the following grounds. When overetching was performed at an etching chamber temperature of 100° C., the mask pattern formed of an oxide layer was eroded and removed, and the edges of the adhesive layer which were converted to Ti or TiO x under the mask pattern were then continuously eroded. As a result, the adhesive layer was 600 Å thick at the center, but was eroded completely at the edges causing the etching slope of the adhesive layer sidewall to be 45°. When overetching was performed at an etching chamber temperature of 130° C., the thickness of the adhesive layer on the Pt layer was 600 Å at the center, but was eroded significantly at the edges. Accordingly, the adhesive layer was still eroded too much to enhance the etching slope significantly.
However, when the etching chamber temperature was set at 160° C. and the surface of the semiconductor substrate was at 140° C., even though the uppermost mask pattern is eroded, the adhesive layer thereunder is not eroded. In this case, therefore, the adhesive layers are 600 Å thick at both the edge and the center, and the etching slopes of the sidewalls are close to vertical (90°). Accordingly, it is possible to prevent the reduction of the etching slope of the Pt layer due to Pt atoms through sputtering while the Pt layer is anisotropically etched.
The respective etch rates, when the etching was performed under the above-described conditions, were 395 Å/min at 100° C., 368 Å/min at 130° C. and 371 Å/min at 160° C. Generally, when a new volatile compound is formed on the sidewall of the Pt layer to improve the etching slope, the etch rate increases corresponding to the temperature increase. However, as evidenced by this data, the resultant etch rates were similar at each of the various temperatures in this embodiment. Accordingly, the etch rate of the Pt layer sidewall was neither improved nor significantly adversely affected by the chemical reaction generated from the Pt layer at higher temperatures. Also, there is a possibility that Pt does not form volatile compounds under the above process conditions.
According to the present invention, the etching slope of the Pt layer which is used as both plate and storage nodes of the capacitor may be improved. This improvement results from the fact that the erosion degree of the adhesive layer, which is used as an additional etching mask during the Pt layer etching process, changes according to the temperature.
It should be understood that the invention is not limited to the illustrated embodiment and that changes and modifications which can be made will be apparent to those skilled in the art and fall within the spirit and scope of the following claims. | A method for etching a platinum (Pt) layer of a semiconductor device is provided which improves the etching slope of a sidewall of the platinum layer used as a storage node of the semiconductor device. The semiconductor device consists of a semiconductor substrate including a bottom layer on which various other layers are formed. Specifically, according to this invention, a Pt layer is formed on a bottom layer of a semiconductor substrate. An adhesive layer is then formed on the Pt layer while a mask layer is formed on the adhesive layer. After formation of the various layers, the mask layer and adhesive layer are patterned using an etching process to form a mask pattern and an adhesive layer mask pattern, respectively. The semiconductor substrate is then heated and an etching process is performned on the Pt layer using the mask pattern and the adhesive layer mask pattern to form etching slope sidewalls of the Pt layer having etching slopes close to vertical. Accordingly, the Pt electrodes of the semiconductor device of the present invention have a finer pattern than those of the prior art. Finally, overetching is done to remove the mask pattern. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/815,573, filed Jun. 15, 2010, which is titled “End User License Agreement On Demand” and which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/312,364, filed Mar. 10, 2010, which is titled “End User License Agreement On Demand.” The entire contents of U.S. patent application Ser. No. 12/815,573 and U.S. Provisional Patent Application Ser. No. 61/312,364 are incorporated herein by reference.
TECHNICAL FIELD
The subject disclosure relates to end user license agreements (EULAs), and more specifically, to providing EULAs on demand for third-party content.
BACKGROUND
Currently, no cloud service or network service provider can effectively provide information as a service on any platform such that publishers, developers, and consumers/subscribers can easily publish, generate applications for and consume any type of data in a way that can be tracked, audited for publishers, developers and/or consumers/subscribers and such that publisher restrictions on the use of content can be enforced. Further, restrictions on the use of content are typically negotiated by content negotiators (e.g., attorneys). As such, terms and conditions tend to be content-specific and vary widely in language and complexity. As such, no single system can currently receive and enforce the customized terms and conditions provided for disparate content. Additionally, terms and conditions that are presumably similar or the same are often unrecognizable as such by a human or a single system processing and attempting to enforce the customized terms.
The above-described deficiencies of today's services are merely intended to provide an overview of some of the problems of conventional systems, and are not intended to be exhaustive. Other problems with the state of the art and corresponding benefits of some of the various non-limiting embodiments may become further apparent upon review of the following detailed description.
SUMMARY
A simplified summary is provided herein to help enable a basic or general understanding of various aspects of one or more of the exemplary, non-limiting embodiments that follow in the more detailed description and the accompanying drawings. This summary is not intended, however, as an extensive or exhaustive overview. Instead, the sole purpose of this summary is to present some concepts related to some exemplary non-limiting embodiments in a simplified form as a prelude to the more detailed description of the various embodiments that follow.
Various approaches are described herein for, among other things, enforcing conditions of use associated with disparate data sets. An example method is described. In accordance with the method, content is published to provide published content that includes disparate data sets. Conditions of use that are associated with the published content are specified. Each data set is associated with its own condition(s) of use. The condition(s) of use associated with each data set are enforced.
An example system is described. The system includes a publication module, a condition generation module, and an enforcement module. The publication module is configured to publish content. The condition generation module is configured to specify conditions of use that are associated with published content from the publication module. The published content includes disparate data sets. Each data set is associated with its own condition(s) of use. The enforcement module is configured to enforce the condition(s) of use that are associated with each data set.
An example computer-readable storage medium is described. The computer-readable storage medium has instructions stored thereon that, when executed, cause a processor to perform functions. The functions include publishing content to provide published content that includes disparate data sets. The functions further include specifying conditions of use that are associated with the published content. Each data set is associated with its own condition(s) of use. The functions further include enforcing the condition(s) of use that are associated with each data set.
Other embodiments and various non-limiting examples, scenarios and implementations are described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
Various non-limiting embodiments are further described with reference to the accompanying drawings in which:
FIG. 1 is a block diagram illustrating an exemplary non-limiting infrastructure for information provided as a service from any platform;
FIG. 2 is a flow diagram illustrating an exemplary non-limiting embodiment for information provided as a service from any platform;
FIG. 3 is an exemplary non-limiting implementation of the infrastructure for information as a service as described above according to one or more features;
FIG. 4 is a block diagram illustrating an exemplary end to end flow diagram from data to consumers of the data for enabling information as a service from any platform;
FIG. 5 is a block diagram illustrating an exemplary computing system for generating a EULA on demand as information as a service from any platform;
FIGS. 6 and 7 are flow diagrams illustrating exemplary non-limiting embodiments for generating a EULA on demand as information as a service from any platform;
FIG. 8 is a block diagram illustrating an exemplary user interface for generating a EULA on demand as information as a service from any platform;
FIG. 9 is a block diagram illustrating an exemplary end to end flow diagram from content owner to consumer for generating a EULA on demand as information as a service from any platform;
FIG. 10 is a block diagram representing exemplary non-limiting networked environments in which various embodiments described herein can be implemented; and
FIG. 11 is a block diagram representing an exemplary non-limiting computing system or operating environment in which one or more aspects of various embodiments described herein can be implemented.
DETAILED DESCRIPTION
The following description contains context regarding potential non-limiting infrastructure, architectures and/or associated services to further aid in understanding one or more of the above embodiments. Any one or more of any additional features described in this section can be accommodated in any one or more of the embodiments described above with respect to dynamically generating an end user license agreement (EULA) for third-party content. While such combinations of embodiments or features are possible, for the avoidance of doubt, no embodiments set forth in the subject disclosure should be considered limiting on any other embodiments described herein.
FIG. 1 is a block diagram illustrating an exemplary non-limiting set of implementation specific details for an infrastructure for information provided as a service from any platform. FIG. 1 generally illustrates the various parties that may participate in an ecosystem providing information as a service as described herein. For instance a set of network accessible information services 100 provide access to a variety of trusted or untrusted data stores 110 , depending on the sensitivity or other characteristics of the data. As shown, thus, what type of data store, 112 , 114 , . . . , 116 is not so important since the ecosystem supports any kind of data, blob, structured, unstructured, etc. As mentioned, the system includes publishers 120 that add data to the ecosystem, subscribers 130 that consume the data and application developers or providers 150 who can consume the data with their applications. An access information generator 170 can also govern access to the data by various parties through maintaining or enforcing account information, key information, etc. In this respect, content owners 160 can span any of the roles in that a content owner 160 can be a publisher 120 , a subscriber 130 and/or an application developer as well. In one aspect, the common infrastructure for all parties enables administration 165 , auditing 173 , billing 175 as well as other desired ancillary services to the data transactions occurring across the infrastructure.
In this regard, various embodiments for the user friendly data platform for enabling information as a service from any platform is an infrastructure to enable consumers of data (Information Workers (IWs), developers, independent software vendors (ISVs)) and consumers of data to transact in a simple, cost effective and convenient manner. The infrastructure democratizes premium (private) and community (public) data in an affordable way to allow IWs to draw insights rapidly, allows developers to build innovative apps using multiple sources of data in a creative manner and enables developers to monetize their efforts on any platform. For instance, the infrastructure supports Pay Per Use as well as Subscription Pricing for Content, Pay for Content (“retail price”—set by content owner), Pay Data Fee (“Shipping and Handling”), and further supports Data fees as a brokerage fee on a per-logical transaction basis (per report, per application program interface (API), per download, etc.).
For Information Workers (e.g., OFFICE®, SQL SERVER®, MICROSOFT DYNAMICS® users), the infrastructure supports subscriptions to allow for future enterprise architecture (EA) integration as well as predictable spend requirements (as well as caching to support on and off-premise Business Intelligence (BI) as well as high performance computing (HPC) workloads). Thus, alternatives include content priced per-user per-month; which may or may not bundle to deliver content packs or per-transaction pricing, e.g., allowing cloud reporting/business intelligence on-demand pricing to eliminate the need to move large amounts of data while allowing per-usage pricing, or vertical apps via report galleries.
For data owners (any data type; any cloud), using any platform, the infrastructure becomes a value proposition to incent sales within any particular desired platform; auto-scaling, higher level service level agreement (SLA) possibilities at no additional cost. For some non-limiting examples, data can be secure and associated data in the following domains: Location aware services & data, Commercial and residential real estate, Financial data and services, etc. A non-limiting scenario may include delivery of data to top 30 non-governmental organization (NGO) datasets. In addition, the infrastructure may include the ability to showcase BI & visualization through BING™ for information as a service, HPC, etc. Vertical application opportunities exist as well.
In one non-limiting embodiment, the data brokerage can be analogized to conventional brick and mortar strategies: For instance, capacity can be represented as shelf space (e.g., a mix of structured and unstructured/blob data), cost of goods (COGS) can be represented as square footage (e.g., platform dependency, bandwidth) and content can be represented as merchandise (e.g., optimize data owners to cover COGS, maximize profits from IWs and developers). In various embodiments, an onboarding process can be implemented with quality bars for data and services, as well as accommodation of service level agreements (SLAs).
FIG. 2 is a flow diagram illustrating an exemplary non-limiting embodiment for information provided as a service from any platform. As shown in the flow diagram of FIG. 2 , at 200 , described herein are various ways for content owners or publishers to publish data via the infrastructure. At 210 , there are a variety of tools that allow developers to develop applications for consuming the data via the infrastructure. At 220 , consumers or information workers use the applications or can directly query over the data to consume the data. Lastly, the infrastructure provides a rich variety of tools at 230 that enable automatic administration, auditing, billing, etc. on behalf of all parties in the content chain, enabled by the transaction model.
In this regard, some key parties in the infrastructure include data owners, the application developers/ISVs and the consumers/information workers. In general, data owners are entities who want to charge for data, or who want to provide data for free for other reasons, or enforce other conditions over the data. In turn, application developers/ISVs are entities who want to monetize their application (e.g., through advertising, direct payments, indirect payments, etc.), or provide their application for free for some beneficial reason to such entities. Information workers and consumers are those who can use the raw data, or those who want to use an application provided by the application developers.
FIG. 3 is an exemplary non-limiting implementation of the infrastructure 310 for information as a service as described above according to one or more features. At the interaction side are information workers 300 , developers 302 and consumers 304 who can communicate with the infrastructure via secure sockets layer (SSL)/representational state transfer (REST) based APIs 306 . A load balancer 308 can be used to help steer traffic in an optimal way. In this regard, the input is routed to portal web roles 320 or API web roles 322 . From the infrastructure 310 to the data side is additional load balancing 324 or 326 for access to blob data sets 342 , or blob data set 355 of cloud storage framework 340 , or to data sets 352 or data set 354 of relational database frameworks 350 . Proxy layers 328 can be used to access data 362 or data 364 of third party clouds 360 . Content data abstract layers (DALs) 330 can be used to access content, where applicable. In this regard, there can be duplication or overlap of data sets across different types of storage, e.g., the same data might be represented as blob data and as structured data, e.g., SQL SERVER®.
As supplemental services to the data, billing and discovery services 370 can include online billing 372 (e.g., MICROSOFT® Online Customer Portal (MOCP)) or discovery services 374 (e.g., pinpoint) and authentication services 380 can include credentials management 382 (e.g., MICROSOFT® Windows Live ID) or content authentication 384 , e.g., authenticated content services (ACS). Accounts services 390 can include logging/audit services 386 or account management 388 . Management and operations services 392 can include an operations dashboard service 394 and network operations service 396 , e.g., Gomez.
FIG. 4 is a block diagram illustrating an exemplary end to end flow from data to consumers of the data in accordance with one or more embodiments of the general infrastructure for enabling information as a service. For instance, information as a service 400 can include commercial data 402 and free data 404 , which can be of interest to various for profit developers 410 , nonprofit developers 412 with non-profit motives and other information workers 414 who are interested in consuming the data generally for productive goals. These entities can use discovery services 420 to determine what applications 422 , 424 , . . . , 426 may be of interest to them, and to ultimately transmit the data to indirect license acquisition (ILA) consumers 430 and direct license acquisition (DLA) consumers 432 alike.
FIG. 5 is a block diagram of a system for providing a EULA on demand for third-party content as described herein. The system 500 will be described with reference to FIGS. 1 , 3 , 4 and 5 . In some embodiments, the system 500 can be part of the information service 200 illustrated in FIG. 2 .
The system can include a processor 510 , a publication module 520 , a memory 530 and a condition generation module 540 . In some embodiments, the system can also include a user interface 550 and/or an enforcement module 560 .
The processor 510 can be configured to execute computer-readable instructions stored in the memory 530 and perform one or more functions of the system 500 described herein.
The publication module 520 can be configured to published content and output the published content from the publication module 520 for experience by a consumer 304 . The published content can include, but is not limited to, data in the data stores 212 , 214 , . . . , 216 and/or commercial data 402 owned or controlled by owners 260 . In various embodiments, the owners 260 can be third-party content owners.
The condition generation module 540 can be configured to generate a representation of one or more conditions associated with use of the published content. The representation can be a EULA on demand generated visually and/or in audio format for review and acceptance by the consumer 304 prior to experience of the published content by the consumer 304 .
In some embodiments, the one or more conditions included in the EULA can be or be indicative of disallowed activity in some embodiments. By way of example, but not limitation, the one or more conditions can be indicative of disallowed printing, downloading, dissemination, rendering, copying activity or any other disallowed activity.
In some embodiments, some of the conditions can be canonicalized such that similar or the same language is used for similar or the same disallowed activity. In some embodiments, some of the conditions can be stored in the system 500 as non-standard terms that are not canonicalized. Such non-standard terms can be included in the EULA using the free form text input to the system 500 by a third-party content owner generating the EULA for the published content.
Because the sentences and/or phrases making up the conditions can be canonicalized, the EULA conditions for any number of different media owned by different third-parties can have a recognizable degree of uniformity. As such, the complexity of terms and presentation format in the EULAs output from the system 500 for different third-parties can be reduced.
In some embodiments, the condition generation module 540 can include or be operably coupled to a taxonomy module (not shown) configured to classify the one or more conditions. The conditions can be classified in a number of ways, as described below, including, but not limited to, according to a type of the content, a disallowed activity and/or can include a hierarchy of condition, or term, definitions.
In various embodiments, the conditions can be classified by the type of the published content. For example, particular conditions can be typically employed for typical types of content. Such particular conditions can be classified together. By way of example, but not limitation, conditions that are typically employed for electronic books can be classified in one category, conditions that are typically employed for downloadable music can be classified in another category and conditions that are typically employed for films can be classified in another category.
Accordingly, selection of the EULA condition can be based on an input solely indicative of the published content type. In some embodiments, selection of the EULA condition can include inferring a EULA condition typically suitable for inclusion in a EULA for content of the type indicated. Accordingly, EULAs can be dynamically generated to include conditions typically suitable for a particular content type, thereby increasing the likelihood of generating a more complete EULA while expending less financial and time resources.
In various embodiments, the conditions can be classified by the disallowed activity. For example, conditions related to disallowed printing and copying can be classified in a first category while conditions related to disallowed dissemination and downloading can be provided in a second category. As such, the categories can be arranged in one or more buckets that can accommodate various different conditions.
For example, selecting a EULA condition can be based on a disallowed manner of using particular content. By way of example, but not limitation, the selection can be indicative of a maximum number of times that the published content can be printed and/or whether printing privileges are provided to the consumer in general. The EULA condition can therefore be a sentence or phrase providing simple language to the consumer regarding the number of times that the content can be printed and/or that the content cannot be printed.
In some embodiments, the system 500 can be configured to receive one or more inputs from a third-party content owner, and the condition generation module 540 can determine appropriate conditions with which to publish the EULA on demand. In some embodiments, the conditions can be determined by querying over the conditions using OData or other querying protocols.
In some embodiments, the conditions can be determined based on mapping, semantics, pattern recognition or other techniques for selecting data that corresponds to an input.
The inputs can be received via the user interface 550 communicatively coupled to the system 500 . In some embodiments, the user interface 550 particularly, or the system 500 generally, can be configured to receive the input for generating the EULA on demand.
The input, or selection, can be a free-form selection received in a text box displayed via the user interface 550 and/or a selection of a menu option displayed via the user interface 550 . In some embodiments, the user interface can receive audio selections from third-parties. The selections can be indicative of disallowed activity and/or indicative of the content type in various embodiments. In some embodiments, the selections can be indicative of the identity of the third-party (for embodiments wherein the third-party chooses to generate EULAs that are substantially the same for all of the published content owned by the third-parties).
The system 500 can include an enforcement module 560 in some embodiments. The enforcement module 560 can be configured to enforce the one or more conditions associated with the published content, and on any platform. In some embodiments, enforcing the one or more conditions of use can include disallowing a disallowed activity indicated by the one or more conditions. In various embodiments, the enforcement module 560 can enforce the conditions of the EULA to prevent disallowed activity over MICROSOFT OFFICE® platforms, WINDOWS® platforms, SQL® platforms, MAC® platforms, and/or OPENOFFICE.ORG® platforms.
The enforcement module 560 can perform the enforcement via an information rights management module (not shown) in some embodiments. The information rights management module can be included within, or be operably coupled to, the enforcement module 560 .
Referring to memory 530 , in some embodiments, the memory 530 can be a computer-readable storage medium having instructions stored thereon that, when executed, cause a processor to perform a method. The method (not shown) can include: displaying an option selection representation via a user interface, wherein the option selection representation is associated with options for use of published content. The method can also include receiving an input via the user interface; and identifying one or more conditions for use with the published content based, at least, on the input, wherein the one or more conditions are end user license conditions.
In some embodiments of the computer-readable storage medium, the option selection representation comprises a text box, and wherein the receiving the input comprises receiving a free form selection input at the text box. In some embodiments of the computer-readable storage medium, the option selection representation comprises menu of options, and wherein the receiving the input comprises receiving a selection indicative of at least one option of the menu of options.
In some embodiments of the computer-readable storage medium, the method also includes receiving a selection of a type of the published content, wherein the displaying the option selection representation is based on the receiving the selection of the type of the published content.
In some embodiments of the computer-readable storage medium, the method also includes generating an end user license agreement including the end user license conditions. In some embodiments of the computer-readable storage medium, the end user license conditions are canonicalized, standard terms.
FIG. 6 is a flowchart illustrating a method of generating a EULA on demand as information for a service on any platform according to an embodiment described herein.
At 610 , method 600 can include publishing content to a consumer. The content can be any type of content owned by a third-party including, but not limited to, music, electronic books, films, video games, website or the like.
At 620 , method 600 can include receiving an input indicative of a condition of use for the published content. The input can be received from an owner of the published content. The input can indicate a type of content, a disallowed activity and/or an owner of the content in various embodiments.
At 630 , method 600 can include selecting a condition for the EULA based on the input received. Selecting the condition can be performing through any number of methods including, but not limited to, querying the one or more conditions to determine the condition that most closely relates to the input, mapping, pattern recognition, semantics or the like.
The conditions can be standard terms that are canonicalized or non-standard terms that are not canonicalized. The non-standard terms can result from free form text inputs or audio inputs by the content owner.
The conditions can be classified according to a taxonomy. The taxonomy can be based on a type of the content, the disallowed activity and/or the owner of the content. In various embodiments, the disallowed activity can be associated with rendering, printing, derivation, dissemination or copying.
At 640 , method 600 can include outputting a representation of one or more conditions to a consumer or subscriber. The representation can be the EULA on demand in some embodiments. The representation can be visual and/or audio in different embodiments.
At 650 , method 600 can include enforcing the conditions of the EULA. Enforcing the conditions of the EULA can comprise monitoring the use of the published content by the consumer and disallowed forbidden activity. In some embodiments, disallowing can include operating an information management module to prevent the disallowed activity.
FIG. 7 is a flowchart illustrating a method according to an embodiment described herein. At 710 , method 700 can include displaying an option selection representation via a user interface. The representation can be associated with determining conditions for use with published content. At 720 , method 700 can include receiving an input via the user interface.
In some embodiments, the option selection representation can include a text box, and the input is a free form selection input at the text box. Identifying one or more options can include selecting the one or more options associated with the free form selection. In some embodiments, displaying the option selection representation can include displaying the one or more options as a menu of options. The input can be a menu selection from the menu of options.
At 730 , method 700 can include selecting one or more conditions based, at least, on the input. The one or more conditions can be classified according to a taxonomy. In some embodiments, some of the conditions can be standard terms that are canonicalized while some of the conditions can be non-standard terms that are not canonicalized.
Selecting the one or more conditions can be performed by any known techniques including querying. Pattern recognition, semantics or the like can be employed.
At 740 , method 700 can include displaying a representation of the one or more conditions selected. The representation can be the EULA on demand in some embodiments. The conditions selected can be displayed via a user interface to a third-party content owner prior to storage and/or display to a consumer using the published content.
In some embodiments, a user interface can be provided to facilitate generation of the end user license agreement. In some embodiments, the user interface can be configured to display an option selection representation. The option selection representation can include information indicative of one or more options for use of published content.
The user interface can also be configured to receive an input selecting at least one of the one or more options for use. The input can be received by an owner of the published content and/or the publisher of the content.
The user interface can also be configured to display one or more conditions for inclusion in a EULA. The conditions can be based, at least, on the input that is received.
The user interface can also be configured to display a representation of the EULA. The representation can be visual or audio in various embodiments.
In some embodiments, the option selection representation comprises a text box. In these embodiments, the input received can be free form text. In some embodiments, in addition to, or in lieu of the text box, the option selection representative can include a menu of options for use of the published content. The options can be selectable by the user providing the input.
In various embodiments, the displayed one or more conditions for inclusion in the EULA can be canonicalized, standard terms and/or conditions that are not canonicalized. For example, the conditions that are not canonicalized can be the free form text that can be received via the text box.
The user interface can provide visual and/or audio displays. In some embodiments, the user interface can receive inputs through inputs provided at the user interface screen and/or through audio signals via voice commands provided to the user interface. In some embodiments, the user interface is a touchscreen user interface.
FIG. 8 is block diagram illustrating an exemplary user interface (UI) for generating a EULA on demand as information as a service from any platform. As shown in FIG. 8 , UI 800 can include an option display region 810 , an input region 820 and a preview region 830 .
The option display region 810 can comprise information indicative of published content or use of the published content. In some embodiments, the information indicative of the published content is one or more types of published content. The one or more types of published content can include music, an electronic book, a film, a television show or a video game.
In some embodiments, the information indicative of the use of the published content is one or more types of disallowed activity, which can be provided at region 840 . The types of disallowed activity can be indicative of at least one of editing privileges, printing, copying, writing privileges or re-distribution or dissemination rights.
The input region 820 can be configured to display a region for receiving an input. The input region can include a text box 850 or a selectable menu of options. The text box 850 can be configured to receive free form text in some embodiments. In some embodiment, the input region 820 and/or the surface of the UI 800 in totality can have touchscreen capabilities. In some embodiments, the selectable menu of options can be as shown at region 840 .
The preview region 830 can be configured to display a preview of one or more conditions for inclusion in an end user license agreement. In various embodiments, at least one of the one or more conditions is canonicalized, standard terms. In various embodiments, at least one of the one or more conditions is not canonicalized, standard terms and is the free form text. In some embodiments, the preview region 830 can be configured to display a preview of the end user license agreement 860 .
In some embodiments, a UI (not shown) configured to generate EULA can include an option display region that comprises information indicative of published content or use of the published content. The EULA UI can also include an input region configured to display a region for receiving an input; and a preview region configured to display a preview of one or more conditions for inclusion in an end user license agreement. The preview region can be configured to display the end user license agreement.
In some embodiments, one or more of the one or more conditions can be canonicalized, standard terms. In some embodiments, one or more of the one or more conditions is not canonicalized, standard terms and are the free form text.
In some embodiments, the option display region comprises information indicative of the published content and the information indicative of the published content is one or more types of published content.
In some embodiments, the option display region comprises information indicative of the use of the published content and the information indicative of the use of the published content is one or more types of disallowed activity. In some embodiments, one or more types of disallowed activity is indicative of at least one of editing privileges, writing privileges or re-distribution rights.
In some embodiments, one or more types of published content comprises at least one of music, an electronic book, a film, a television show or a video game.
In some embodiments, the input region comprises a text box. The text box can be configured to receive free form text. In some embodiments, the input region comprises a selectable menu of options.
In some embodiments, the UI is a touchscreen user interface.
FIG. 9 is a block diagram illustrating an exemplary end to end flow diagram from content owner to consumer for generating a EULA on demand as information as a service from any platform. The flow diagram shall be described with reference to FIGS. 8 and 9 .
The content owner can provide selections indicative of options of use for published content owned by the content owner. The selections can be provided at a UI 800 accessible by the content owner.
The content owner can select one or more types of disallowed activity 840 from the UI 800 . In the embodiment shown, the disallowed activity is editing the published content and copying the published content. As such, the content owner has selected read only privileges and no copying privileges to be associated with the published content.
The selected options for use can be received by the platform-independent engine. The platform-independent engine 900 can include a condition generation module 910 for selecting one or more conditions (which can be canonicalized, as shown in FIG. 9 , or not canonicalized). The platform-independent engine 900 can include a condition generation module 910 . The one or more conditions can be classified according to a selected taxonomy, which can be based on the disallowed activity, the type of the published content, the identity of the content owner or otherwise. The condition generation module can select the one or more conditions associated with the options for use from the data stores 912 , 914 , . . . , 916 .
The EULA generation module 920 can receive the conditions for the EULA and generate the EULA, including the conditions received. The consumer platform 930 can receive the EULA and display the EULA to the consumer.
Exemplary Networked and Distributed Environments
One of ordinary skill in the art can appreciate that the various embodiments of methods and devices for an infrastructure for information as a service from any platform and related embodiments described herein can be implemented in connection with any computer or other client or server device, which can be deployed as part of a computer network or in a distributed computing environment, and can be connected to any kind of data store. In this regard, the various embodiments described herein can be implemented in any computer system or environment having any number of memory or storage units, and any number of applications and processes occurring across any number of storage units. This includes, but is not limited to, an environment with server computers and client computers deployed in a network environment or a distributed computing environment, having remote or local storage.
FIG. 10 provides a non-limiting schematic diagram of an exemplary networked or distributed computing environment. The distributed computing environment comprises computing objects 1010 , 1012 , etc. and computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc., which may include programs, methods, data stores, programmable logic, etc., as represented by applications 1030 , 1032 , 1034 , 1036 , 1038 . It can be appreciated that objects 1010 , 1012 , etc. and computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc. may comprise different devices, such as PDAs, digital video disks (dvds), compact discs (cds), audio/video devices, mobile phones, MP3 players, laptops, etc.
Each object 1010 , 1012 , etc. and computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc. can communicate with one or more other objects 1010 , 1012 , etc. and computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc. by way of the communications network 1040 , either directly or indirectly. Even though illustrated as a single element in FIG. 10 , network 1040 may comprise other computing objects and computing devices that provide services to the system of FIG. 10 , and/or may represent multiple interconnected networks, which are not shown. Each object 1010 , 1012 , etc. or computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc. can also contain an application, such as applications 1030 , 1032 , 1034 , 1036 , 1038 , that might make use of an API, or other object, software, firmware and/or hardware, suitable for communication with or implementation of an infrastructure for information as a service from any platform as provided in accordance with various embodiments.
There are a variety of systems, components, and network configurations that support distributed computing environments. For example, computing systems can be connected together by wired or wireless systems, by local networks or widely distributed networks. Currently, many networks are coupled to the Internet, which provides an infrastructure for widely distributed computing and encompasses many different networks, though any network infrastructure can be used for exemplary communications made incident to the techniques as described in various embodiments.
Thus, a host of network topologies and network infrastructures, such as client/server, peer-to-peer, or hybrid architectures, can be utilized. In a client/server architecture, particularly a networked system, a client is usually a computer that accesses shared network resources provided by another computer, e.g., a server. In the illustration of FIG. 10 , as a non-limiting example, computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc. can be thought of as clients and objects 1010 , 1012 , etc. can be thought of as servers where servers, etc. provide data services, such as receiving data from client computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc., storing of data, processing of data, transmitting data to client computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc., although any computer can be considered a client, a server, or both, depending on the circumstances. Any of these computing devices may be processing data, or requesting services or tasks that may implicate an infrastructure for information as a service from any platform and related techniques as described herein for one or more embodiments.
A server is typically a remote computer system accessible over a remote or local network, such as the Internet or wireless network infrastructures. The client process may be active in a first computer system, and the server process may be active in a second computer system, communicating with one another over a communications medium, thus providing distributed functionality and allowing multiple clients to take advantage of the information-gathering capabilities of the server. Any software objects utilized pursuant to the user profiling can be provided standalone, or distributed across multiple computing devices or objects.
In a network environment in which the communications network/bus 1040 is the Internet, for example, the servers etc. can be Web servers with which the client computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc. communicate via any of a number of known protocols, such as HTTP. Servers etc. may also serve as client computing objects or devices 1020 , 1022 , 1024 , 1026 , 1028 , etc., as may be characteristic of a distributed computing environment.
Exemplary Computing Device
As mentioned, various embodiments described herein apply to any device wherein it may be desirable to implement one or pieces of an infrastructure for information as a service from any platform. It should be understood, therefore, that handheld, portable and other computing devices and computing objects of all kinds are contemplated for use in connection with the various embodiments described herein, i.e., anywhere that a device may provide some functionality in connection with an infrastructure for information as a service from any platform. Accordingly, the below general purpose remote computer described below in FIG. 11 is but one example, and the embodiments of the subject disclosure may be implemented with any client having network/bus interoperability and interaction.
Although not required, any of the embodiments can partly be implemented via an operating system, for use by a developer of services for a device or object, and/or included within application software that operates in connection with the operable component(s). Software may be described in the general context of computer-executable instructions, such as program modules, being executed by one or more computers, such as client workstations, servers or other devices. Those skilled in the art will appreciate that network interactions may be practiced with a variety of computer system configurations and protocols.
FIG. 11 thus illustrates an example of a suitable computing system environment 1100 in which one or more of the embodiments may be implemented, although as made clear above, the computing system environment 1100 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of any of the embodiments. Neither should the computing environment 1100 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment 1100 .
With reference to FIG. 11 , an exemplary remote device for implementing one or more embodiments herein can include a general purpose computing device in the form of a handheld computer 1110 . Components of handheld computer 1110 may include, but are not limited to, a processing unit 1120 , a system memory 1130 , and a system bus 1121 that couples various system components including the system memory to the processing unit 1120 .
Computer 1110 typically includes a variety of computer readable media and can be any available media that can be accessed by computer 1110 . The system memory 1130 may include computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) and/or random access memory (RAM). By way of example, and not limitation, memory 1130 may also include an operating system, application programs, other program modules, and program data.
A user may enter commands and information into the computer 1110 through input devices 1140 . A monitor or other type of display device is also connected to the system bus 1121 via an interface, such as output interface 1150 . In addition to a monitor, computers may also include other peripheral output devices such as speakers and a printer, which may be connected through output interface 1150 .
The computer 1110 may operate in a networked or distributed environment using logical connections to one or more other remote computers, such as remote computer 1170 . The remote computer 1170 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, or any other remote media consumption or transmission device, and may include any or all of the elements described above relative to the computer 1110 . The logical connections depicted in FIG. 11 include a network 1171 , such local area network (LAN) or a wide area network (WAN), but may also include other networks/buses. Such networking environments are commonplace in homes, offices, enterprise-wide computer networks, intranets and the Internet.
As mentioned above, while exemplary embodiments have been described in connection with various computing devices, networks and advertising architectures, the underlying concepts may be applied to any network system and any computing device or system in which it is desirable to publish, build applications for or consume data in connection with interactions with a cloud or network service.
There are multiple ways of implementing one or more of the embodiments described herein, e.g., an appropriate API, tool kit, driver code, operating system, control, standalone or downloadable software object, etc. which enables applications and services to use the infrastructure for information as a service from any platform. Embodiments may be contemplated from the standpoint of an API (or other software object), as well as from a software or hardware object that facilitates provision of an infrastructure for information as a service from any platform in accordance with one or more of the described embodiments. Various implementations and embodiments described herein may have aspects that are wholly in hardware, partly in hardware and partly in software, as well as in software.
The word “exemplary” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, for the avoidance of doubt, such terms are intended to be inclusive in a manner similar to the term “comprising” as an open transition word without precluding any additional or other elements.
As mentioned, the various techniques described herein may be implemented in connection with hardware or software or, where appropriate, with a combination of both. As used herein, the terms “component,” “system” and the like are likewise intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on computer and the computer can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers.
The aforementioned systems have been described with respect to interaction between several components. It can be appreciated that such systems and components can include those components or specified sub-components, some of the specified components or sub-components, and/or additional components, and according to various permutations and combinations of the foregoing. Sub-components can also be implemented as components communicatively coupled to other components rather than included within parent components (hierarchical). Additionally, it should be noted that one or more components may be combined into a single component providing aggregate functionality or divided into several separate sub-components, and any one or more middle layers, such as a management layer, may be provided to communicatively couple to such sub-components in order to provide integrated functionality. Any components described herein may also interact with one or more other components not specifically described herein but generally known by those of skill in the art.
In view of the exemplary systems described supra, methodologies that may be implemented in accordance with the disclosed subject matter will be better appreciated with reference to the flowcharts of the various figures. While for purposes of simplicity of explanation, the methodologies are shown and described as a series of blocks, it is to be understood and appreciated that the claimed subject matter is not limited by the order of the blocks, as some blocks may occur in different orders and/or concurrently with other blocks from what is depicted and described herein. Where non-sequential, or branched, flow is illustrated via flowchart, it can be appreciated that various other branches, flow paths, and orders of the blocks, may be implemented which achieve the same or a similar result. Moreover, not all illustrated blocks may be required to implement the methodologies described hereinafter.
While in some embodiments, a client side perspective is illustrated, it is to be understood for the avoidance of doubt that a corresponding server perspective exists, or vice versa. Similarly, where a method is practiced, a corresponding device can be provided having storage and at least one processor configured to practice that method via one or more components.
While the various embodiments have been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function without deviating therefrom. Still further, one or more aspects of the above described embodiments may be implemented in or across a plurality of processing chips or devices, and storage may similarly be affected across a plurality of devices. Therefore, the present invention should not be limited to any single embodiment, but rather should be construed in breadth and scope in accordance with the appended claims. | Techniques are described herein that are capable of enforcing conditions of use associated with disparate data sets. For example, content may be published. Conditions of use that are associated with the published content may be specified. The published content may include disparate data sets. Each data set may be associated with its own condition(s) of use. The condition(s) of use associated with each data set may be enforced. | 7 |
BACKGROUND
The claimed subject matter relates generally to electronic mail, or email, and, more specifically, to a method to ensure that an email attachment is the correct file.
SUMMARY
The claimed subject matter comprises a technology to scan a document for file attachments, generate alternative file names corresponding to a particular attachment, determine whether or not the particular file attachment is the latest version of a file or has a name and/or file path that could be confused with the name and/or path of another file. In the event one of the above conditions are met, the technology provides the means for a user to verify that the file attachment is the desired file and, if necessary, to select an alternative file for attachment.
This summary is not intended as a comprehensive description of the claimed subject matter but, rather, is intended to provide a brief overview of some of the functionality associated therewith. Other systems, methods, functionality, features and advantages of the claimed subject matter will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the claimed subject matter can be obtained when the following detailed description of the disclosed embodiments is considered in conjunction with the following figures, in which:
FIG. 1 is one example of a computing system architecture that may implement the claimed subject matter.
FIG. 2 is a block diagram of an Attachment Validation Component (AVC), first introduced in FIG. 1 , in more detail.
FIG. 3 is a flow chart illustrating a Process File process that incorporates an example of processing that may implement an aspect of the claimed subject matter.
FIG. 4 is a flow chart illustrating a Check Attachment process that is one example of processing that may implement an aspect of the claimed subject matter.
FIG. 5 is a flow chart illustrating a Process Attachment process that is one example of processing that may implement an aspect of the claimed subject matter.
DETAILED DESCRIPTION
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
One embodiment, in accordance with the claimed subject, is directed to a programmed method for validating file attachments. The term “programmed method”, as used herein, is defined to mean one or more process steps that are presently performed; or, alternatively, one or more process steps that are enabled to be performed at a future point in time. The term ‘programmed method” anticipates three alternative forms. First, a programmed method comprises presently performed process steps. Second, a programmed method comprises a computer-readable medium embodying computer instructions, which when executed by a computer performs one or more process steps. Finally, a programmed method comprises a computer system that has been programmed by software, hardware, firmware, or any combination thereof, to perform one or more process steps. It is to be understood that the term “programmed method” is not to be construed as simultaneously having more than one alternative form, but rather is to be construed in the truest sense of an alternative form wherein, at any given point in time, only one of the plurality of alternative forms is present.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
Over the past several decades, computer users have become increasingly connected by networks, including the Internet. This connectivity has enabled users to communicate via electronic mail, or “email.” As email has become more ubiquitous, the utility has also expanded. Today, most people use email for a variety of personal and business reason.
One common utility associated with email is the attachment of files. In addition to a typical text message, people transmit as attachments photographs, documents, spreadsheets and so on as file attachments. If a user who is in the process of editing a document, transmits the document as an email attachment before the latest changes have been saved to memory, currently available email programs will attach a copy of the document that is out of date, i.e. the attached document does not include any changes made after the last save. This is because many programs such as, but not limited to, word processors, photo editors and spreadsheets create a temporary file when a particular file is opened. These programs save changes to the temporary file and only update the original file when the user explicitly saves the file.
In another scenario, an email program displays a file listing so that a user can select a particular file to attach to an email. If there are multiple files with similar names such as a file with multiple versions or multiple files with the same name that are stored in different directories, a user may inadvertently select the wrong version or the wrong file for attachment.
Provided is a method for validating file attachments to ensure that the attached files are not, among other things, stale or outdated. The Specification uses a word processing program as an example but it should be understood that the disclosed techniques are applicable to, but not limited to, word processing, spreadsheet and any other document application that relies upon making, or relies upon another application that makes, a temporary copy of a document. The disclosed techniques are also applicable to any operating systems, or “platform,” including but not limited to, WINDOWS®, published by the Microsoft Corporation of Redmond, Wash., and versions of Linus/Unix.
Turning now to the figures, FIG. 1 is a block diagram of one example of a computing system architecture 100 that may incorporate the claimed subject matter. A client system 102 includes a processor 104 , coupled to a monitor 106 , a keyboard 108 and a mouse 110 , which together facilitate human interaction with computing system 100 and client system 102 . Also included in client system 102 and attached to processor 104 is a data storage component 112 , which may either be incorporated into processor 104 , i.e. an internal device, or attached externally to processor 104 by means of various, commonly available connection devices such as but not limited to, a universal serial bus (USB) port (not shown).
Data storage 112 is illustrated storing an operating system (OS) 114 that controls the operation of computing system 102 , an example of an application that employs file attachments, or App_ 1 116 , a Attachment Verification Component (AVC) 118 that implements the claimed subject matter, a file used as an example throughout the Description, or File_ 1 120 , and a file used throughout the Description as an example of attachment, or Atth_ 1 122 . In this example, AVC 118 is configured to work in conjunction with OS 114 to implement the claimed subject matter and is described in more detail below in conjunction with FIGS. 3-5 . In the alternative AVC 118 could be incorporated into App_ 1 116 , either as an integral component or as a plug-in module. Those with skill in the computing arts should appreciate that there are multiple OSs, or “platforms,” to which the claimed subject matter applies.
Client system 102 and processor 104 are connected a local area network (LAN) 124 , which is also connected to a server computer 126 . Although in this example, processor 104 and server 126 are communicatively coupled via LAN 124 , they could also be coupled through any number of communication mediums such as, but not limited to, the Internet (not shown). Further, it should be noted there are many possible computing system configurations, of which computing system 100 is only one simple example.
Server computer 126 is coupled to a data storage 128 , which like data storage 114 , which may either be incorporated into server 126 , i.e. an internal device, or attached externally to server 126 by means of various, commonly available connection devices such as but not limited to, a USB port (not shown).
Also communicatively coupled to the LAN 124 is a second client computer 132 , which like client computer 102 , includes a data storage 134 . Data storage 134 also includes an AVC component 136 , which may handle file attachment issues with respect to various applications (not shown) on client 132 in a fashion similar to AVC 118 on client computer 102 . Although not shown in FIG. 1 , it should be understood that each of server 126 and client 132 include a processor, monitor, keyboard and mouse like components 104 , 106 , 108 and 110 , respectively.
FIG. 2 is a block diagram of AVC 118 , first introduced in FIG. 1 , in more detail. In this example, AVC 118 is stored on data storage 112 ( FIG. 1 ) and executed on processor 104 ( FIG. 1 ) of client system 102 ( FIG. 1 ). Of course, AVC 118 could also be stored and executed on another computing system such as server 122 that executes services for client system 102 . For example, electronic mail servers are often located on remote computing systems. AVC 118 includes an input/output (I/O) module 140 , an AVC Configuration module 142 , an AVC Control module 144 and a data cache component 146 . It should be understood that the representation of AVC 118 in FIG. 2 is a logical model. In other words, components 140 , 142 , 144 , 146 and other components described below may be stored in the same or separate files and loaded and/or executed within system 100 either as a single system or as separate processes interacting via any available inter process communication (IPC) techniques.
I/O module 140 handles communication AVC 118 has with other components of computing system 102 and system 100 . AVC configuration module 142 stores parameters defined by an administrator to control the setup and operation of AVC 118 . Examples of such configuration parameters include, but are not limited to, security settings, display options and so on. In addition, parameters may be defined that list potential users, applications and computing hosts and corresponding degrees of file matching and specific implementations of the claimed technology.
AVC Control module 144 stored the logic that controls the operation of AVC 118 . Examples of logic modules that may be included in module 144 include a Discovery Engine 150 and a Sort module 152 . Control logic 144 extracts filenames and directories corresponding to an attachment and feed this information into discovery engine 150 . Discovery engine 150 scans file directories of data storage 112 to locate possible alternative files for any particular attached file. Particular portions of data storage 112 that are searched as well as the degree of correspondence between an attached file and a potential alternative are controlled by parameters stored in AVC configuration 142 .
Discovery engine 150 includes a Discovery Algorithms module 154 and a Directory Explorer module 156 , both of which execute logic associated with Discovery engine 150 . Discovery algorithms module 154 includes a Regular Expression (RE) generator 158 , which generates regular expressions corresponding to a file under examination, and a Associate Filename (AFN) Generator 160 , which employs the regular expressions generated by module 158 to create a list of possible alternative file names.
AVC control 144 also includes Sort module 152 that organizes the information collected by Discovery Engine 150 . The operation of Discovery Engine 150 , Discovery Algorithms module 154 , RE generator 158 , AFN generator 160 , Directory Explorer 156 and Sort module 152 are explained in more detail below in conjunction with FIGS. 3-5 .
Data Cache 146 is a data repository for information, including settings and lists that AVC 118 requires during operation. Examples of the types of information stored in cache 146 include, but are not limited to, specific files and directories employed in conjunction with AVC control 144 , corresponding patterns associated with the processing of modules 154 and 156 . In addition, cache 146 may store intermediate results associated with the processing of AVC 118 .
FIG. 3 is a flow chart illustrating an Process File process 200 that is one example of an application the incorporates the claimed subject matter. In this example, logic associated with process 200 is stored on data storage 112 ( FIG. 1 ) as part of AVC 118 ( FIG. 1 ) and executed on processor 104 . In the alternative, process 200 may be incorporated into App_ 1 116 ( FIG. 1 ).
Process 200 starts in a “Begin Process File” block 202 and proceeds immediately to a “Retrieve File” block 204 . During block 204 , a file, in this example file_ 1 120 ( FIG. 1 ), associated with App_ 1 116 is transmitted to AVC 118 as part of an example of an implementation of the claimed subject matter. Typically, file_ 1 120 is transmitted to AVC 118 once has user has indicated that processing of file_ 120 is complete. For example once an email has been prepared and a “Send” button has been clicked. In the alternative, app_ 1 116 may provide the option of checking a file at any time.
During a “File Attachment?” block 206 , process 200 determines whether or not file_ 1 120 includes one or more attachments such as attch_ 1 122 . If so, process 200 proceeds to a “Check Attachments” block 208 , which is described in detail below in conjunction with FIG. 4 . During an “Attachments Approved” block 210 , process 200 determines whether or not the attachments detected during block 206 and checked during block 208 have been approved for transmission. It should be noted that parameters may be set to establish automatic approval procedures, e.g. the attached file is the most current, or require that all attachments be subjected to user scrutiny.
If all attachments have not been approved, either automatically or explicitly by a user depending upon setup parameters, process 200 proceeds to a “Process Attachment” block 212 during which the user who attached the file is given the opportunity to either select another file form a list provided by AVC 118 or cancel the attachment and start over with a selection. Processing associated with block 212 is described in more detail below in conjunction with FIG. 5 . Control then returns to Check Attachments block 208 and processing continues as described above.
If process 200 determines during block 206 that file_ 1 120 does not include an attachment or if, during block 210 , the user has indicated that attached files are the intended attachments, control proceeds to a “Complete Processing” block 214 . During block 214 , the original intention of app_ 1 116 is executed. For example, if app_ 1 116 is an email program, the file and the attachment, if there is one, is transmitted, or sent, to the intended recipient(s). Finally, during an “End Process File” block 219 , process 200 is complete.
FIG. 4 is a flow chart illustrating a Check Attachment process 250 that is one example of processing that may implement the claimed subject matter (see 208 , FIG. 3 ). In this example, logic associated with process 250 is stored on data storage 112 ( FIG. 1 ) as part of AVC 118 ( FIGS. 1 and 2 ) and executed on processor 104 . In the alternative, process 200 , as well as AVC 118 , may either be incorporated into either OS 114 ( FIG. 1 ) or an application such as App_ 1 116 ( FIG. 1 ).
Process 250 starts in a “Begin Check Attachment (Attch.)” block 252 and proceeds immediately to a “Get Attch. Info” block 254 . During block 254 , process 250 gathers information about file that is being processed, in this example Attch_ 1 122 (see element 150 , FIG. 2 and process 200 , FIG. 3 ). Information typically includes, but is not limited to, the name of the file, dates and times associated with the file, the directory from which the file originated and a version number if the file is part of a series of related files.
During a “Generate Regular Expression File Names (REFN)” block 256 , process 250 , based upon the name of the file of attch_ 1 122 and information from AVC configuration 142 ( FIG. 2 ), generates regular expressions corresponding to the name of attch_ 1 122 (see element 158 , FIG. 2 ). For example, if attch_ 1 122 has a name of “FileName v1.txt” a regular expression may be “FileName*.txt,” which would match and files such as “FileName v2.txt” and “FileName v3.txt.” Regular expressions may be based upon the name of a file and/or on conventions associated with OS 114 such as, but not limited to, particular directory naming or file extension conventions. For example, some platforms store temporary files in a specific directory, e.g. a “/tmp” directory while other platforms store temporary in a current directory and either add a ‘˜’ character at the beginning of a file name or modify the file extension.
During a “Generate Associated Names” block 258 , process 250 generates the names of possible alternative file name that may be associated with attch_ 1 122 (see element 160 , FIG. 2 ). For example, if a user is working with revisions of documents, alternative files include the different revision numbers. Files names may be collected based upon the date and time the files were created and modified. The names of files that have similar spellings may also be generated employing algorithms typically associated with spell-checking logic. In addition, names are generated that may be associated with any temporary versions of a file. For example, if a file entitled “file.txt” is currently opened by a word processing application (WPA), the WPA may be storing unsaved changes to a file entitled “˜file.txt.” Those with skill in the computing arts should appreciate the many variations that could be employed to generate associated file names. Control of how thorough the generation of alternative files is to be depends upon configuration parameters set by a system administrator or user (see element 142 , FIG. 2 ).
During a “Search System” block 260 , process 250 scans memory associated with client system 102 , which may include such memory as data storage 112 and remote storage such as data storage 128 ( FIG. 1 ) to locate actual files that match the file names generated during block 258 (see element 150 , FIG. 2 ). During a “Sort List” block 262 , process 250 sorts the list of actual file names collected during block 260 to produce a sorted list of file names (see element 152 , FIG. 2 ). Depending upon configuration parameters, the list may be sorted by version number, date/time of creation or modification or any of a number of possible scenarios. Files may be sorted based upon the closeness of a name or directory match. In this manner, more likely alternative files may be listed first and less likely files listed later. A displayed listing may also include a degree of correlation between a particular selected files and possible alternatives.
During a “Meet Parameters?” block 264 , process 250 determines whether or not the original file, which in this example is attch_ 1 122 , meets the configuration parameters established for automatic acceptance. As noted above, the parameters may also be set so that any attachment must be verified by a user, i.e. there is not automatic approval. If so, attch_ 1 122 is marked as “Approved” during a “Mark Not Approved (NA)” block 266 and, if not, attch_ 122 is marked as not approved during a “Make Not Approved” block 268 . Control then proceeds to a “More Attach.?” block 266 during which process 250 determines whether or not there are more attachments associated with file_ 1 120 . If so, control returns to block 254 and processing continues as described above with respect to the next attachment. If not, control proceeds to an “End Check Attach.” block 269 in which process 250 is complete.
FIG. 5 is a flow chart illustrating a Process Attachment process 300 that is one example of processing that may implement the claimed subject matter (see element 212 , FIG. 3 ). In this example, logic associated with process 300 is stored on data storage 112 ( FIG. 1 ) as part of AVC 118 ( FIGS. 1 and 2 ) and executed on processor 104 . In the alternative, process 300 , as well as AVC 118 , may either be incorporated into either OS 114 ( FIG. 1 ) or an application such as App_ 1 116 ( FIG. 1 ).
Process 300 starts in a “Begin Process Attachment (Attch.)” block 302 and proceeds immediately to a “Get Attch.List” block 304 . During block 304 , process 300 receives a list associated with an attachment such as attch_ 1 122 ( FIG. 1 ) that has been checked and possibly marked for closer review in conjunction with a list of alternative file names that have been generated (see process 250 , FIG. 4 ). During an “Offer Selection” block 306 , process 300 generates a graphical user interface (GUI) for display on monitor 106 so that the user can see the alternative files and make a selection.
During a “Attch. Approved?” block 308 , process 300 determines whether or not the user has selected a file in the list displayed during block 306 or has indicated that more attachments need to be scrutinized for selection. If the user has approved an attachment, control proceeds to a “Select Attch.” block 310 during which the selected file is added to file_ 1 120 as an attachment for transmission.
If no attachment is a list of attachments has been approved during block 308 , process 300 proceeds to a “Delete Selection” block 314 during which attch_ 1 122 is deselected for attachment. Once processing has completed in blocks 310 or 316 , control proceeds to a “More Lists?” block 312 during which process 300 determines whether or no there are more lists of attachments to process. If so, control returns to block 304 and processing continues as described above on the next list. If not, control proceeds to an “End Process File” block 319 in which process 300 is complete.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions. | The claimed subject matter comprises a technology to scan a document for file attachments, generate alternative file names corresponding to a particular attachment, determine whether or not the particular file attachment is the latest version of a file or has a name and/or file path that could be confused with the name and/or path of another file. In the event one of the above conditions are met, the technology provides the means for a user to verify that the file attachment is the desired file and, if necessary, to select an alternative file for attachment. | 6 |
FIELD OF THE INVENTION
This invention relates to a device for hydraulic jet cleaning of elevated and extended positions on a building or structure and more particularly to a roof gutter and downspout cleaner having interchangeable end fittings for adapting the device to clean hard to reach locations with a strong spray of water.
BACKGROUND OF THE INVENTION
Collection of roofing debris, leaves, and twigs in gutters and downspouts is a commonly recognized problem requiring frequent cleaning and dislodgement of items which restrict water flow through a gutter and downspout system. Various devices have been employed to facilitate cleaning of gutters and downspouts without a ladder which generally comprise an extended handle having a turned end for ejecting water or fluid into a clogged area to relieve and dislodge particles. However, none provide a cleaning device with easily interchangeable end attachments having comparable flow regulating outlets forming water discharge ends which direct water under pressure at a desired angle relative to the object being cleaned, for example a gutter or downspout.
SUMMARY OF THE INVENTION
A cleaning device of this invention has a generally elongated tubular body, a reverse bend at an outlet end, and a flow regulating outlet device for emitting a pressurized spray of cleaning fluid or water. To facilitate angular positioning of interchangeable outlet devices, a garden hose splitter connector can be inserted between the outlet end and outlet device. A flow control valve is provided at a body inlet for regulating fluid flow and the outlet end forms a coupling for mating with outlet devices.
In a first assembled embodiment of the invention, a flow regulating garden hose nozzle is mated in sealed engagement with a tubular body outlet end to form an outlet device with a flexible hose portion having a flow nozzle at the distal end. The resulting outlet device can be easily inserted within a down spout to more strategically deliver pressurized water at lodged particles within the downspout. Alternatively, the outlet device can be sealingly connected to a hose splitter connector at one of its outlet ends, with the splitter inlet end being sealingly connected to the tubular body outlet end. By capping off, or valve closing the splitters other outlet end, the outlet device can be presented into a gutter at a desired angle to deliver pressurized fluid flow to clean the gutter. By reversing attachment to the other splitter outlet end, the nozzle angular orientation can be biased in a reverse direction. The device can then be positioned and moved within a gutter to deliver high pressure water flow from the nozzle which displaces debris where it is eventually delivered to the downspout and dislodged.
Objects, features and advantages of this invention are to provide an adaptable outlet end cleaning device having a variety of interchangeable flow regulating outlet devices with nozzles which can be carried in a preferred orientation on the devices outlet end. The device is constructed from an elongated tubular body with a reverse bend outlet end which delivers water from an inlet end through a flow control valve to provide pressurized water at the flow nozzle for cleaning structures such as gutters and downspouts. The resulting device provides the preceding in a strong and lightweight structure which can be designed for compact storage using take apart components, and is simple, stable, rugged, durable, reliable, quick and easy to use and adapt, and is of relatively simple design and economical manufacture.
These and other objects, features and advantages of the invention will become apparent from a consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary sectional view of a house with a gutter being cleaned by the cleaning device embodying this invention;
FIG. 2 is an enlarged view of the outlet end of the cleaning device depicted in FIG. 1 showing an alternative outlet device attached to the outlet end and being used to clean a downspout on a house;
FIG. 3 is a vertical sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a partial sectional view of hose splitter connector as utilized in the FIG. 1 embodiment; and
FIG. 5 is an elevational centerline sectional view of an alternative arrangement with a flow regulating outlet device which can be incorporated in either the FIG. 1 or FIG. 2 assembled embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in more detail to the drawings, FIGS. 1 and 3 illustrate a cleaning device 10 for cleaning gutters and downspouts which embodies this invention. The device has an elongated tubular body 12 with a reverse bend 14 at an outlet end 16 and an inlet coupling 18 formed by a flow control valve 24 which couples to a garden hose 19 adjacent its inlet end 20 for delivering a flow of pressurized water through a flexible hose end attachment 26, or outlet device, at the cleaning device's outlet end. The cleaning device facilitates cleaning of gutters, downspouts, and other elevated surfaces without using a ladder. To position the hose end attachment 26 for cleaning a gutter 27, a hose splitter adapter 30 is connected between attachment 26 and tubular body outlet end 16 which orients the attachment at an angle to the outlet end to produce a lateral flow of fluid from the outlet end of the attachment. Preferably, outlet end 16 has a sealable threaded outlet coupling 22 which complementarily mates with a corresponding complementary coupling 23 on either adapter 30 or attachment 26. Preferably, inlet end 20 also has an end flange 35 supporting a coupling collar 34 which mates and seals with a complementary coupling 40 on flow control valve 24. The other end of valve 24 forms female inlet coupling 18 which threads and seals to the end of a garden hose 19.
As shown in FIG. 1, tubular body 12 is preferably constructed with an upper tube 32 which is sealably and releasably joined to a lower tube 36 to enable disassembly during storage. A female coupling collar 34 is rotatably carried on tube 32 where it is retained by a tube end flange 35, and a male coupling 38 is provided on tube 36 which, when coupled to the collar, seals with the tube end flange. The resulting self sealing joint can be hand tightened without the use of tools. Similarly, inlet end 20 on tube 36 forms another tube end flange 35 which retains a female coupling collar 34. A complementary threaded male coupling 40 on valve 24 is releasably engaged to inlet end 20 where it forms a seal with flange 35. This joint can also be finger tightened by rotatably engaging collar 34 to coupling 40. Preferably, inlet coupling 18, outlet coupling 22, and male and female couplings 34, 38, and 40 are formed from readily commercially available 3/4 inch male and female garden hose coupling fittings with self sealing end features. Alternatively, circumferential washers (not shown) should be provided in fittings to produce a water tight seal when assembled.
FIG. 2 depicts an alternative arrangement for assembling the device in FIGS. 1 and 3 where hose end attachment 26 is directly coupled to outlet end 16 for cleaning downspouts. The reverse bend 14 on device 10 facilitates easy insertion of end attachment 26 into a downspout 41 where high pressure fluid exits restriction 28 to dislodge debris within the downspout.
FIG. 4 depicts the splitter adapter 30 of FIG. 1, which has a pair of diverging outlet ends 44 and 46 for regulating flow and an inlet end 42. One of the outlet ends receives attachment 26, in a manner which orients the attachment at a desired angular position to direct the pressurized fluid flow accordingly. A valve 48 and 50 disposed within each outlet end 44 and 46, respectively, for regulating and directing fluid flow to the outlet end carrying an end attachment. Each valve 48 and 50 is controlled from the exterior of the adapter with valve handles 52 and 54, respectively, forming stop cocks. Alternatively, a rigid tubular segment (not shown) with an outlet end angularly biased from an inlet end can be substituted for the adapter.
As shown in FIG. 3 and 4, by turning handle 52 to an open position and handle 54 to a closed position, flow which is received through inlet end 42 leaves through outlet end 44 where it continues to hose end attachment 26 and exits as a pressurized fluid flow for cleaning debris from a gutter. Preferably, the inlet end is provided with female threaded portion 23, comprising a 3/4 inch female hose connection which is received on threads 22 of outlet end 16. Likewise, each outlet end forms a 3/4 inch standard male threaded hose connection 51. Additionally, the splitter adapter is preferably constructed with molded plastic to minimize corrosion and electrolysis between the tubular body, connector and hose end attachment.
FIG. 5 depicts an alternative embodiment which uses a flexible hose extender 56 mated to tubular body outlet end 16 in place of the flexible hose end attachment 26 of FIG. 2. One end of the extender has a 3/4 inch female hose connection 58 for engaging with outlet coupling 22 and the other end has a 3/4 inch male hose connection 60 for coupling to a standard garden hose nozzle 62. Alternatively, extender 56 and nozzle 62 can be used in place of attachment 26 in the FIG. 1 and FIG. 3 embodiment.
As shown in FIGS. 2 and 5, respectively, attachment 26 and flexible hose extender 56 are preferably made of flexibly resistant material such as rubber, plastic, or metal hose. Preferred lengths as shown in the above Figures were arrived at by experimentation. The flexibly resistant material provides for a hydraulic snake, such as a plummer's snake which is a tool of flexible metal of varying lengths as required for the job at hand. It is effective when used to push, prod and penetrate a clog in a pipe by physical up and down and rotative manipulation.
The gutter and downspout cleaning device of this invention is assembled to clean debris in gutters in the FIG. 1 embodiment and is easily re-assembled into the FIG. 2 embodiment for cleaning downspouts. Additionally, the device provides the preceding in an adaptable arrangement which can be taken apart and stored compactly and which is lightweight and of low maintenance to the end user and provides for shut off of high pressure fluid flow into the device, while further providing for interchangeable end attachments to clean various locations, such as cleaning window ledges on buildings, etc.
It is to be understood that the invention is not limited to the exact construction illustrated and described above, but that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. | A cleaning device having a regulated supply of pressurized fluid which is delivered to an outlet end through one of several interchangeable outlet devices having an outlet flow nozzle for cleaning clogged debris from gutters and downspouts, as well as other elevated structures. Reassembly of interchangeable outlet devices in combination with an outlet end adapter provides for adaptation of the device to optimize cleaning of gutters, and then to optimize cleaning of downspouts. All of the preceding is provided in a device which is quick and easy to assemble, and can be taken apart for storage, without wrenches. | 4 |
FIELD OF THE DISCLOSURE
[0001] The present invention relates to the field of connectors, in particular electrical cable connectors.
BACKGROUND OF THE DISCLOSURE
[0002] In the field of connectors, in particular cable connectors, it is known to use a cable clamp, clamping the cable to the connector housing, for strain relief. Generally, the cable clamp is screwed to the housing. This requires screws, thus additional separate parts, and the screwing complicates assembly of the connector.
[0003] The connector housing and/or the cable clamp generally are formed providing an opening optimized for receiving a cable of a particular outer diameter and compressibility. Such connectors are not well suited for accommodating a cable of a different diameter and/or compressibility.
[0004] If the opening for the cable is small, portions of the cable may be pinched or crushed, which affects its transmissive and/or structural properties. This is in particular the case for cables for signal transmission, especially high speed signal transmission, and for multi-wire cables. Conversely, a large cable opening may allow slipping of the cable with respect to the housing, possibly affecting or compromising connections of and/or to the cable inside the housing. Thus, connectors having a cable clamp may have limited usefulness for many purposes. As a result, stocking and/or selling various sizes and types of connector housings and/or cable clamps for suitably clamping different cables is required. This substantially increases costs.
[0005] Therefore, a need exists for an improved cable connector reducing or alleviating the above-referenced problems.
SUMMARY OF THE DISCLOSURE
[0006] An object of the present invention is to provide a cable clamp that can be used for different cable diameters. This object is achieved with a cable connector comprising a connector housing with an opening for receiving a cable, and a cable clamp mounted to the connector housing wherein the clamp comprises an intermediate section between two or more mounting portions, at least one of the mounting portions comprising locking means for interlocking with one of at least two cooperative locking means of the housing. When the cable clamp is put in place in the housing, one of the two or more present locking means in the housing can be selected, depending on the type of cable to be clamped. This way, the position of the cable clamp can selectively be adjusted between at least two alternative clamping positions so it can be used for more than one cable diameter.
[0007] Optionally, the housing comprises at least two slots, each being dimensioned to interlock a locking means formed by a matching extension of the cable clamp. Alternatively, the clamp can be provided with one or more slots dimensioned to cooperate with one or more matching interlocking means, such as hooks or projections, of the housing.
[0008] With only one slot of the two or more slots being used, the slots which have not been brought into engagement with the matching cable clamp extension, can for example be covered by a foil of electromagnetic shielding material. This prevents that the unused slot or slots forms a leak in the electromagnetic shielding. Alternatively, the slots can be replaced by blind holes.
[0009] The cable clamp extension forming the locking means comprise for example a hook.
[0010] To improve the grip of the cable clamp on the cable jacket, the intermediate portion of the cable clamp may be provided with one or more piercing teeth, e.g., piercing into the cable jacket. Optionally, the teeth may penetrate through the braid that has been folded back on the isolating jacket or sheath at the end of the cable, so as to bite into the isolating sheath so as to improve EMI shielding.
[0011] The intermediate portion can be provided with a flange bridging the gap between the intermediate portion and the adjacent edge of the cable receiving opening. The flange can be made of an electromagnetic shielding material.
[0012] In an alternative embodiment the intermediate cable clamp portion is provided with resilient teeth alternately folded in opposite directions. In use, the teeth resiliently clamp against the cable jacket. Such an arrangement of resilient teeth can effectively reduce freedom of forward movement of the clamped cable as well as backward movement.
[0013] In a further alternative embodiment, the intermediate section comprises at least two curved sections of different curving diameter. This way, the clamp can be used for stiffer cables having a diameter corresponding to one of the curved sections, and it can also be used for cables of larger diameter with higher compressibility.
[0014] An object of the invention is also achieved with a cable connector comprising a connector housing with an opening for receiving a cable, and a cable clamp mounted to the connector housing wherein the cable clamp comprises an intermediate section between two or more mounting portions, wherein the intermediate cable clamp portion is provided with resilient teeth alternately folded in opposite directions to resiliently clamp against the cable jacket. Optionally, the intermediate portion of the cable clamp is provided with a series of outwardly bent shielding teeth, to cover the gap between the intermediate portion and the interior edge or wall of the cable opening and to complete the electromagnetic shielding. These teeth may have rounded end parts, e.g., be mushroom shaped, to maximize coverage of the gap between the cable clamp and the cable opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 : shows in perspective view a connector according to the present invention;
[0016] FIG. 2A : shows in perspective view the interior of the connector of FIG. 1 ;
[0017] FIG. 2B : shows in perspective view a multi-connector variant of the connector of FIG. 2A ;
[0018] FIG. 3A : shows a side view of the cable clamp of FIG. 1 ;
[0019] FIG. 3B : shows a plan view of the cable clamp of FIG. 1 ;
[0020] FIG. 3C : shows a perspective view of the cable clamp of FIG. 1 ;
[0021] FIG. 4 : shows a perspective view of a second embodiment of a connector according to the invention;
[0022] FIG. 5A : shows a perspective view of a cable clamp of the connector of FIG. 4 ;
[0023] FIG. 5B : shows a side view of the cable clamp of FIG. 5A ;
[0024] FIG. 6A : shows a perspective view of a third embodiment of a connector according to the invention;
[0025] FIG. 6B : shows another perspective view of the connector of FIG. 6A ;
[0026] FIG. 7A : shows a perspective view of the cable clamp of the connector of FIG. 6A ;
[0027] FIG. 7B : shows a side view of the cable clamp of FIG. 7A .
DETAILED DESCRIPTION OF EMBODIMENTS
[0028] FIG. 1 shows in perspective view a cable connector 1 comprising a connector housing 2 and a cable clamp 3 for clamping a cable (not shown) to the housing 2 .
[0029] The housing 2 is made of two matching casing sections 4 , 5 both comprising a semi-circular collar section 6 , 7 together forming a cylindrical collar 8 when both casing sections 4 , 5 are joined together to form the housing 2 . FIG. 2 shows the interior of the connector 1 with the shell section 5 broken away. The collar 8 surrounds an opening 9 in the housing 2 for receiving a cable. In line with the collar 8 located within the housing 2 is a cable clamp 3 , which is shown in more detail in FIGS. 3A-C .
[0030] The cable clamp 3 comprises a first mounting portion 11 , a second mounting portion 12 aligned with respect to the first mounting portion, and a curved intermediate portion 13 . The first mounting portion 11 has a rounded end and comprises an opening 14 allowing passage of a fixation screw, as shown in FIG. 2 . According to a preferred embodiment, the second mounting portion is provided with a bend portion or makes an angle with respect to the first mounting portion in order to make the mounting step easier.
[0031] The second mounting portion 12 forms a locking means provided with a slanting top edge 15 .
[0032] The curved intermediate portion 13 has a concave side provided with five evenly distributed triangular teeth 16 . On its convex side, the clamp 3 is provided with a collar or flange 17 . To facilitate bending the flange 17 , openings or slots 18 are provided on the folding line 19 of the flange 17 .
[0033] The clamp 3 and the housing 2 are made of an electromagnetic shielding material.
[0034] The top side of the housing 2 is provided with locking means formed by slots 20 , 21 , both dimensioned to receive locking means 12 of the cable clamp 3 . When the locking portion 12 is put into the first slot 20 , the clamp leaves open a larger opening for passage of a cable than if portion 12 is put into the second slot 21 . As a result, cables of different diameter can be clamped using the same cable clamp 3 . If a smaller diameter cable is used, the cable clamp portion 12 is brought into engagement with slot 21 . In that position, flange 17 covers the gap between the curved clamp portion 13 and the housing wall surrounding cable opening 9 . Flange 17 can be made of an electro conductive material. The interior wall of the housing facing the flange 17 can be provided with projections or teeth contacting flange 17 . This way, flange 17 completes the electromagnetic shielding of the connectors interior.
[0035] When a cable is clamped in the opening 9 by clamp 3 , the triangular teeth 16 pierce into the cable jacket to give improved fixation of the cable. Optionally, the teeth penetrate through the braid that has been folded back on the isolating jacket or sheath at the end of the cable, so as to bite into the isolating sheath so as to improve EMI shielding. Alternatively, the teeth penetrate through the isolating sheath to such extent that it contacts the underlying conductive shielding braid.
[0036] Slots 20 , 21 may be dimensioned to limit passage of electromagnetic wavelengths above a particular cut-off wavelength of electromagnetic noise, corresponding to a lower frequency limit for EMI noise. Optionally, slots 20 , 21 can be sealed with a foil of an electromagnetic shielding material. When the clamp portion 12 is brought into engagement with one of the slots, the corresponding seal is broken while the other slot remains sealed.
[0037] The slanting edge 15 of cable clamp portion 12 juts out off the slot 20 , 21 , allowing visual inspection, particularly if the portion 12 and the housing 2 have different colours, shades or brightness.
[0038] The opening 9 in housing 2 is provided with ribs or protrusions or teeth 22 to further reduce movement of the cable.
[0039] The cable to be used comprises electro conductive wires to be connected to contact points in a terminal block 23 closing off the housing 2 .
[0040] In FIG. 2B , a double connector is shown comprising a cable clamp 3 A similar to the cable clamp in FIG. 2A but with a larger flange 17 A. A resilient fin 24 presses the flange 17 A against the interior housing surface peripheral to the cable opening. Corner parts 25 with an L-shaped cross section surround the two side edges of the flange 17 A, protecting the fin 24 from breaking when a certain force is exercised onto the cable and the cable clamp in the direction of fin 24 .
[0041] A set of different exchangeable cable clamps can be used having different sizes of flanges. Clamps for cables of smaller diameter have to bridge a larger gap between the clamp and the cable opening edge and can for that purpose be provided with larger flanges. A set can for instance include the clamp 3 of FIG. 2A and the clamp 3 A of FIG. 2B and optionally further type variations, wherein each clamp type can be used for two or more corresponding cable diameters.
[0042] Another embodiment of a cable clamp 103 according to the present invention is shown in FIGS. 4 and 5A and 5 B.
[0043] FIG. 4 shows a housing 102 with an opening 109 for receiving a cable. In line with the opening 109 is a cable clamp 103 , shown in detail in FIGS. 5A and 5B . The cable clamp 103 comprises a first portion 11 with an opening 114 allowing passage of a fixation screw, a second portion 112 provided with a hook 115 , and a curved intermediate portion 113 . End portions 111 and 112 are bent over right angles with the intermediate portion 113 . On its concave side, the curved intermediate portion 113 is provided with teeth or leaf springs 116 alternately bent in opposite directions. The convex side of the curved portion 113 is provided with a series of mushroom shaped projections 117 , bent under an angle of about 60-70 degrees relative to the intermediate portion 113 .
[0044] When mounted in a connector housing and after connecting a cable to the connector, hook 115 of portion 112 is brought into engagement with a corresponding slot in the housing 2 and a fixation screw fixes the clamp via opening 114 in end portion 111 . Teeth 116 resiliently clamp on the cable. Due to the alternating orientation of the teeth backward as well as forward movement of the cable is effectively reduced. The mushroom shaped projections 117 resiliently engage with the interior wall of opening 109 , effectively bridging the gap between the cable clamp 113 and the interior wall of opening 109 and completing the electromagnetic shielding. The resiliency of the mushroom shaped projections 117 increases the range of cable diameters that can be used with the cable clamp 103 .
[0045] A third embodiment of a cable clamp 203 according to the invention is shown in FIGS. 6A-7B . FIG. 6A shows a triple cable connector having three cable openings 209 and cable clamps 203 . As shown in detail in FIG. 7A , the cable clamps 203 are provided with a first end portion 211 with an opening 204 for a fixation screw or similar fastening means, and a second end portion 212 with a hook 215 . As shown in FIG. 6B , hook 215 is mounted in a corresponding slot 220 in housing 202 of the connector. The cable clamp 203 has a curved intermediate section 213 having a profile with two rounded bulges of different diameter. Such a clamp can be used for stiffer cables having a diameter corresponding to either one of the bulges 222 , 223 , but also for more compressible cables with a larger diameter.
[0046] The described embodiments are intended to be illustrative rather than restrictive. Various modifications, variations and re-combinations of features of the embodiments as described can be made without departing from the spirit or scope of the disclosure. | Cable connector including a connector housing and a cable clamp for clamping a cable to the housing. The cable clamp having an intermediate portion between a first and a second mounting portion. At least one of the two mounting portions of the cable clamp is provided with locking means selectively cooperative with at least two matching locking means, such as slots, of the connector housing to hold the cable clamp in respective different positions corresponding to different cable diameters. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of the filing date of copending provisional application Ser. No. 60/142,908, filed Jul. 9, 1999.
FIELD OF THE INVENTION
The present invention relates to lubricant compositions, and to their use, for example, to coat beverage containers or conveyor systems for beverage containers. the invention also relates to beverage containers and conveyor systems treated with such lubricant compositions.
DESCRIPTION OF RELATED ART
In the commercial distribution of most beverages, the beverages are packaged in containers of varying sizes made of a variety of materials. In most packaging operations, the containers are moved along conveying systems, usually in an upright position with the opening of the container facing vertically up or down, and moved from station to station, where various operations, such as filling, capping, labeling, sealing, and the like, are performed.
Lubricants are often used on conveying systems in the beverage industry during the filling of containers with beverages. There are a number of different attributes that are desirable for such lubricants. For example, the lubricant should provide an acceptable level of lubricity for the system. For containers made from plastics such as polyethylene terephlthalate (PET), the lubricant should not cause environmental stress cracking (crazing and cracking that occurs when the plastic polymer is under tension). It is also desirable that the lubricant have a viscosity which allows it to be applied by conventional pumping or application apparatus, such as sprayers, roll coaters, wet bed coaters, and the like, commonly used in the industry.
It is also important that the lubricant be compatible with the beverage so that the lubricant does not form solid deposits when it accidentally contacts spilled beverages on the conveyor system. This is important since the formation of deposits on the conveyor system may change the lubricity of the system and could require shutdown of the equipment to facilitate cleaning. Unfortunately, many currently-used lubricants contain ingredients that react with, for example, carbonated beverages to form such deposits.
SUMMARY OF THE INVENTION
The present invention provides, in one aspect, a beverage container or a conveyor for a beverage container, whose surface is coated at least in part with a coating that has been thermally cured at less than 200° C. or radiation-cured, whereby the cured coating forms a lubricant layer on the surface of the container or the conveyor.
The invention also provides a method for lubricating a beverage container, comprising applying to at least a portion of a surface of the beverage container a thermal or radiation curable coating, and thermally curing the coating at less than 200° C. or radiation curing the coating to provide a lubricant layer on the surface of the container.
The invention also provides a method for lubricating a conveyor system used to transport beverage containers, comprising applying a thermal or radiation curable coating to at least part of the conveying surface of a conveyor and then thermally curing the coating at less than 200° C. or radiation curing the coating to provide a lubricant layer on the conveying surface.
In addition, the invention provides a conveyor used to transport beverage containers, which is coated on portions that contact the container with a coating that has been thermally cured at less than 200° C. or radiation-cured, whereby the coating forms a lubricant layer on the conveyor.
The invention also provides thermal or radiation curable container or conveyor lubricating compositions comprising a film former that can be thermally cured at less than 200° C. or radiation-cured, a thermal initiator or photoinitiator, and at least 3 weight percent of lubricating fluoropolymer particles.
The compositions used in the invention can be applied in relatively low amounts and do not require in-line dilution with significant amounts of water. The compositions of the invention provide thin, dry lubricating films. In contrast to dilute aqueous lubricants, the lubricants of the invention provide dry lubrication of the conveyors and containers, a cleaner and drier conveyor line and working area, and reduced lubricant usage, thereby reducing waste, cleanup and disposal problems. Further features and advantages of the invention will become apparent from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates in partial cross-section a side view of a plastic beverage container and conveyor partially coated with a lubricant composition of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention relates to a lubricating coating that provides good lubricity to a beverage container or to a conveyor surface for the beverage container, thus enabling proper movement of containers along the conveyor system. The coating is formed by thermal- or radiation-induced curing. The resulting coating is dry to the touch following cure, and relatively water-insoluble (that is, the cured coating will not be washed away when exposed to water). The coating can be reapplied as needed, on the conveyor line if desired, to compensate for coating wear. The lubricant composition does not require in-line dilution with significant amounts of water; that is, it can be applied undiluted or with relatively modest dilution, e.g., at a water:lubricant ratio of about 1:1 to 5:1. In contrast, conventional dilute aqueous lubricants are applied using significant amounts of water, at dilution ratios of about 100:1 to 500:1. The entire container or conveyor can be coated or treated, but it is usually preferred to coat only those portions of the container or conveyor (or both container and conveyor) that come into contact with one another. The lubricant coating preferably is substantially non-dripping prior to cure; that is, preferably, the majority of the lubricant remains on the container or conveyor following application until such time as the lubricant coating is cured.
The invention is further illustrated in FIG. 1, which shows a conveyor belt 10 , conveyor chute guides 12 , 14 and beverage container 16 in partial cross-sectional view. The container-contacting portions of belt 10 and chute guides 12 , 14 are coated with thin layers 18 , 20 and 22 of a cured lubricant composition of the invention. Container 16 is constructed of blow-molded PET, and has a threaded end 24 , side 25 , label 26 and base portion 27 . Base portion 27 has feet 28 , 29 and 30 , and crown portion (shown partially in phantom) 34 . Thin layers 36 , 37 and 38 of a lubricant composition of the invention cover the conveyor-contacting portions of container 16 on feet 28 , 29 and 30 , but not crown portion 34 . Thin layer 40 of a lubricant composition of the invention covers the conveyor-contacting portions of container 16 on label 26 .
A variety of coating compositions can be used. The coating composition typically will include at least one film-forming ingredient that can be cured using thermal cure at less than 200° C. or radiation-induced cure (e.g., UV or visible light cure). Coating compositions that can be thermally cured at less than 200° C. or radiation cured can be applied to and cured in place upon thin-walled plastic beverage containers made of materials such as polyethylene terephthalate (M.P. 260° C.) and polyethylene naphthalate (M.P. 262° C.). For thermally cured film formers, the thermal cure temperature preferably is less than 160° C., and more preferably is less than 120° C. Coating compositions that can be thermally cured at less than 120° C. or radiation cured can be applied to and cured in place upon polyacetal plastic parts, which are commonly employed in beverage conveyors. Suitable film formers include polymerizable or crosslinkable materials that are capable of being hardened and formed into a film. Preferably the film former is radiation-curable, and most preferably it is UV-curable. Film formers that are waterborne or otherwise substantially solvent free (e.g., 100 percent solids low viscosity formulations) are preferred for environmental reasons. Representative film formers include free-radically-polymerizable materials such as butyl acrylate, allyl acrylate, zinc acrylate, 1,6-hexanediol diacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate and polymers with vinyl or (meth) acrylate functional units such as those described in U.S. Pat. No. 5,849,462; polymerizable silicone compounds such as trimethylsilylmethacrylate, and poly(acryloxypropylmethyl)siloxane; cationically-polymerizable or crosslinkable materials such as bisphenol-A diglycidyl ether; and monomers, oligomers and polymers that are polymerized or crosslinked through their reactive functional units, such as by the photogenerated 2+2 cycloaddition of poly(vinylidene acetate), curing reactions between bisphenol A-epoxy resin and diethylenetriamine, and condensation reactions of diols and dianhydrides. Preferred film formers include urethanes, acrylics, epoxies, melamines and blends or copolymers thereof. Waterborne UV curable acrylates and urethanes are particularly preferred film formers. Suitable commercially available film formers include UV curable acrylate coatings from UV Coatings Limited; ROSHIELD™ 3120 UV curable acrylate coating from Rohm & Haas; NEORAD™ NR-3709 UV curable aliphatic urethane coating from Zeneca Resins, curable urethane coatings such as those described in U.S. Pat. Nos. 30 5,453,451 and 5,773,487; COURTMASTER II™ waterborne acrylic urethane, available from Ecolab, Inc.; LAROMER™ PE 55W polyester acrylate, LR 8895 polyester acrylate, LR 8949 aliphatic urethane and LR 8983 aromatic urethane waterborne acrylic ester resins, all available from BASF Corp.; VIAKTIN™ VTE 6155 aliphatic urethane acrylate, VTE 6161 polyester urethane acrylate, VTE 6165 aromatic urethane acrylate and VTE 6169 aliphatic polyester urethane acrylate radiation curing resins, all available from Vianova Resins GmbH & Co. KG; 98-283W urethane acrylate, available from Hans Rahn & Co.; partially acrylated bisphenol-A epoxy resins such as Ebcryl resin 3605 (available from Radcure) and coating compositions such as those described in U.S. Pat. No. 5,830,937. The film former usually represents up to about 99 wt. %, more preferably about 50 to about 97 wt. %, and most preferably about 70 to about 95 wt. % of the final coating weight.
The film former can be used by itself if it provides a sufficiently lubricious surface when cured. Typically, however, the film former will be combined with a liquid, semi-solid or solid lubricant that imparts lubricity to the cured lubricating coating. A variety of lubricants can be used in the invention. The lubricant should provide reduced lubricity between the conveyor and container surfaces and not adversely affect the intended thermal or radiation curability of the lubricating composition. Preferred lubricants include solid materials such as molybdenum disulfide, boron nitride, graphite, silica particles, silicone gums and particles, polytetrafluoroethylene (PTFE) particles, fluoroethylene-propylene copolymers (FEP), perfluoroalkoxy resins (PFA), ethylene-chlorotrifluoroethylene alternating copolymers (ECTFE), poly (vinylidene fluoride) (PVDF), waxes and mixtures thereof. Fatty acids, phosphate esters and mixtures thereof can also be employed. Lubricants containing fluoropolymers such as PTFE are especially preferred. Preferred commercially or experimentally available lubricants include the EVERGLIDE™ and ULTRAGLIDE ™ series of micronized wax powders, dispersions and emulsions such as EVERGLIDE UV-636 (25% carnauba wax emulsified in tripropylene glycol diacrylate), EVERGLIDE UV-231 D (35% fluoroethylene wax dispersed in tripropylene glycol diacrylate), ULTRAGLIDE UV-701 (40% PTFE dispersed in tripropylene glycol diacrylate) and ULTRAGLIDE UV-801 (35% PTFE in tridecyl stearate), all commercially available from Shamrock Technologies, Inc.; and the MICROSPERSION™, POLYFLUO™ AND SYNFLUO™ series of micronized waxes such as MICROSPERSION 190-50 50% aqueous dispersion of polyethylene wax and PTFE and POLYFLUO 190 micronized fluorocarbon, all commercially available from Micro Powders Inc. A preferred amount of lubricant is at least about 1 wt. %, more preferably about 3 to about 50 wt. %, and most preferably about 5 to about 30 wt. %, based on the weight of lubricant (exclusive of any carrier or solvent that may have been used to disperse or dissolve the lubricant) in the final cured coating.
If the lubricant composition is thermally curable, then it optionally (and preferably) will include at least one thermal initiator or catalyst to promote polymerization or crosslinking of the film former. A variety of thermal initiators or catalysts can be employed. Examples of suitable thermal initiators or catalysts include peroxides such as benzoyl peroxide, dicumyl peroxide and t-butyl perbenzoate; and azo compounds such as 2,2′-azobisisobutyronitrile, 1,1′-azobis(1-cyclo-hexanecarbonitrile) and 2,2′-azobis(isobutyramide)dihydrate. The amount of thermal initiator or catalyst that should be employed will depend in part on the efficiency of the initiator or catalyst and on the thickness of the lubricant coating. Preferably, the thermal initiator or catalyst will be present in an amount of about 0.01% to about 15 wt. % of the coating, more preferably about 0.5% to 10 wt. % of the coating.
If the lubricant composition is radiation curable, then it optionally (and preferably) will include at least one photoinitiator to promote polymerization or crosslinking of the film former. A variety of photoinitiators can be employed. Photoinitiators that become active when exposed to radiation over some portion of the spectrum between 200 and 1200 nm (e.g., ultraviolet, visible-light and infrared radiation) are preferred, and more preferably those that become active over some portion of the spectrum between 250 and 850 nm. Examples of suitable visible-light and ultraviolet induced photoinitiators include benzil, benzoin, acyloins, acyloin ethers, and ketones such as 2-methyl-1-[4-(methylthio)phenyl]-2-morpholino propan-1-one (commercially available from Ciba Specialty Chemicals as IRGACURE 907), 2,2-dimethoxy-2-phenylacetophenone (commercially available from Ciba Specialty Chemicals as IRGACURE™ 651), 2-benzyl-2-N,N-dimethylamino-1-(4-morphomophenyl)-1-butanone (commercially available from Ciba Specialty Chemicals as IRGACURE™ 369) and 1-hydroxycyclohexyl phenyl ketone (commercially available from Ciba Specialty Chemicals as IRGACURE™ 84). Also useful are sensitized and non-sensitized diaryliodonium salts and triarylsulfonium salts; iron-arene complexes such as (n5-2,4-cyclopentadien-1-y10[1,2,3,4,5,6-n)-(1-methyl ethyl)benzene]-iron(+)-hexafluorophosphate(−1) (commercially available from Ciba Specialty Chemicals as IRGACURE™ 261); and thiol-ene systems based on the reaction of thiols with olefinic double bonds, such as n-pentylmercaptan. The photoinitiators can be used alone or with suitable accelerators (e.g., amines or peroxides) or with suitable sensitizers (e.g., ketone or alpha-diketone compounds such as camphorquinone). The amount of photoinitiator that should be employed will depend in part on the efficiency and other characteristics of the photoinitiator and energy source, and on the thickness of the lubricant coating. Preferably, the photoinitiator will be present in an amount of about 0.01% to about 10 wt. % of the coating, more preferably about 0.5% to 5 wt. % of the coating.
The lubricant composition can include additional components to provide desired properties. For example, the lubricant compositions can contain adjuvants such as antimicrobial agents, colorants, foam inhibitors or foam generators, plasticizers, adhesion promoters, cracking inhibitors (such as PET stress cracking inhibitors), viscosity modifiers, solvents, antioxidants, coating aids, antistatic agents, and surfactants. The amounts and types of such additional components will be apparent to those skilled in the art. For applications involving plastic containers, care should be taken to avoid the use of components or contaminants that might promote environmental stress cracking in plastic containers when evaluated using the PET Stress Crack Test set out below.
For applications involving plastic containers, the lubricant compositions preferably have a total alkalinity equivalent to less than about 100 ppm CaCO 3 , more preferably less than about 50 ppm CaCO 3 , and most preferably less than about 30 ppm CaCO 3 , as measured in accordance with Standard Methods for the Examination of Water and Wastewater, 18th Edition, Section 2320, Alkalinity.
A variety of kinds of conveyors and conveyor parts can be coated with the lubricant composition. Parts of the conveyor that support or guide or move the containers and thus are preferably coated with the lubricant composition include belts, chains, gates, chutes, sensors, and ramps having surfaces made of fabrics, metals, plastics, composites, or combinations of these materials.
The lubricant composition can also be applied to a wide variety of containers including beverage containers; food containers; household or commercial cleaning product containers; and containers for oils, antifreeze or other industrial fluids. The containers can be made of a wide variety of materials including glasses; plastics (e.g., polyolefins such as polyethylene and polypropylene; polystyrenes; polyesters such as PET and polyethylene naphthalate (PEN); polyamides, polycarbonates; and mixtures or copolymers thereof); metals (e.g., aluminum, tin or steel); papers (e.g., untreated, treated, waxed or other coated papers); ceramics; and laminates or composites of two or more of these materials (e.g., laminates of PET, PEN or mixtures thereof with another plastic material). The containers can have a variety of sizes and forms, including cartons (e.g., waxed cartons or TETRAPACK™ boxes), cans, bottles and the like. Although any desired portion of the container can be coated with the lubricant composition, the lubricant composition preferably is applied only to parts of the container that will come into contact with the conveyor or with other containers. Preferably, the lubricant composition is not applied to portions of thermoplastic containers that are prone to stress cracking. In a preferred embodiment of the invention, the lubricant composition is applied to the crystalline foot portion of a blow-molded, footed PET container (or to one or more portions of a conveyor that will contact such foot portion) without applying significant quantities of lubricant composition to the amorphous center base portion of the container. Also, the lubricant composition preferably is not applied to portions of a container that might later be gripped by a user holding the container, or, if so applied, is preferably removed from such portion prior to shipment and sale of the container. For some such applications the lubricant composition preferably is applied to the conveyor rather than to the container, in order to limit the extent to which the container might later become slippery in actual use.
The lubricant composition can be a liquid or semi-solid at the time of application. Preferably, the lubricant composition is a liquid having a viscosity that will permit it to be pumped and readily applied to a conveyor or containers, and that will facilitate rapid film formation and curing whether or not the conveyor is in motion. The lubricant composition can be formulated so that it exhibits shear thinning or other pseudo-plastic behavior, manifested by a higher viscosity (e.g., non-dripping behavior) when at rest, and a much lower viscosity when subjected to shear stresses such as those provided by pumping, spraying or brushing the lubricant composition. This behavior can be brought about by, for example, including appropriate types and amounts of thixotropic fillers (e.g., treated or untreated funned silicas) or other rheology modifiers in the lubricant composition. The lubricant coating can be applied in a constant or intermittent fashion. Preferably, the lubricant coating is applied in an intermittent fashion in order to minimize the amount of applied lubricant composition. For example, the lubricant composition can be applied for a period of time during which at least one complete revolution of the conveyor takes place and then cured in place. Application of the lubricant composition can then be halted for a period of time (e.g., minutes or hours) and then resumed for a further period of time (e.g., one or more further conveyor revolutions). The cured lubricant coating should be sufficiently thick to provide the desired degree of lubrication, and sufficiently thin to permit economical operation and to discourage drip formation. The lubricant coating thickness preferably is maintained at at least about 0.0001 mm, more preferably about 0.001 to about 2 mm, and most preferably about 0.005 to about 0.5 mm.
Application of the lubricant composition can be carried out using any suitable technique including spraying, wiping, brushing, drip coating, roll coating, and other methods for application of a thin film. If desired, the lubricant composition can be applied using spray equipment designed for the application of conventional aqueous conveyor lubricants, modified as need be to suit the substantially lower application rates and preferred non-dripping coating characteristics of the lubricant compositions used in the invention. For example, the spray nozzles of a conventional beverage container lube line can be replaced with smaller spray nozzles or with brushes, or the metering pump can be altered to reduce the metering rate.
If the lubricant composition is thermally curable, then it can be cured using a variety of energy sources that will generate sufficient heat to initiate and promote hardening of the lubricant coating, while staying within the thermal cure temperature limits noted above. Suitable sources include conventional heaters, infrared radiation sources, and microwave energy sources.
If the lubricant composition is radiation curable, then it can be cured using a variety of energy sources that will induce a photochemical reaction and thereby harden the film former, including ultraviolet radiation, visible light, infrared radiation, X-rays, gamma rays, and electron beams. Preferred energy sources include mercury vapor arc lamps, fluorescent lamps, tungsten halide lamps, visible lasers and infrared lamps.
For example, a UV-cured solid lubricant coating can be obtained on the bottom of a container by passing the container through a coating station to apply photosensitive solution to the bottom of the container and photoexposing the solution to cure the lubricant coating. Photoexposure can be carried out from underneath the container by transmitting the curing energy through the conveyor belt. In such a case, the conveyor belt should be sufficiently transparent to the desired wavelength of curing energy so that efficient cure will take place. Also, the coated container can be photoexposed from above or from one or more sides of the container. In such a case, the container should be sufficiently transparent to the desired wavelength of curing energy so that efficient cure will take place.
The lubricant compositions can, if desired, be evaluated using a Rotating Disc Frictional Test and a PET Stress Crack Test.
Rotating Disc Frictional Test
Lubricity can be evaluated by measuring the drag force (frictional force) of various weighted cylinders riding on a rotating polyacetal disc. The disc is uncoated or coated with a cured sample of the tested lubricating composition. The cylinders are made of glass, aluminum or PET, and have respective weights of 88.8 g, 125.9 g and 135.5 g. Drag force is determined using a solid state transducer connected to the cylinder via a thin, flexible string. Relative coefficient of friction (Rel COF) values are calculated using the equation Rel COF=COF(sample)/COF(uncoated)=drag force (sample)/drag force (uncoated). A Rel COF value less than 1 indicates that the tested material served as a lubricating composition, with lower values indicating better lubricity.
PET Stress Crack Test
Standard 2-liter PET beverage bottles (commercially available from Constar International) are charged with 1850 g of chilled water, 31.0 g of sodium bicarbonate and 31.0 g of citric acid. The charged bottle is capped, rinsed with deionized water and set on clean paper towels overnight. The bottoms of 12 bottles are dipped in a 200g sample of the undiluted lube in a 125×65 mm crystal dish, then cured using an appropriate energy source, placed in a bin and stored in an environmental chamber at 37.8° C., 90% relative humidity for 14 days. The bottles are removed from the chamber, observed for crazes, creases and crack patterns on the bottom. The aged bottles are compared with 12 control bottles that are exposed to a standard dilute aqueous lubricant (LUBODRIVE™ RX, commercially available from Ecolab) prepared as follows. A 1.7 wt. % solution of the LUBODRIVE lubricant (in water containing 43ppm alkalinity as CaCO 3 ) is foamed for several minutes using a mixer. The foam is transferred to a lined bin and the control bottles are dipped in the foam. The bottles are aged in the environmental chamber as outlined above.
The invention can be better understood by reviewing the following examples. The examples are for illustration purposes only, and do not limit the scope of the invention.
EXAMPLE 1
UV-Cured Lubricating Coating
Two parts CN981 B88 acrylate blend (urethane acrylate and 1,6 hexanediol diacrylate, commercially available from Sartomer, Inc.), 4 parts ULTRAGLIDE UV-701 wax dispersion (40% PTFE dispersed in tripropylene glycol diacrylate, commercially available from Shamrock Technologies, Inc.), 0.3 parts IRGACURE 907 photoinitiator (2-methyl-1-[4-(methylthio)phenyl]-2-morpholino propan-1-one, commercially available from Ciba Specialty Chemicals) and 14 parts isopropyl alcohol were well mixed. Excluding the isopropyl alcohol, the resulting lubricating composition contained 25.4 wt. % PTFE particles in a photocurable film former. The lubricating composition was evaluated using the Rotating Disc Frictional Test by wiping the composition onto the polyacetal disc, drying the composition and photocuring it for 60 sec under a nitrogen atmosphere using a Xenon-pulsed UV curing unit, Model RC-600 (commercially available from Xenon Corp.). In a comparison run, three commercially available conventional aqueous conveyor lubricants were diluted to 0.25 wt. % in soft water and applied to the uncoated rotating disc. The following relative COF values were obtained:
Aqueous Lube
Aqueous Lube
Aqueous Lube
Example
Substrate
1 1
2 2
3 3
1 Lube
Glass
0.66
0.92
0.88
0.77
Aluminum
0.50
0.53
0.62
0.83
PET
0.63
0.62
0.47
0.71
1 LUBODRIVE ™ RX, commercially available from Ecolab
2 DICOLUBE ™ PL, commercially available from DiverseyLever
3 WEST GLIDE ™ PET, commercially available from West Agro, Inc.
This example showed that the dry film lubricant composition of Example 1 served as a lubricant on all three substrates and had better performance on glass than two of the three comparison dilute aqueous lubricants.
EXAMPLE 2
UV-Cured Lubricating Coating
Using the method of Example 1, 42.86 parts VIATKIN VTE 6165 aromatic urethane acrylate resin (commercially available from Vianova Resins GmbH &Co. KG), 10 parts MICROSPERSION 190-150 50% aqueous dispersion of polyethylene wax and PTFE (commercially available from Micro Powders Inc.), 1.57 parts IRGACURE 500 photoinitiator (commercially available from Ciba Specialty Chemicals), 0.1 parts PI-35™ defoamer (commercially available from Ultra Additives, Inc.), 0.05 parts FC-120™ fluorinated wetting agent (commercially available from 3M) 5 and 53.32 parts deionized water were well mixed. Excluding the deionized water, the resulting lubricating composition contained a total of 10 wt. % polyethylene wax and PTFE particles in a waterborne photocurable film former. The lubricating composition was evaluated using the Rotating Disc Frictional Test as in Example 1. Relative COF values of 0.73, 0.64 and 0.59 were obtained on glass, aluminum and PET, respectively. 10 This example showed that the dry film lubricant composition of Example 2 served as a lubricant on all three substrates, and had better performance on glass and on PET than two of the three comparison dilute aqueous lubricants.
EXAMPLE 3
UV-Cured Lubricating Coating
Using the method of Example 1, 86 parts VIATKIN VTE 6161 polyester urethane acrylate (commercially available from Vianova Resins GmbH &Co. KG), 53.32 parts POLYFLUO™ 190 micronized fluorocarbon (commercially available from Micro Powders Inc.), 4 parts IRGACURE 500 photoinitiator (commercially available from Ciba Specialty Chemicals) and 80 parts acetone were well mixed. Excluding the acetone, the resulting lubricating composition contained 37 wt. % fluorocarbon particles in a solvent-borne photocurable film former. The lubricating composition was evaluated using the Rotating Disc Frictional Test as in Example 1. Relative COF values of 0.84, 0.76 and 0.74 were obtained on glass, aluminum and PET, respectively. This example showed that the dry film lubricant composition of Example 3 served as a lubricant on all three substrates, and had better performance on glass than two of the three comparison dilute aqueous lubricants.
EXAMPLE 4
UV-Cured Lubricating Coating
Using the method of Example 2, a lubricating composition was prepared by substituting 10 parts NANOFLON AQ-60 60% aqueous dispersion of PTFE particles (commercially available from Shamrock Technologies, Inc.) in place of the MICROSPERSION 190-150 PTFE dispersion used in Example 2. Excluding the deionized water, the resulting lubricating composition contained 11.9 wt. % PTFE particles in a waterborne photocurable film former. The lubricating composition was evaluated using the Rotating Disc Frictional Test as in Example 1. Relative COF values of 0.88, 0.86 and 0.79 were obtained on glass, aluminum and PET, respectively. This example showed that the dry film lubricant composition of Example 4 served as a lubricant on all three substrates, and had better performance on glass than one of the three comparison dilute aqueous lubricants and equal performance on glass to one of the other comparison dilute aqueous lubricants.
EXAMPLE 5
UV-Cured Lubricating Coating
Using the method of Example 4, a lubricating composition was prepared by substituting 53.32 parts ULTRAGLIDE UV-701 wax dispersion in place of the POLYFLUO™ 190 micronized fluorocarbon used in Example 2. Excluding the acetone, the resulting lubricating composition contained 14.8 wt. % PTFE particles in a solvent-borne photocurable film former. The lubricating composition was evaluated using the Rotating Disc Frictional Test as in Example 1. Relative COF values of 1.16, 1.00 and 0.91 were obtained on glass, aluminum and PET, respectively. This example showed that the dry film lubricant composition of Example 5 served as a lubricant on PET.
EXAMPLE 6
UV-Cured Lubricating Coating
Using the method of Example 1, 5 parts CN981 B88 acrylate blend, 20 parts EVERGLIDE UV-636 25% emulsion of carnauba wax in tripropylene glycol diacrylate (commercially available from Shamrock Technologies, Inc.), 1.25 parts IRGACURE 907 photoinitiator and 0.125 parts isopropyl thioxanthone (commercially available from Ciba Specialty Chemicals) can be well mixed. The resulting lubricating composition would contain 18.3 wt. % carnauba wax in a photocurable film former.
EXAMPLE 7
Thermally-Cured Lubricating Coating
Using the method of Example 1, 5 parts CN981 B88 acrylate blend, 20 parts EVERGLIDE UV-636 carnauba wax emulsion and 1.5 parts LUPERSOL™ 757 (t-amylperoxy-2ethyl-hexanoate, commercially available from ATOCHEM) can be well mixed. The resulting lubricating composition would contain 18.9 wt. % carnauba wax in a thermally-curable film former.
Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention, and are intended to be within the scope of the following claims. | The passage of a container along a conveyor is lubricated by applying to the container or conveyor a lubricating coating that is thermally cured at less than 200° C. or radiation-cured. The mixture can be applied in relatively low amounts and with relatively low or no water content, to provide thin, substantially non-dripping, renewable lubricating films. In contrast to dilute aqueous lubricants, the lubricants of the invention provide dry lubrication of the conveyors and containers, a cleaner conveyor line and reduced lubricant usage, thereby reducing waste, cleanup and disposal problems. | 2 |
This application is a continuation of application Ser. No. 321,116 filed Jan. 4, 1973 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention deals with the removal of metals such as lead, cadmium, mercury, arsenic, zinc, chromium, tin iron and cobalt from compositions containing such metals as organic and inorganic compounds. The need for the removal of such metals is evidenced by the fact that their presence in hydrocarbon charge stocks conducted to catalytic cracking and catalytic reforming units is known to poison and shorten the life of the catalyst with which such metal contaminated stocks come into contact.
It is also desirable to remove trace metals from lubricating oils or to recover soluble metal catalysts from reactor effluents of polymer solutions. The removal of heavy metals such as mercury, silver, cadmium and the like from the water effluents of chemical, electrolysis, metal deposition or photographic plants is also highly desired from an ecological standpoint.
It is known that residues of alkyl lead moieties from combustion of leaded gasoline tend to poison catalysts available for cleaning automotive exhaust gases by the catalytic oxidation of carbon monoxide and unburned hydrocarbons in the exhaust. Such poisoning severely shortens the useful life of exhaust combustion catalysts. It has thus been heretofore proposed that substantially metal-free, and primarily substantially lead-free gasoline be supplied for use in automobiles equipped with emission control devices which utilize catalysts to help further oxidize exhaust gases.
The normal network of petroleum product distribution involves railroad tank cars, pipelines, water borne tankers, tank trucks and bulk storage tanks. For commercial operation these are presently set up to handle different products. For example, the same pipeline might be used to convey a shipment of regular grade gasoline, premium grade gasoline, distillate fuel and other light liquid products in succession. According to present procedures, that portion of the fluids carried by the pipeline which constitutes an intermingling of the two products at their interface will be diverted to storage for the lower grade product, thus avoiding degradation of the higher grade product.
However, when leaded and/or when metal containing gasoline is followed by metal-free gasoline, not just the interface comprising an intermingling of the two products, but the entire lead-free shipment becomes degraded. When leaded gasoline, containing tetraethyl lead, tetramethyl lead or a mixture or transalkylation product of the two is contacted with the metal surfaces of transportation and storage facilities, a significant amount of lead is left deposited in scale and on the metallic surfaces. Upon later using the same facilities for lead-free gasoline the latter product becomes contaminated to an extent which may run as high as about 0.07 gram of lead per gallon. This amount of lead is sufficient to impair the life of exhaust emission control oxidation catalysts.
2. Description of the Prior Art
Techniques have heretofore been known for removal of dissolved or suspended heavy metal contaminants from liquid products.
In catalytic cracking and reforming operations, the use of guard chambers containing a variety of sorbents intended to remove heavy metal contaminant from the charge stock before contact is made with the catalyst have been described.
Systems for removal of lead from gasoline have also been proposed. Presently known techniques require considerable time or are non-selective in effecting removal from the gasoline of those additives which are desired to be retained, such as anti-oxidants, anti-icing additives, metal passivators and the like.
One previously proposing system for removing lead is described in U.S. Pat. No. 2,386,261. There, acid activated clay such as bentonite which has been treated with hydrochloric or sulfuric acid is used. Leaded gasoline is percolated through the clay to remove 95% of the lead present. Acid activated clays will also remove the additives which are required for proper protection and functioning of automotive equipment.
Another approach is that described in U.S. Pat. No. 2,392,846. According to an example in this patent, a five gallon lot of leaded gasoline is treated with 20 ml. of stannic chloride followed by addition of 100 grams of activated carbon. This results in decomposition of the tetraalkyl lead and adsorption of the lead decomposition product on the activated carbon thus drastically reducing the lead content. The gasoline is removed from the activated carbon by decantation. This is a very slow process which permits the processing of about 35 gallons of gasoline per hour. Here also even the additives desired to be retained in the gasoline will also be adsorbed by the activated carbon.
Both the processes described in the cited prior patents depend for effectiveness on a chemical conversion of the tetraalkyl lead. The lead compounds can be reacted with such materials as halogens, halogen acids, metal halides, metal salts, sulfur dioxide, carboxylic acids, metals in the presence of hydrogen, etc. The resulting decomposition products are not readily soluble in hydrocarbons and hence are selectively adsorbed on high surface adsorbents. This avoids the property of tetraalkyl lead moieties which presents the greatest difficulty in this separation, namely infinite solubility in hydrocarbons.
SUMMARY OF THE INVENTION
According to the present invention, sulfur particles ranging in size from a few atoms to a diameter of about 0.1 micron are deposited on solid substrates, such as silicas, aluminas, aluminsilicates, clays, metal oxides, metal sulfides, the surfaces of macroeticular resins and high surface area resins, and polymers containing polar groups such as OH, SO 3 = , N and COO - and the like. The term "macroreticulate resins" is used herein in the sense defined by Kun and Kunin, "Macroreticular Resins, III. Formation of Macroreticular Styrene-Divinylbenzene Copolymers", Journal of Polymer Science, Vol 6, pp. 2689-2701 (1968). Gasoline or other organic fluids are contacted with such active sulfur containing solid substrate under conditions sufficient to produce lead-sulfur reaction products which are then removed from the fluid by electrophoresis. One approach to removal by electrophoresis is based on the method recently discovered for the coalescence of emulsions as described by F. M. Fowles et al., Environ, Sci. Techn. 4,510 (1970). A second approach is based on methodology proposed for the removal of lead particles from engine exhausts discussed in API abstract 70-15118.
In the first referred to method, a bed consisting of two dissimilar particles, for example aluminum and iron, carbon and iron or the like is utilized to produce a high potential difference between particles, e.g., in the order of 100 volts at separations of 10 - 2 centimeters. In such an electrical field, colloidal particles, such as the sulfur reaction products produced when leaded fuel is contacted with a sulfur modified substrate, with the usual electrophoretic velocity approximating 10 - 4 cm. per sec. per volt per cm. would be plated out in one second. The second approach, dealing with the removal of lead particles from auto exhausts, utilizes aluminum oxide on metal wool and steel wool coated with aluminum.
A third and novel approach based on depositing iron on carbon or other solids, polymers and plastics by electroless deposition could also be utilized. In this way the separation between dissimilar materials would be much smaller and the electric field significantly larger and more effective. Metals and/or metal compounds such as metal oxides or metal sulfides, which are not suitable for electroless deposition, may be chemically exchanged with suitable metals which have been deposited on a solid polymer or plastic through electroless deposition. For purposes of this disclosure, the term dissimilar particles is defined herein so as to include at least two of aluminum, cobalt, iron and carbon.
A novel method of forming or preparing the dissimilar materials described in the aforementioned approaches involves depositing the materials on their substrates in separate and discrete particles rather than in a continuous coating or layer. This method of deposition allows for greater reactivity of the metal particles, as they are not bonded to each other.
In a preferred embodiment of this invention a cartridge of sulfur modified substrate followed by materials suitable for removal of sulfur reactions products by electrophoresis may be placed in a discharge line from a service station pump. The second bed containing such material suitable for removal of sulfur reaction products by electrophoresis may be more particularly defined in a preferred embodiment as follows: said second bed section containing particles of at least two dissimilar metals or metal compounds having an electrochemical potential difference between said particles of a minimum of about 0.1 v. at a distance of 1.0 cm., whereby plating out sulfur reaction products produced in said first bed. This permits utilization of presently installed service station and distribution equipment and avoids the changes in design which would be required if the treating agent were installed in the fill pipe to the local storage tank, in the tank itself, in the suction line to the pump or within the pump housing, all of which alternatives are contemplated within the scope of the invention. A further alternative is placement of the lead removal cartridge in the automotive fuel system between the fuel tank of the vehicle and the carburetor. Flow rates are very small compared to those in bulk and retail distribution equipment, permitting long residence times and small volume cartridges.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 of the drawings attached hereto represents a typical service station gasoline pump modified according to the present invention.
FIG. 2 is an enlarged view of the cartridge for containing the lead removal agents.
FIG. 3 is a view in fragmentary section of a cartridge for containing the lead removal agents.
DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 1, a gasoline dispensing pump of convention design includes a housing indicated generally at 10 within which are contained a motor driven pump and a metering device, not shown. The metering device drives, through suitable gearing, indicators within a panel 11 to report gasoline dispensed and price for the amount so dispensed. The fuel after passing through the metering device, is conducted to the outside of the housing through a pipe connection 12 and into a discharge hose 13 equipped with a valve nozzle 14.
The modification to convention dispensing pumps is a canister 15 connected to the fuel discharge 12 by a pipe 16 provided with a valve for which the operating handle is shown at 17. Fuel from the pipe 16 is conducted to the top of canister 15 from which it passes through a suitably prepared cartridge and is thence discharged to hose 13 and nozzle 14.
A typical cartridge is shown in FIG. 3 as constituted by a gauze container 18 within a wire mesh supporting case 19. Disposed within the container gauze 18 is a mass of lead removal agents of the type which characterize this invention.
For the usual service station, a cartridge having a diameter of four inches and a length of twelve inches will be adequate to reduce the lead content to acceptable levels for a working life of about one month. When it is desired to change the cartridge, valve 17 is closed, the hose 13 is drained and the canister 15 is removed by unthreading from the top portion thereof. It is thus a simple matter to replace the cartridge in a very short period of time and return the dispensing pump to duty.
A suitable sulfur modified substrate may be prepared according to the following specific examples:
EXAMPLE 1
1 g. of sodium X-type aluminosilicate (13X) is ball milled with 3 g. of powdered sulfur and then heated to fusion temperature. The excess sulfur is removed by further heating until the solids become free flowing.
EXAMPLE 2
1 g. of macroreticular resin such as Amberlite IRA 938 or Amberlite XAD is suspended in 10 ml. of benzene into which SO 2 gas followed by H 2 S gas is bubbled in, each for a period of 5 minutes or less. The resin is then removed from the benzene by filtration.
EXAMPLE 3
10 cc of a macroreticular resin as prepared according to the procedure of Example 2 is contacted with 50 cc of a gasoline leaded to a level of 0.33 to 0.38 grams of lead/gallon of gasoline. The reacted gasoline is then contacted with 10 cc of material comprising cobalt deposited on carbon through electroless deposition. The method of deposition is as described by Frieze, Said and Well in their article "Some Properties of Electroless Cobalt" published in the Journal of Electrochemical Society: Electrochemical Science at p. 586-91 (June 1968). The lead content of the gasoline following contacting with the mixture of cobalt and carbon would be about 0.03 grams of lead/gallon of gasoline.
The novelty of applicant's invention resides in the combination of a bed of sulfur modified substrate which reacts with metal contaminants in a liquid stream forming sulfur reaction products, and a bed of dissimilar metals or metal derivatives which remove the sulfur reaction products through electrophoresis, as sulfur particles deposited on a solid substrate and electrophoresis are not individually novel per se. | Sulfur is deposited on a solid substrate. Metal compounds containing sulfur reaction products produced when hydrocarbon streams contaminated with the metals are contacted with the sulfur modified substrate are removed by electrophoresis. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is in the field of hangers for clothing and other items needing hanging and methods therefor, and more particularly, is a system and method for a hanger system that provides an indication that a hanger is unused.
2. Description of the Related Art
Hangers for clothing, towels, and other articles have existed for a very long time. Today, these hangers come in various shapes and sizes, including triangular hangers mass-produced using metal and plastic materials, and wooden hangers shaped for shirts, suit coats, pants etc. All of these hangers suffer from a severe drawback however. When looking at a rack full of hangers, used and unused, it is very difficult to identify unused hangers buried amidst the used hangers, particularly where a hanger is used to hold something other than a shirt or coat e.g. a pair of pants, shirt, scarf or tie This problem is even more acute when the user is looking down a row of hangers at a parallel angle trying to find an empty hanger hidden among the used hangers.
Therefor a need existed for a system and method of providing a hanger comprising an indicator device that would quickly and easily provide a visual indication that the hanger to which the indicator system is coupled is unused.
Additionally, a need existed for a system of adapting an unused hanger indicator device to be quickly and easily coupled to pre-existing hangers and a method therefor.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a system and method of providing a hanger comprising an indicator device that will quickly and easily provide a visual indication that the hanger to which the indicator system is coupled is unused.
Another object of the present invention is to provide a system and method for adapting an unused hanger indicator device to be quickly and easily coupled to preexisting hangers.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with one embodiment of the present invention an unused hanger indicator system is disclosed. The unused hanger indicator system comprises; a structural support point, a hanger suspended from the structural support point and adapted to receive an article, and means for visually indicating that the hanger is not in use.
In accordance with another embodiment of the present invention, an unused hanger indicator system is disclosed. The unused hanger indicator system comprises; a weight, coupling tabs coupled to and extending from the weight wherein the coupling tabs are adapted to couple the weight to a hanger at a point distant from a center of gravity of the hanger, wherein the hanger is adapted to receive an article.
In accordance with yet another embodiment of the present invention, an unused hanger indicator method is disclosed. The unused hanger indicator method comprises the steps of; providing a weight, providing coupling tabs coupled to and extending from the weight, and coupling the weight to a hanger at a point distant from a center of gravity of the hanger.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view, of the unused hanger indicator system shown unattached from the support rod of the present invention.
FIG. 2 is a perspective view, of the unused hanger indicator system showing an exemplary usage of the present invention.
FIG. 3 is a front view, of the unused hanger indicator system of the present invention.
FIG. 4 is a cut-away view, of the unused hanger indicator system of the present invention along the line 4--4 of FIG. 3.
FIG. 5 is a front view, of an first alternate embodiment of the unused hanger indicator system of the present invention.
FIG. 6 is a front view, of a second alternate embodiment of the unused hanger indicator system of the present invention.
FIG. 7 is a perspective view, of a weight used for a second alternate embodiment the unused hanger indicator system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a perspective view, of the unused hanger indicator system "the system 10" hereinafter) of the present invention is shown. The system 10, in a referred embodiment, comprises a hanger 20. The hanger 20 is further comprised of two ends, the inboard end 20i, and the outboard end 20o. The terms "inboard" and "outboard" are meant to provide identification relative to a typical method of placing a hanger on a support rod i.e. inserting a hanger with the hook 12 facing away, or outboard, from the user so as to engage a support rod as the hanger is moved in the outboard direction from the user toward the support rod. Using this convention the end of a hanger 20 on the same side as the hook 12 opening is the outboard end 20o, and the opposite end of the hanger is the inboard end 20i. Fitted within the crook of the outboard end 20o is a weight 30. The weight 30 may be coupled to a hanger in many ways well known to those skilled in the art. Some examples of coupling include, without being limited to, using adhesives, mechanical fastening, or molding to or as part of the hanger 20. (Of course the weight 30 may optionally, though not preferably, be coupled to the inboard end 20i.)
Referring to FIG. 2, a perspective view of the unused hanger indicator system showing an exemplary usage of the present invention is shown. In a preferred embodiment of the system 10, hangers 20a-d are placed upon a support rod 22. Though a typical support rod is shown herein, this is merely exemplary. Those skilled in the art will recognize that any structural support over which the hook 12 of a hanger 20 may be placed may be suitable for use with the invention of the present system. Additionally, as those skilled in the art are aware, the use of hangers in some locations such as hotel rooms comprises the use of hangers that are coupled with other than a hook 12. Some examples of these alternative hanger coupling methods comprise; hangers that are permanently, rotatably coupled to a support rod (not shown); and hangers that are hung upon a support rod coupling device using a ball appended to the hanger and supported within a socket suspended from the support rod (not shown). The purpose of many of these alternative hanger coupling arrangements is the prevention or discouragement of routine hanger theft. Those skilled in the art will recognize that the actual means of coupling a hanger to a support rod is not limiting in any embodiment of the present invention, an unused hanger indicator system and method therefor.
Continuing with FIG. 2, a support rod 22 is used to provide a support point for hangers 20a-d. Typical uses for hangers 20 include shirt or blouse type garments 80 and 82 as are hung on hangers 20a and b. As is known by the average person, hangers 20 may be used for just about any clothing item including shirts, t-shirts, pants, skirts, coats, scarves, robes, etc. A further use of a hanger is for draping towels or other textile type products such as the cloth 84 draped upon hanger 20c. Each of the hangers 20a-d are a preferred embodiment of the present invention and comprise a weight 30 coupled to the outboard end 20o of each hanger 20a-d.
The weight 30 is an important element in the operation of the present invention. The coupling of the weight 30 to a hanger 20, at a point distant from a center of gravity of the hanger 20 causes the hanger 20 to tilt when not balanced by an article 80, 82, or 84 draped upon the hanger 20a, b, or c (While the weight 30 is preferably proximate an outboard end 20o, it could optionally be placed at some other point along the hanger 20 that is distant from the center of gravity of the hanger 20. The weight 30 is designed to have sufficient mass so that the hanger 20 will tilt when unused, but to be light enough so that a typical garment 80, 82, or 84 draped on the hanger 20 a, b, or c respectively will substantially balance out the mass distribution of the hanger 20 a, b, or c and its hung item, thus causing the hanger 20 a, b, or c to hang in a normal fashion parallel to a floor. A weight 30 is coupled to each of the hangers 20a-d, though as shown in FIG. 2, the hangers 20, a, b, and c are draped with articles 80, 82 and 84 are hanging normally, i.e. substantially parallel to the floor, while the hanger 20d that is empty has the inboard end 20i tilted upward. This upward fit of the inboard end 20i enables the quick and easy identification of the unused hanger 20d.
Referring to FIG. 3, a front view of the unused hanger indicator system of the present invention is shown. As previously described, a weight 30 is coupled to the outboard end 20o of the hanger 20.
Referring to FIG. 4, a cut-away view of the unused hanger indicator system 10 of the present invention along the line 4--4 of FIG. 3 is shown. In a preferred embodiment of the present invention, a weight 30 is coupled by molding or using adhesives so that, as shown in FIG. 4, the weight 30 is form fitted into the crook of an end of the hanger 20.
Referring to FIG. 5, a front view of a first alternate embodiment of the unused hanger indicator system 10 of the present invention is shown. In a first alternate embodiment of the present invention, the weight 40 comprises a set of weights embedded within the material of a hanger 50. The weight 40 set is embedded at the outboard end 50o of the hanger 50 in order to achieve the purpose of placing the weight 40 at a point distant from a center of gravity of the hanger 50. Those skilled in the art will recognize that the weight 40 could also comprise a single element of sufficient mass molded or coupled, within or on, any point suitably distant from a center of gravity of a hanger 50.
Referring to FIG. 7 a perspective view of a weight 70 used for a second alternate embodiment of the unused hanger indicator system 10 of the present invention is shown. In this second alternate embodiment, a weight 70 is designed for after-market attachment to pre-existing hangers. The weight 70 comprises coupling tabs 72a and b for coupling the weight 70 to a hanger. The weight 70 in this embodiment also features a grooved channel 74 circumscribing the perimeter of the weight 70. The grooved channel 74 enhances the coupling of the weight 70 to a hanger by proving a channel that positions the weight 70 securely in the crook of a hanger end.
Referring to FIG. 6 a front view of the second alternate embodiment of the unused hanger indicator system 10 of the present invention is shown in use. The weight 70 has been placed in the crook of the outboard end 60o of a hanger 60. The coupling tabs 72a and b have been wrapped around the hanger 60 body to secure the weight 70 to the hanger 60. Those skilled in the art will recognize that the shape of the weight 70 may be changed herein. For example, the weight 70 could be an elongated rectangular box-shaped device (not shown herein) coupled to the bottom of a hanger outboard end 60o, or a u-shaped channel of some suitably massed material (not shown herein) wrapped around, or within, the periphery of the outboard end 60o of a hanger 60. These three embodiments, round weight 70, box-shaped device (not shown herein), and u-shaped channel (not shown herein) are by no means the only suitable method of constructing an after-market attachment for pre-existing hangers, but are intended to represent and suggest the wide range of possible adaptations within the scope of the present invention's concept.
Additionally, though not shown herein, the present invention is by no means limited to standard triangle shaped hangers such as hanger 20 of FIG. 3. The present invention may be suitably used upon hangers not having a bottom pants rung, hangers that are straight across in design for hanging pants by gripping of the cuffs or waist, hangers that are shaped for sports or suit coats, etc. The idea of the present invention, is to provide for a hanger system and method that provides a visual indication that a hanger is unused. Also of consideration in regard to the present invention, are alternate high-tech systems and methods meeting the scope and spirit of the present invention, an unused hanger indicator system and method. A high-tech system could comprise, for example, an electrical system coupled to a hanger, sensitive to weight or the presence of a hung article, that in the absence of the article would provide a visual indication via a light emitting source. For example, a lit LED at the tip of an unused hanger would provide visual indication of an unused hanger, and moreover be visible even in a darkened environment. Variations on this theme would include a hanger comprising light and weight sensitive circuits so that an LED would begin flashing on the unused hanger when an overhead light was turned on. This variation would preserve the battery life of the system.
Although the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that changes in form and detail may be made therein without departing from the spirit and scope of the invention. | An unused hanger indicator system. The unused hanger indicator system, comprises; a structural support point, a hanger suspended from the structural support point and adapted to receive an article, and a weight coupled to the hanger wherein the weight is coupled to the hanger at a point distant from a center of gravity of the hanger. The affect of the weight coupled to the hanger at a point distant from the center of gravity is to cause an end of a hanger so equipped with the weight to tilt the end of the hanger opposite from the weighted end up when the hanger is not constrained to remain level due to the mass of an article hung upon the hanger. | 0 |
This is a continuation of co-pending application Ser. No. 07/576,875, filed on Sep. 4, 1990, now abandoned.
FIELD OF THE INVENTION
The present invention relates to catalysts consisting of mixtures of trivalent antimony and tetravalent titanium halides and their use for liquid phase fluorination with anhydrous hydrofluoric acid of halogenated, especially chlorinated, aliphatic derivatives.
BACKGROUND OF THE INVENTION
Liquid phase fluorination of aliphatic chlorinated derivatives, that is to say the chlorine-fluorine exchange with anhydrous hydrofluoric acid in liquid phase is a known reaction. The most important chlorofluorocarbons, that is to say CFCl 3 , CF 2 Cl 2 , CHF 2 Cl, and C 2 Cl 3 F 3 , can thus be obtained according to a process of this kind by chlorine-fluorine exchange, starting with CCl 4 , CHCl 3 , and C 2 Cl 6 respectively (J. M. Hamilton, "The Organic Fluorochemicals Industry" in the work Advances in Fluorine Chemistry, vol. 3, 1963, pp. 146-150).
The aliphatic fluoro or chlorofluoro derivatives containing at least two carbon atoms and containing at least one hydrogen atom can be obtained according to the same fluorination process from the corresponding chloro derivatives, but they can also generally be obtained from chloroolefins by reaction with hydrofluoric acid according to a reaction whose first stage is an addition of HF to the double bond. Thus, for example, CF 3 CH 3 can be obtained either by fluorination of CCl 3 CH 3 or by fluorination of CCl 2 ═CH 2 (E. T. McBee, et al., I.E.C., 1947, pp. 409-412). Similarly, CF 3 CH 2 Cl can be obtained by fluorination of CCl 3 CH 2 Cl or of CCl 2 ═CHCl (A. K. Barbour, et al., "The Preparation of Organic Fluorine Compounds by Halogen Exchange" in the work Advances in Fluorine Chemistry, vol. 3, 1963, pp. 197-198).
In some cases, with highly reactive chloro derivatives, it is possible to effect these fluorinations merely by heating the chloro derivative with hydrofluoric acid in the absence of catalyst. Thus, it is known that methylchloroform CCl 3 CH 3 can be converted into CF 3 CH 3 by reaction with anhydrous hydrofluoric acid in liquid phase (E. T. McBee, et al., op.cit.). This reactivity of methylchloroform is, however, quite exceptional and, generally speaking, the reaction of HF in the absence of catalyst does not allow the chlorine-fluorine exchange to be effected or permits only a single chlorine atom to be replaced, and even this at very high temperatures. In practice, liquid phase fluorinations are carried out in the presence of a fluorination catalyst. Various catalysts have been proposed, but the most effective ones have been found among pentavalent antimony halides or mixtures of pentavalent and trivalent antimony halides (Houben-Weyl, Vol. V/3, 1962, p. 126). On an industrial scale, antimony pentachloride SbCl 5 or a mixture of antimony trichloride SbCl 3 and chlorine are generally employed, and these, on reacting with hydrofluoric acid, yield mixed chlorofluorides such as SbF 3 Cl.sub. 2 or SbF 2 Cl 3 , which have been found to be particularly effective fluorination catalysts. However, pentavalent antimony chlorofluorides decompose at the temperatures needed for the fluorination and yield trivalent antimony halides and chlorine. Because trivalent antimony halides are practically ineffective in fluorination, catalysts based on antimony 5+ quickly lose their effectiveness and their activity can be maintained only if the antimony is successfully maintained in its 5+ oxidation state. This can be done by reoxidation using chlorine, that is to say by performing the fluorination in the presence of a little chlorine, which enables Sb 3 + to be continually reoxidized to Sb 5+ (Houben-Weyl op.cit.). Nevertheless, catalysts containing antimony exhibit a number of disadvantages:
Mixtures of pentavalent antimony halides and of hydrofluoric acid are highly corrosive, especially at high temperature.
Fluorination in the presence of antimony 5+ is in certain cases accompanied by inconvenient side reactions. Thus, in the case of chloro derivatives containing a hydrogen atom, an olefin can be formed by the loss of HCl, and these olefins can give rise to the formation of heavy products (Houben-Weyl, op.cit., pp. 134-135).
The need for the fluorination to be carried out in the presence of chlorine can also give rise to the formation of a number of secondary reactions. This is the case in particular with the fluorination of chlorinated hydrocarbons still containing one or more hydrogen atoms, which can be replaced by chlorine atoms during this fluorination. In the case where the starting material to be fluorinated is an ethylenic derivative there may be competition between an addition of HF or a chlorine addition to the double bond. In the case of trichloroethylene, it is thus possible to obtain CF 3 CH 2 Cl by HF addition (Houben-Weyl, p. 107) or CF 2 Cl-CFCl 2 by chlorination (Houben-Weyl, p. 134). ##STR1##
Other catalysts for liquid phase fluorination have been proposed. For example, the compounds SnCl 4 , MoCl 5 , WF 6 , NbCl 5 , TaF 5 , TiCl 4 , BF 3 , and CF 3 SO 3 H may be mentioned, but these catalysts are generally much less efficient than antimony 5+. Thus, titanium halides have been proposed for the preparation of chlorofluoro-methane or -ethane compounds by fluorination of the corresponding chlorinated derivatives (U.S. Pat. No. 2,439,299). Titanium tetrachloride can also be employed for the fluorination of chloroolefins such as tri- or tetrachloroethylenes (U.S. Pat. No. 4,374,289 and A. E. Feiring, J. Fluor. Chem. 1979, 13, pp. 7-18), for example:
C.sub.2 Cl.sub.4 →CFCl.sub.2 --CHCl.sub.2 +CF.sub.2 Cl--CHCl.sub.2 CCl.sub.2 ═CHCl.sub.→CFCl.sub.2 --CHCl.sub.2
However, this titanium halide is not a very powerful catalyst, because it generally makes it possible to obtain only monofluorinated or difluorinated products.
DETAILED DESCRIPTION OF THE INVENTION
Applicants have found that, while Ti 4+ and Sb 3+ halides are relatively inefficient catalysts for liquid phase fluorination, a mixture of the two Ti 4+ and Sb 3+ halides is, on the contrary, much more efficient. For example, it permits CF 3 CH 2 Cl to be prepared from CCl 3 CH 2 Cl or from CCl 2 ═CHCl without giving rise to the same disadvantages as the Sb 5+ halides (the need to employ chlorine to reoxidize antimony 3+ to antimony 5+). Other, nonlimiting examples of use of this Ti 4+ /Sb 3+ catalyst are the fluorination of methane chloro derivatives such as CCl 4 , CHCl 3 or CH 2 Cl 2 or of ethane or ethylene chloro derivatives such as C 2 Cl 6 , CCl 3 CHCl 2 , CCl 3 CH 3 , CCl 2 ═CCl 2 , CCl 2 ═CH 2 , CHCl 2 CH 2 Cl and CHCl═CHCl.
Although the catalyst according to the invention is more particularly intended for fluorinating chloro derivatives, it can also be employed for the fluorination of bromo or iodo derivatives such as, for example, CBr 4 , CHBr 3 , CHBr 2 Cl, CF 2 Br 2 , CBr 3 CH 2 Br or CHBr 2 --CHBr 2 .
The active form of the catalyst according to the invention is a mixture of TiF 4 and of SbF 3 . It is thus possible to employ such a mixture of fluorides, but it is also possible to employ a mixture of other halides, especially a mixture of the chlorides TiCl 4 and SbCl 3 , which is converted with hydrofluoric acid into TiF 4 and SbF 3 before or during the fluorination of the halogenated hydrocarbon to be fluorinated.
The proportions of Ti 4+ and of Sb 3+ may vary within wide limits, but it is preferred to employ mixtures containing 30 to 90 mol % of Ti 4+ and 70 to 10 mol % of Sb 3+ and, more particularly, mixtures in which the molar proportion of Ti 4+ is comprised between 50 and 90%.
The temperature of fluorination can also vary within wide limits and temperatures between 40° C. and 180° C. are generally employed. The pressure required for the reaction is at least that needed to keep the reaction mixture in liquid phase. It therefore depends essentially on the reaction temperature and can vary within limits which are as wide as 10 to 100 bars.
The reaction may be carried out noncontinuously, in an autoclave. In this case, the catalyst (TiF 4 --SbF 3 mixture or TiCl 4 --SbCl 3 mixture), hydrofluoric acid and the halogenated derivative to be fluorinated are introduced into the autoclave and the mixture is heated to the reaction temperature, preferably with stirring. The reaction pressure is the autogenous pressure in this case.
The reaction can also be carried out continuously. Because the substitution of a chlorine atom by a fluorine atom is accompanied by a lowering of the boiling point, it is possible, for example, to introduce continuously into a reactor containing the catalyst, hydrofluoric acid and the derivative to be fluorinated and to extract continuously a gaseous phase containing the hydrochloric acid formed, the fluoro derivative and optionally hydrofluoric acid. In this case, the reaction can take place at a constant pressure, which must be at least equal to that needed to keep the reaction mixture in liquid phase at the temperature of reaction.
The quantity of catalyst can vary within wide limits. The molar ratio of the catalyst (antimony plus titanium) to the reactant to be fluorinated can thus vary from 0.1 to 0.6, but lesser or greater quantities can also be employed. However, in the case of substrates which are difficult to fluorinate, it is generally preferred to employ quantities corresponding to a molar ratio of 0.2 to 0.4.
The proportion of hydrofluoric acid to be employed depends to a large extent on the nature of the halogenated derivative to be fluorinated and can vary within wide limits. Nevertheless, an excess of HF is generally employed, that is to say an HF/compound to be fluorinated molar ratio of more than 1, it being possible for this ratio to reach very high values, that is to say 5 to 20 or even higher.
EXAMPLES
The following examples illustrate the invention without limiting it. They were carried out in the equipment and according to the procedures which are described below:
EQUIPMENT
An 800-ml autoclave, stirred with a bar magnet and heated by means of oil circulating in a jacket is employed. It is equipped with a temperature tap, pressure measurement and two branches permitting products to be withdrawn either from the gas phase or from the liquid phase.
PROCEDURE
In all cases the reactants, that is to say hydrofluoric acid and the compound to be fluorinated, are introduced into the autoclave containing the catalyst and maintained at the temperature of liquid nitrogen.
The reactor is then heated to the reaction temperature and is maintained at this temperature for a certain time.
At the end of reaction the autoclave is cooled to ambient temperature. It is then decompressed and then purged with a stream of helium through a water scrubber to remove the hydracids and through a drier containing CaCl 2 . The unabsorbed products are trapped at liquid nitrogen temperature. The content of the trap and optionally that of the autoclave are then analyzed.
EXAMPLE 1
11.6 g of SbCl 3 (0.051 moles) and 9.7 g of TiCl 4 (0.051 moles) are introduced into the autoclave described above. After cooling with liquid nitrogen, 87.3 g of CCl 3 CH 2 Cl (0.52 moles) and 101.3 g of HF (5.06 moles) are introduced.
The autoclave is then heated to 150° C. with stirring over two hours and is maintained at this temperature for 3 and a half hours. At the end of reaction the pressure reaches 82 bars. After cooling, the products formed are recovered using the method described above. 60.5 g of product containing 97% of CF 3 CH 2 Cl and 2% of CF 2 ClCH 2 Cl are thus obtained, which corresponds to a 95% conversion of CCl 3 CH 2 Cl into CF 3 CH 2 Cl and 2% into CF 2 ClCH 2 Cl.
A slightly hygroscopic solid weighing approximately 15.5 g and containing essentially antimony, titanium and fluorine is collected from the autoclave.
EXAMPLE 2
5.7 g (0.025 moles) of SbCl 3 and 5 g of TiCl 4 (0.026 moles) are introduced into the autoclave.
After cooling, 20 g of HF are introduced and the autoclave is then heated to 50° C. and is maintained at this temperature for one hour. After cooling to ambient temperature, the autoclave is degassed and the excess HF and the HCl formed are removed completely by entrainment with a stream of helium. Approximately 7.5 g of product remain in the autoclave, corresponding in weight to a mixture of TiF 4 and SbF 3 .
40.3 g of CCl 3 CH 2 Cl (0.24 moles) and 38.8 g of HF (1.94 moles) are then introduced at the temperature of liquid nitrogen.
The autoclave is heated to 150° C. over 2 hours and is maintained at 150° C. for 3 and a half hours. At the end of reaction the pressure has risen to 52 bars. The usual procedure is then followed to recover 27.8 g of products, analyzed as 98.5% of CF 3 CH 2 Cl and 1% of CF 2 ClCH 2 Cl.
EXAMPLES 3, 4, and 5
Without removing the catalyst after the degassing of test 2, the reactants are recharged three times in succession and 4 successive operations are thus carried out on the same catalyst charge (same temperature and same duration as in the case of Example 2).
______________________________________ Test No. 3 4 5______________________________________CCl.sub.3 CH.sub.2 Cl (g) 43.2 42.7 43.8HF (g) 41.3 41.3 41.9Weight of products obtained (g) 28.9 29 29.5CF.sub.3 CH.sub.2 Cl content 99.6% 99.5% 99.1%______________________________________
The autoclave was weighed between each test and there was no increase in weight. After the last test the autoclave was opened and, as in Example 1, contained only a hygroscopic product consisting solely of antimony, titanium, and fluorine.
EXAMPLE 6
The following are charged onto a catalyst prepared, as in Example 2, from 5.7 g of SbCl 3 , 5 g of TiCl 4 and HF:
44.3 g of CCl 3 CH 2 Cl
41.6 g of HF.
The reactor is heated to 110° C. over one and a half hours and is maintained at this temperature for 4 hours. The pressure has risen to 40.5 bars in this case. The analysis of the product recovered (31 g) makes it possible to calculate a degree of conversion of CCl 3 CH 2 Cl of 71.8% into CF 3 CH 2 Cl and of 24.5% into CF 2 ClCH 2 Cl.
By way of comparison, tests were carried out without catalyst and with titanium and trivalent antimony halides by themselves.
COMPARATIVE TEST 7
24 g of CCl 3 CH 2 Cl and 36 g of HF were charged into the autoclave. After 5 hours' , reaction at 150° C. the products recovered enabled the following balance to be established:
______________________________________CCl.sub.3 CH.sub.2 Cl conversion: 46%Conversion of CCl.sub.3 CH.sub.2 Clinto CCl.sub.2 ═CHCl 17.6%into CFCl.sub.2 --CH.sub.2 Cl 25.8%into CF.sub.2 Cl--CH.sub.2 Cl 0.5%______________________________________
COMPARATIVE EXAMPLE 8
Titanium fluoride was prepared in the autoclave by reacting, as described in Example 2, 10.3 g of TiCl 4 (0.055 moles) and 20 g of HF (1 mole). 42 g of CCl 3 CH 2 Cl (0.25 moles) and 52 g of HF (2.6 moles) were then introduced cold. The reaction mixture was then heated to 150° C. over 2 hours and maintained at this temperature for 3 and a half hours. After degassing, 26.5 g of product were recovered, containing 54.8% of CF 3 CH 2 Cl and 38.4% of CF 2 ClCH 2 Cl.
In this case, the autoclave revealed a weight increase of 1.7 g, corresponding to 4% of the CCl 3 CH 2 Cl employed and consisting essentially of polymerized products.
COMPARATIVE EXAMPLE 9
12 g of SbCl 3 (0.052 moles) and 20 g of HF (1 mole) were reacted as before. 43.7 g of CCl 3 CH 2 Cl (0.26 moles) and 89 g of HF (4.45 moles) were then charged. After reaction in the same conditions as in Example 2, 32 g of product were recovered, its analysis making it possible to calculate the conversions of CCl 3 CH 2 Cl:
3.3% into CF 3 CH 2 Cl
79.4% into CF 2 ClCH 2 Cl
4.2% into CFCl 2 CH 2 Cl
3.2% into CCl 2 ═CHCl
EXAMPLE 10
A catalyst was prepared, as described in Example 2, from 11.4 g of SbCl 3 (0.05 moles), 9.4 g of TiCl 4 (0.05 moles) and 40 g of HF. After removal of the HF and HCl acids, 33.6 g of trichloroethylene (0.255 moles) and 80.7 g of HF (4.03 moles) were charged. The reaction mixture was heated to 150° C. over two hours and maintained at this temperature for 3 and a half hours. The pressure rose to 55 bars. After degassing, 29.5 g of product were recovered, containing 97.9% of CF 3 CH 2 Cl and 2% of CF 2 ClCH 2 Cl, which corresponds to a 95.4% conversion of trichloroethylene into CF 3 CH 2 Cl.
EXAMPLE 11
The operation was carried out in the same conditions as in Example 10, but employing 4.8 g of TiCl 4 and 5.7 g of SbCl 3 and charging 34.9 g of trichloroethylene and 40.6 g of HF. After reaction at 150° C., the pressure stabilized at 41 bars and 31.5 g of product were collected, containing 10% of CF 3 CH 2 Cl and 89% of CF 2 ClCH 2 Cl.
After degassing the autoclave, the increase in weight of the latter corresponded to 6.9 g, that is to say a weight very close to that of the catalyst.
EXAMPLE 12
34.9 g of trichloroethylene (0.265 moles), 41.4 g of HF (2.07 moles) and 12.6 g of HCl (0.34 moles) were charged into the autoclave containing the catalyst of Example 11. The reaction was then carried out at 150° C. as in the case of Example 11 and a pressure of 60 bars was reached. After degassing, 30.1 g of product were collected, containing 99.8% of CF 3 CH 2 Cl, that is a 95.5% conversion of trichloroethylene into CF 3 CH 2 Cl.
EXAMPLE 13
35 g of trichloroethylene and 82 g of HF were charged into the autoclave containing the catalyst employed for Example 10 and which had been obtained from 11.4 g of SbCl 3 and 9.4 g of TiCl 4 . The autoclave was then heated to 110° C. over an hour and a half and maintained at this temperature for 4 hours. The pressure stabilized at 29 bars. After cooling and degassing, 32.3 g of product were recovered, containing 41.3% of CF 3 CH 2 Cl and 51.9% of CF 2 ClCH 2 Cl.
EXAMPLE 14
34.9 g of trichloroethylene and 81.6 g of HF were charged into the autoclave containing the catalyst of Example 13. The reactor was heated to 130° C. over 2 hours and maintained at this temperature for 3 and a half hours. After cooling and degassing, 30.5 g of product were recovered, containing 76.7% of CF 3 CH 2 Cl and 16.4% of CF 2 ClCH 2 Cl.
COMPARATIVE EXAMPLE 15
By forming SbF 3 in the autoclave by reacting 11.4 g of SbCl 3 and 20 g of HF and by then charging 35 g of trichloroethylene and 82.3 g of HF, the following results were obtained after reaction at 150° C. and 5 and a half hours:
______________________________________Unconverted CCl.sub.2 ═CHCl 17%Conversion into CF.sub.2 ClCH.sub.2 Cl 37.5%Conversion into CFCl.sub.2 CH.sub.2 Cl 44.5%Conversion into CF.sub.3 CH.sub.2 Cl 0.3%______________________________________
By carrying out the reaction in the presence of only TiF 4 (obtained from 9.5 g of TiCl 4 and 20 g of HF) and with 34.4 g of trichloroethylene and 40.7 g of HF, a very large quantity of polymers remaining in the reactor, corresponding to more than 40% of the trichloroethylene employed, was obtained after reaction at 150° C. The products recovered during the degassing corresponded, furthermore, to 14.6 g containing 69% of CF 3 CH 2 Cl and 26% of CF 2 ClCH 2 Cl.
EXAMPLE 16
11.6 g of SbCl 3 (0.05 moles) and 8.8 g of TiCl 4 (0.046 moles) were charged into the autoclave. After cooling in liquid nitrogen, 101.1 g of CCl 3 CHCl 2 (0.5 moles) and 81.2 g of HF (4.06 moles) were introduced. The mixture was then heated to 150° C. over 2 hours and maintained at this temperature for 3 and a half hours. After cooling and degassing, 81 g of product were recovered, containing:
______________________________________ CF.sub.2 ═CCl.sub.2 6.3% C.sub.2 Cl.sub.4 4% CF.sub.3 CHCl.sub.2 1% CFCl.sub.2 CHCl.sub.2 3% CF.sub.2 ClCHCl.sub.2 82%______________________________________
EXAMPLE 17
The operation was carried out in the same conditions as in Example 10, but employing 4.75 g of TiCl 4 (0.025 mole) and 5.7 g of SbCl 3 (0.025 mole) and, after fluorination of the catalyst, charging 32.9 g of trichloroethylene (0.25 mole) and 80 g of HF (4 moles). The reaction mixture was heated to 150° C. over two hours and maintained at this temperature for 3 and a half hours. The pressure rose to 52 bars. After degassing, 29 g of product were recovered, containing 83% of CF 3 CH 2 Cl, 14% of CF 2 ClCH 2 Cl and 2% of CFCl 2 CH 2 Cl.
EXAMPLE 18
By operating as in Example 17 with 3.57 g of TiCl 4 (0.0188 mole) and 7.12 g of SbCl 3 (0.031 mole), a product was recovered which contains 55% of CF 3 CH 2 Cl and 44% of CF 2 ClCH 2 Cl.
EXAMPLE 19
By operating as in Example 17 with 7.12 g of TiCl 4 (0.0375 mole) and 2.85 g of SbCl 3 (0.0125 mole), a product was recovered containing 96% of CF 3 CH 2 Cl and 3% of CF 2 ClCH 2 Cl.
EXAMPLE 20
By operating as in Example 17 with 8 g of TiCl 4 (0.042 mole) and 1.8 g of SbCl 3 (0.0078 mole), a product was recovered containing 99.6% of CF 3 CH 2 Cl.
EXAMPLE 21
A catalyst was prepared, as described in Example 2, from 3.6 g of SbCl 3 (0.016 mole), 16 g of TiCl 4 (0.085 mole) and 40 g of HF.
Then, 50.6 g of CCl 3 CHCl 2 (0.25 mole) and 100 g of HF (5 moles) were charged. The reaction mixture was heated to 150° C. over two hours and maintained at this temperature for 3 and a half hours. The pressure rose to and stabilized at 54.5 bars.
After cooling and degassing, 38 g of product were recovered, containing 96.3% of CF 2 Cl--CHCl 2 and 2.3% of CF 3 CHCl 2 .
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. The above mentioned references are hereby incorporated by reference. | The catalysts according to the invention are mixtures of an antimony trihalide and of a titanium tetrahalide.
These catalysts can be used for the liquid phase fluorination of halogenated aliphatic hydrocarbons, especially that of chlorinated ethane and ethylene derivatives. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to metal/insulator interconnect structures found in Very Large Scale Integrated (VLSI) and Ultra Large Scale Integrated (ULSI) devices and packaging, and more particularly to interconnect structures comprising fluorine-containing, low dielectric constant (low-k) dielectrics. Dielectric treatment methods for mitigating reliability problems associated with out-diffusion of fluorine from the low-k dielectric into other parts of such structures are taught.
BACKGROUND OF THE INVENTION
[0002] Device interconnections in Very Large Scale Integrated (VLSI) or Ultra-Large Scale Integrated (ULSI) semiconductor chips are typically effected by multilevel interconnect structures containing patterns of metal wiring layers called traces. Wiring structures within a given trace or level of wiring are separated by an intralevel dielectric, while the individual wiring levels are separated from each other by layers of an interlevel dielectric. Conductiva vias are formed in the interlevel dielectric to provide interlevel contacts between the wiring traces.
[0003] By means of their effects on signal propagation delays, the materials and layout of these interconnect structures can substantially impact chip speed, and thus chip performance. Signal propagation delays are due to RC time constants wherein R is the resistance of the on-chip wiring, and C is the effective capacitance between the signal lines and the surrounding conductors in the multilevel interconnection stack. RC time constants are reduced by lowering the specific resistance of the wiring material, and by using interlevel and intralevel dielectrics (ILDs) with lower dielectric constants.
[0004] The low dielectric constants of fluorine-containing dielectrics (FCD) such as fluorinated diamond-like-carbon (FDLC), fluorinated silicon oxide (FSO), and fluorinated silicate glass (FSG), make them potentially useful as ILD materials in high performance VLSI and ULSI chips where interconnect wiring capacitance must be minimized. This use for FDLC is discussed by S. A. Cohen et al. in U.S. Pat. 5,559,367 which issued Sep. 24, 1996 entitled “Diamond-like carbon for use in VLSI and ULSI interconnect systems.”
[0005] FDLC films can be fabricated by a variety of methods including Sputtering, ion beam sputtering, and dc or rf plasma assisted chemical vapor deposition with a variety of carbon-bearing source materials, as described for non-fluorinated DLC films by A. Grill and B. S. Meyerson, “Development and Status of Diamond-like Carbon,” Chapter 5 , in Synthetic Diamond: Emerging CVD Science and Technology, editors K. E. Spear and J. P. Dismukes, John Wiley and Sons, New York 1994, and by F. D. Bailey et al. in U.S. 5,470,661 which issued Nov. 28, 1995. However, fluorine-containing ILDs such as FDLC cannot be integrated into these interconnect structures without suitable capping and/or liner layers to prevent fluorine in these FCD's from reacting with other materials in the interconnect structure during required processing steps at elevated temperatures above 300 C. While ILDS with reduced fluorine contents would be expected to have smaller amounts of fluorine available to react, lower fluorine-content ILDs typically also have undesirably higher k values.
[0006] Capping materials such as the insulators silicon oxide and silicon nitride, and the conductive liner materials such as TiN have previously been described for use with fluorine-free ILDs as (i) diffusion barriers (to prevent atoms of wiring material from diffusing into the ILD, from where they may readily diffuse into active device regions), (ii) etch stop and permanent masking materials, and (iii) adhesion layers.
[0007] These prior art utilizations of capping and liner materials illustrated in FIGS. 1, 2, 3 A and 3 B. FIG. 1 shows a schematic cross section view of a generic, 2-wiring-level interconnect structure 10 . Interconnect structure 10 comprises substrate 20 , conductive device contacts 30 in a first dielectric 40 , a first and second level of conductive wiring (50, 60), and two layers of conductive vias (70, 80) embedded in layers of a second dielectric 90 . Contacts to packaging dies are provided by conductive contact pads 100 in a third dielectric 110 and a capping layer or insulating environmental isolation layer 120 . Interconnect structure 10 incorporates three capping materials: a conductive capping or liner material 130 lining the sidewalls and bottom surfaces of the conductive wiring and vias, an insulating capping material layer 140 overlying each wiring level over those areas not contacted by an overlying via, and an optional insulating capping layer 150 over some or all (shown) of each layer of dielectric 90 . Conductive liner or capping material 130 acts to provide adhesion and prevent metal diffusion into dielectric 90 ; its conductivity provides electrical redundancy to conductive wiring 60 , and allows it to remain in the contact regions between conductive features in different levels. Insulating capping material 140 primarily serves to prevent metal diffusion into the overlying dielectric layers, but can also prevent other potentially undesirable interactions as well as acting as an etch stop. Insulating capping material 150 is optionally left in the structure after use as an etch mask, etch stop, and/or polish stop during interconnect structure fabrication.
[0008] Interconnect structure 10 of FIG. 1 would typically be by Damascene processing in which layers of dielectric are sequentially deposited, patterned to form cavities corresponding to the pattern of conductive material desired, overfilled with the conductive material, and then planarized to remove conductive material above the dielectric. This process is repeated as necessary for each additional layer.
[0009] Interconnect structures may also be fabricated by Dual Damascene processing, in which approximately double thicknesses of second dielectric material 90 are patterned with dual relief cavities corresponding to the pattern of a wiring level and its underlying via level. FIG. 2 shows a schematic cross section view of a prior art 2-wiring-level interconnect structure 160 analogous to interconnect structure 10 in FIG. 1, except that the disposition of the capping materials 130 and 150 reflects the Dual Damascene method of processing. For example, since wiring level 60 and its underlying via level 80 are filled with conductive material in the same deposition step, there is no conductive cap material 130 between 50 and 70 , a characteristic distinguishing feature of all Dual Damascene processed interconnect structures.
[0010] [0010]FIGS. 3A and 3B show two other Dual Damascene processed interconnect structures similar to interconnect structure 160 of FIG. 2, but different in the presence of insulating cap layer 170 , used as an etch stop to facilitate the patterning of the dual relief cavities in the double (via plus wiring level) layers of the dielectric material 90 . In interconnect structure 180 in FIG. 3A, exposed regions of etch stop layer 170 are not removed before filling the dual relief cavities with conductive material; in interconnect structure 190 in FIG. 3B, exposed regions of etch stop layer 170 are removed before filling the dual relief cavities with conductive material.
[0011] While the interconnect structures 10 , 160 , 180 and 190 show two wiring levels, the number of wiring levels may be as few as one or as many as ten or more. In FIGS. 2, 3A and 3 B like references are used for functions corresponding to the apparatus of an earlier figure.
[0012] In interconnect structures wherein FCD's are introduced in place of the dielectric layers such as 90 and 110 in FIGS. 1 to 3 B, delamination is encountered during the deposition of cap layers such as cap material 120 and 140 and liners such as 130 if elevated temperatures are required during their deposition. Even if the structure survives the deposition step, delamination can also occur during subsequent processing steps that require temperature excursions in excess of 300° C. For example, capping material delamination and cracking was observed in cap/FDLC(1000 nm)/Si samples after a 350° C./4 hr anneal in He. Delamination and cracking were present even in samples in which the FDLC forming the third dielectric layer 110 had been given a “stabilization” anneal (400° C. in He for 4 hours) prior to capping.
[0013] it should be noted that the need for permanent capping and liner materials in interconnect wiring structures would be substantially lessened with the use of ILD's formulated to additionally function as diffusion barriers. However, the delamination problems described above would still be a concern due to the use of these same capping/liner materials as temporary etch stops and/or hard mask materials.
[0014] It is thus an object of this invention to provide a high performance interconnect structure comprising one or more layers of uniquely conditioned and stabilized fluorine-containing dielectric insulation and one or more conductive wiring levels electrically connected by conductive vias, the wiring levels and vias optionally isolated from the fluorine-containing dielectric by current state-of-the-art insulating cap materials which may or may not be fluorine-resistant. It should be noted that the term “fluorine-resistant” is meant to describe materials that do not readily react with fluorine to form fluorine-containing compounds that interfere with the function or the mechanical integrity of the interconnect structure. One set of such fluorine-resistant materials is Al, Co and Cr which do not form volatile fluorides by reaction with fluorine at temperatures below 400° C.
[0015] It is yet another object of this invention to provide a high performance interconnect structure comprising one or more layers of uniquely conditioned and stabilized fluorine-containing dielectric insulation and one or more conductive wiring levels electrically connected by conductive vias, the wiring levels and vias completely isolated from the fluorine-containing dielectric by current state-of-the-art insulating cap materials which may or may not be fluorine-resistant.
[0016] It is a further object of this invention to provide a high performance interconnect structure comprising one or more layers of uniquely conditioned and stabilized fluorine-containing dielectric insulation and one or more conductive wiring levels electrically connected by conductive vias, the wiring levels and vias being isolated from the fluorine-containing dielectric on a first set of selected surfaces by a state-of-the-art electrically insulating capping material which may or may not be fluorine-resistant, and isolated from the fluorine-containing dielectric on a second set of selected surfaces by a state-of-the-art electrically conductive capping and/or liner material which may or may not be fluorine-resistant.
SUMMARY OF THE INVENTION
[0017] The present invention relates to metal/insulator interconnect structures found in Very Large Scale Integrated (VLSI) and Ultra Large Scale Integrated (ULSI) devices and packaging, and more particularly to interconnect structures comprising fluorine-containing dielectrics (FCD), such as low-k FCD's with or without state-of-the-art capping and/or liner materials selected primarily to prevent reliability problems associated with delamination of the various interfaces, and the out-diffusion of the conductor metal through the dielectric. Delamination problems between the fluorine-containing dielectric and the current state-of-the-art capping layers or liners are obviated by reducing the concentration of fluorine in the region of the fluorine-containing dielectric (FCD) near the FCD-capping/liner layer interface. This reduction is achieved through a combination of ultraviolet irradiation and thermal annealing of the FCD to remove fluorine from the near-interface region. By virtue of this conditioning and stabilization of the FCD, the selection of the capping layers and liners are not constrained by a need to be fluorine-resistant, thus facilitating a broader choice of materials and processing options.
[0018] The invention further provides an interconnect structure comprising one or more layers of conductive wiring patterns electrically connected by conductive vias; one or more layers of fluorine-containing dielectric (FCD) between at least some of the conductive wiring patterns; the FCD modified so that at least some of the FCD with other materials in the interconnect structure are provided with a near-interface region that extends from the interface into the FCD and has a substantially lower fluorine content. The FCD may be selected from the group consisting of fluorinated diamond like carbon (FDLC); FDLC with additives selected from the group consisting of H, Si, Ge, O, and N; fluorinated silicon oxide (FSO); fluorinated silicate glass (FSG); organo-inorganic dielectrics containing fluorine; and organic dielectrics containing fluorine.
[0019] The invention further provides a method to achieve a reduced-fluorine content region in a fluorine containing dielectric layer comprising the steps of exposing the region in the FCD layer to ultraviolet radiation to at least partially disrupt at least some of the bonded fluorine in the region; and annealing the region in the FCD layer at an elevated temperature for a certain duration to liberate at least some of the at least partially disrupted fluorine from the region thereby making the region substantially lower in fluorine concentration. At least some of the step of annealing may occur concurrently with the step of exposing the region in the FCD layer to ultraviolet radiation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and other features, objects, and advantages of the present invention will become apparent upon a consideration of the following detailed description of the invention when read in conjunction with the drawings, in which:
[0021] [0021]FIG. 1 shows a schematic cross section view of a generic prior art interconnect structure comprising two wiring levels;
[0022] [0022]FIG. 2 shows a schematic cross section view of a variation of the generic prior art interconnect structure of FIG. 1;
[0023] [0023]FIGS. 3A and 3B show a schematic cross section view of two more variations of the generic prior art interconnect structure of FIG. 1;
[0024] [0024]FIG. 4 shows the change or loss in FDLC film thickness with increasing amounts of UV radiation exposure.
[0025] [0025]FIG. 5 shows Rutherford Backscattering Spectroscopy (RBS) results for a fluorinated diamond-like carbon film as-deposited (A), after UV irradiation in ambient air (B), and after UV irradiation followed by a subsequent anneal at 400° C. in helium (C).
[0026] [0026]FIGS. 6A to 6 D illustrate one method of incorporating the UV stabilization method of the present invention into a dual damascene process leading to a two level wiring structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The interconnect structures of the present invention comprise layers of fluorine-containing dielectric (FCD) which are selected for low dielectric constant and processability and integrated with wiring conductor materials and optional capping/liner materials selected from materials known and used in the current state-of-the-art in microelectronic interconnection technology. For example, the electrically conductive materials used for the wiring patterns and the vias can be selected from the set comprising copper and its alloys, aluminum and its alloys, and tungsten. The insulating cap layer applied over the fluorine-containing low-k dielectric can be selected from the group comprising but not limited to inorganic materials such as silicon oxide, silicon nitride and silicon oxynitride; silicon carbide, silicon carbo-oxide and their hydrogen containing compounds, organic materials such as polyimides, diamond-like carbon with or without additives, poly-para-xylylene sold under the trademark “PARALYENE”; organo-inorganic materials such as spin on glasses. The capping materials selected need not be fluorine-resistant and can instead be chosen from a larger set of materials based on their high electrical resistance, adhesion, low dielectric constant, high hardness and chemical mechanical polishing resistance, resistance reactive ion etching plasmas, ability to protect the wiring conductor material from thermal and process chemical exposures associated with multilevel interconnect fabrication, and ability to prevent diffusion of the wiring conductor material into the fluorine-containing dielectric.
[0028] The liner material, again, need not be specially selected to be fluorine-resistant but can instead be chosen for good adhesion to the dielectric, high conductivity, efficacy as a diffusion barrier to the wiring/via materials and low ohmic contact resistance to wiring/via materials. As a result, the capping and liner materials can be chosen from a wide variety of materials available in the state-of-the-art without limiting the choices to fluorine-resistant materials such as Al, Co and Cr.
[0029] It is difficult to integrate fluorine-containing dielectrics in the prior art multilevel build process schemes because of the reactivity of the fluorine present in these FCD materials in their as-deposited state. When the next overlayer is deposited or processed at elevated temperatures (300C. and above), this fluorine appears to react with the overlayer at its interface with the fluorine-containing dielectric. This reaction often results in a catastrophic loss of adhesion and delamination of the overlayer, thus frustrating the multilevel interconnect build process. Such a problem has been encountered while depositing capping layers like silicon oxide, silicon nitride, silicon oxynitride, and liner layers such as Ti, Ta and their nitrides, on fluorine-containing dielectrics such as fluorinated silica, fluorinated polyimides and fluorinated diamond-like carbon (FDLC). Even if the deposition is performed at ambient temperatures, the same problem occurs when the composite structure is heated to elevated temperatures in a subsequent process step.
[0030] Since the reaction and delamination appear to be phenomena localized in the region immediately adjacent to the interface between the FCD and the overlayer material with which it is in intimate contact, it is important to minimize the amount of fluorine in this region. Moreover, since fluorine is required in the bulk of the fluorine-containing dielectric to facilitate the desirably low dielectric constant, it is imperative that the defluorination does not extend throughout the bulk of the dielectric layer.
[0031] We have demonstrated a method to minimize the amount of fluorine in selected regions in fluorinated diamond-like carbon (FDLC) by means of a controlled dose exposure of the film to broad band ultraviolet radiation followed by a thermal annealing process. In a previous study, the effects of ultraviolet irradiation in non-fluorinated diamond-like carbon (DLC) films were examined as described in patent application 08/664,729 filed Jun. 17, 1996 by K. Babich et al., Ser. No. 08/664,729 filed Jun. 17, 1996 (Docket Y0996-083) entitled “Chemically and optically stable carbon films” and assigned to the assignee herein and found that UV irradiation of DLC in air produces an oxygen-rich surface layer at moderate UV exposure. DLC etching occurs at higher UV exposures, a fact attributed to the diffusion of surface oxygen etchant species into the bulk of the film.
[0032] In the present invention, the interaction of the UV radiation with FCD's is harnessed, in combination with a post-irradiation thermal annealing to achieve a desirable defluorination of the near-surface region of the FCD's.
[0033] Example 1 describes the effect of UV exposure on films of FDLC exposed to various doses of UV radiation in ambient air. The results show that significant loss of film thickness can occur in the FDLC at high UV exposure doses, but that little or no thickness loss occurs at lower doses. This result is shown by curve 210 in FIG. 4. In FIG. 4 the ordinate represents thickness loss in angstroms and the abscissa represents UV dose in Joules per square centimeter. Curve 210 shows that thickness loss is proportional to the UV dose above 20 J/cm 2 . Based on this result for FDLC, we explored the possibility of using controlled dose UV exposure as a means to reduce near-surface fluorine content and provide enhanced overlayer adhesion.
[0034] The ultraviolet radiation incident in FDLC films is strongly absdorbed in a top surface layer. Typical 1/e absorption depths are in the range from 750 Å to 2000 Å in the wavelengths ranging from 193 nm to 248 nm. For a film with a 1 /e absorption depth of 1000 Å, 95% of the incident light would be absorbed in the top 3000 Å of the film.
[0035] The attenuation of the UV light resulting from this strong surface absorption would be thus expected to confine the disruption of fluorine to the near surface region and reduce the UV dose to the remainder of the FDLC film to negligible levels.
[0036] The effect of the FDLC UV treatment on the adhesion of subsequently deposited overlayers was tested by depositing a bilayer overcoat on treated FDLC. The bilayer overcoat comprised a thin bottom layer of amorphous silicon layer grown by plasma enhanced chemical vapor deposition (PECVD) at 180° C., and a top layer of silicon nitride, deposited by PECVD at 380° C. This particular structure was selected as the overlayer because its adhesion to the FDLC is very sensitive to the presence of the fluorine. we found that although in the as-deposited condition the overcoat was adherent to the untreated FDLC, adhesion loss occurred during a subsequent exposure to 400° C. annealing. Thermal annealing of the untreated FDLC at 400° C. for four hours in a helium gas ambient prior to the bilayer overcoat deposition did not produce good adhesion either. In the next experiment, the FDLC layer was first annealed at 400° C. in He for 4 hours and then subjected to UV radiation as in Example 1. This treatment also resulted in a significant delamination of the overcoat during the PECVD silicon nitride deposition.
[0037] The only combination of UV exposure and heat treatment that produced a well adhering overcoat was a controlled dose UV exposure followed by a thermal treatment, in this case an anneal at 400° C. for four hours. These results are described in Example 2. we have also demonstrated that this combination of irradiation followed by thermal annealing leads to defluorination near the surface, as shown by Rutherford Backscattering Spectroscopy (RBS). The results from this measurement, shown in FIG. 5, clearly demonstrate that fluorine is depleted from a shallow region of the FDLC near its top surface. In FIG. 5, the ordinate represents normalized yield of backscattered helium ions and the abscissa represents RBS channel number or ion energy in MeV. The depth of the def luorinated region can be changed by adjusting the total UV dose to which the FDLC films are subjected by either changing the UV radiation flux, the UV exposure time or both. It is important to control the depth of the said shallow def luorinated region because the loss of fluorine from the bulk of the fluorine-containing dielectric would result in an undesirable increase in its dielectric constant. As seen from the Examples that follow, a defluorinated depth of about 50% or less of the total FCD thickness is optimal. In Example 2, it is demonstrated that good adhesion results, as well as the preservation of the low dielectric constant, are achieved only with unique combination of controlled dose UV irradiation followed by a thermal annealing. It is also important to note that this combination of treatments also produces a minimal change in the FDLC film thickness, typically less than 50 nm.
[0038] Although these results were demonstrated for FDLC films, with one type of thermal treatment, other thermal treatments in a broad range of temperatures (for example, 200° C. to 600° C.) and duration times (for example, 1s to 12 hr) might be expected to have a similar effect. In addition, we believe that this process can be extended to other organic, inorganic or organo-inorganic fluorine-containing dielectrics such as fluorosilicate glasses, fluorinated silicon oxide, fluorinated polyimides, fluorinated poly-para-xylylene such as the one sold under the trademark “PARALYENE-AF” material manufactured by Novellus Systems, Inc. and others, by adjusting the UV radiation wavelength, UV dose, and the post irradiation annealing temperature and time as required. Judicious combinations of UV irradiation and substrate heating, during as well as before and after UV exposure, could also be used to further optimize the stabilization process.
[0039] The above described invention, comprising stabilization of fluorine-containing dielectrics by a combined UV exposure and a thermal treatment can be readily used in conjunction with state-of-the-art interconnect fabrication unit processes described earlier to obtain acceptably adherent interconnect structures that intergrate capping layer and liner materials known in the current art with fluorine-containing low-k dielectrics.
[0040] Examples of capping materials include silicon, silicon nitride, silicon oxide, silicon oxynitride, silicon carbide, silicon carbo-oxide and their hydrogen containing compounds, electrically insulating silicon-metal nitride, polyimide, diamond-like carbon, diamond-like carbon with additives selected from the group consisting of H, Si, Ge, O, and N, and combinations thereof.
[0041] Examples of liner materials include Cr, Ti, Ta, Nb, Zr, Mo, W, Al and electrically conductive oxides, oxynitrides, silicides, nitrides, metal silicon nitrides and combinations thereof.
[0042] [0042]FIGS. 6A to 6 D show how the UV stabilization method may be incorporated into a dual damascene process flow to construct a reliable multilevel interconnect structure comprising FCD'S. On an electronic device substrate 20 provided with via terminations 30 embedded in a device passivation dielectric 40 , a layer of FCD 250 is applied by a suitable coating process which may be for example CVD, PACVD or spin coating and curing. The thickness of this FCD layer 250 is chosen so that its post-stabilization thickness will be equal to the total thickness required for a via level and a wiring level dielectric combined. The wafer surface is then subjected to a controlled dose UV exposure 255 , which is tailored for the specific FCD material, such as several tens of Joules/cm 2 in air ambient for FDLC, for example. The FCD layer is subsequently subjected to an elevated temperature annealing process, for example at 400° C. for 4 hours in an inert gas ambient such as helium. This results in a near-surface region 260 in the FCD layer 250 that is substantially free of reactive fluorine, as shown in FIG. 6A. By substantially free of fluorine, we mean that the chemical activity of fluorine in the said region is insufficient to cause the formation of fluorine-containing compounds that interfere with the function of the interconnect structure. In the next step, a single or multilayer hard mask material 270 , such as silicon oxide, silicon nitride or a layered combination of such, is deposited on top of the stabilized FCD layer 250 . An optional adhesion promoter layer 280 such as, for example, amorphous hydrogenated silicon (a-Si:H) can be used to enhance adhesion levels. No delamination problems are encountered since the interface region 260 in the FCD layer 250 is substantially free of reactive fluorine. Next, via and wiring level patterns are lithographically defined in hard mask layer 270 , they are transferred to the appropriate portions of optional adhesion promoter layer 280 , treated FCD surface layer 260 and bulk FCD layer 250 to produce the structure of FIG. 6B. The structure of FIG. 6B is then subjected to a second stabilization with UV exposure and annealing to ensure that the exposed sidewall regions of the trenches in the patterned FCD are also substantially free of reactive fluorine. It should be noted that the patterned hard mask layer 270 and optional adhesion promoter layer 280 of FIG. 6B may selected to be strongly UV absorbing or UV reflecting to minimize further UV exposure to treated FCD surface layer 260 during the sidewall UV exposure step. A diffuser 300 (see FIG. 6C) or substrate rotation during irradiation may optionally be used to direct the UV flux to the FCD sidewalls. This UV exposure results in a region 290 along the side walls and exposed horizontal portions of the trenches and vias in the FCD layer 250 that is substantially free of reactive fluorine, as shown in FIG. 6C. At this juncture, the trenches and vias in FCD layer 250 are optionally lined with a thin conducting liner material 310 and filled with a thick higher conductivity material 320 and optionally planarized by a chemical mechanical polishing process (CMP). The resulting structure is shown in FIG. 6D. It should be noted that cap or hard mask layer 270 and liner 310 are materials known in the art and are not required to be fluorine-resistant because they are in contact with regions 260 or 290 which have been rendered substantially free of reactive fluorine so as to obviate this requirement. Multilevel structures can be fabricated by repeating this process sequence for each of the dual damascene levels needed to obtain the desired number of wiring and via levels.
[0043] Although the example above describes one particular process flow and one particular embodiment of the present invention, other process flows can also be modified in a similar fashion to integrate the FCD's without deviating from the spirit of the present invention. For example, some or all of the step of heating be applied concurrently with the step of UV exposure, and UV irradiation may be supplied by excimer or other lasers instead of broad band lamps.
[0044] Following are detailed examples of the process steps for the UV and thermal stabilization of FDLC.
EXAMPLE 1 Effect of UV Radiation on FDLC
[0045] FDLC films were deposited on polished silicon wafers in a parallel plate reactor by PACVD using a mixture of hexafluorobenzene (C 6 F 6 ), hydrogen and argon. To prevent interactions between the Si substrate and the FDLC film during deposition, a thin (40 nm) DLC layer is deposited first. The FDLC film thicknesses for UV radiation experiments were nominally 1100 nm. These wafers were cleaved into nominally identical pieces and subjected to different doses of UV radiation using a broad band mercury-xenon arc lamp source that produced UV radiation in the 200 to 400 nm wavelength range. Irradiation was performed in ambient air. Radiation flux was measured using a radiometer/band pass filter arrangement which sampled a bandwidth of 230 to 266 nm. UV dose was varied by changing the time of exposure. Samples were examined for thickness changes using step height measurements by surface profilometry, and for composition changes and mass loss by RBS analysis with 2.3 MeV 4 He ions.
[0046] [0046]FIG. 4 shows the FDLC layer thickness loss as a function of the UV dose for a radiation flux of about 4 mJ/cm 2 - S. It is clear that UV doses of up to 15 J/cm 2 do not cause any measurable thickness change. However, significant etching of the film occurs at higher doses increasing linearly with the total UV dose. For example, at 284 J/cm 2 dose a 52% thickness loss is observed. A subsequent anneal at 400° C. in He for four hours leads to an additional 34% loss of the already thinned film. In contrast, a thermal anneal at 400° C. for four hours (in helium or nitrogen) without any UV irradiation generally leads to a slight swelling of the film by up to 8% in thickness. However, if the FDLC film is exposed to low doses of UV and then thermally annealed to 400° C., thickness changes are minimal.
[0047] RBS analysis of the film before and after irradiation shows that there is a loss of fluorine from the near-surface region as a result of the irradiation. FIG. 5 shows RBS results for an FDLC sample as-deposited (FIG. 5 curve 212), after 18.3 J/cm 2 dose of UV exposure only (FIG. 5 curve 214 ), and after a combined treatment of 18.3 J/cm 2 UV exposure and a 400° C. anneal in helium for four hours (FIG. 5 curve 216 ). The elemental markers on the abscissa of FIG. 5 indicate the maximum ion energy (or channel number) expected for 4 He ions backscattered from atoms of the specified element present in the sample. Analysis of curve 212 indicates that the fluorine in the as-deposited film is uniformly distributed throughout the film thickness, and has a concentration approximately 36 at. %. The uniform distribution of fluorine can be inferred from the flatness of curve 212 between channels 125 and 155 . Analysis of the film after UV irradiation alone showed the film to have a near-surface region with a fluorine concentration of 25 at. %, extending about one third of the way into the film, and a fluorine concentration of about 30 to 36 at. % in the remainder of the film. This non-uniform distribution of fluorine can be inferred from the more gentle slope of curve 214 between channels 150 and 155 , which indicates that the near-surface region is depleted of F.
[0048] The RBS results for the sample subjected to UV and subsequent thermal annealing, shown as curve 216 , indicate some additional fluorine loss (perhaps 20%) from the top portion of the near-surface fluorine-depleted region identified in sample B, exposed to UV only shown by curve 214 . However, the thermal annealing did not appear to affect fluorine content in the subsurface region of film, which remained similar to that of sample B. As will be shown below, this fluorine depletion at the FDLC surface is correlated with an improvement in the adhesion of a subsequently deposited amorphous hydrogenated silicon/silicon nitride bilayer.
[0049] Dielectric constants of the FDLC films were also measured after the combined UV plus thermal treatment. A test structure was fabricated by depositing a 1100 nm thick FDLC film on heavily doped silicon wafers using the process described above followed by a deposition of an array of Al/Au dots on top of the FDLC film. Capacitance between the top dots and the highly conductive Si wafer substrate was measured and the dielectric constant was then calculated using the known area of the dots and the thickness of the films. The as-deposited film had a dielectric constant (k) of 2.85 while a film after UV radiation of 12 J/cm 2 had a k of about 3.01. Thermal anneals of the UV exposed samples for 1 or 4 hours in nitrogen at 400° C. resulted in samples with a k of 2.64. The thickness change in these samples after the combined UV exposure and thermal annealing was about 50 nm.
[0050] The experimental results detailed above demonstrate that controlled dose UV exposure in air of FDLC film combined with a post-irradiation anneal in an inert ambient can selectively reduce the fluorine content of the FDLC in the near-surface region without a significant change in film thickness or its dielectric constant.
EXAMPLE 2 Good a-Si:H/SiN x overlayer adhesion to FDLC with UV treatment first, followed by thermal anneal
[0051] FDLC samples were deposited onto polished Si as in Example 1. The samples were then subjected to a UV treatment as in Example 1 followed by a 4 hour anneal at 400° C. in a pure nitrogen ambient.
[0052] The samples then received a thin (5 nm) amorphous hydrogenated silicon layer (a-Si: H) deposited at 180° C. using PECVD from 2% silane (SiH 4 ) in Ar gas mixture.
[0053] A 100 nm SiN x layer was then deposited onto the structure using a PECVD deposition process at 380° C. with a silane-ammonia-nitrogen gas mixture. In this case the films were well adherent after the deposition and could not be peeled off using a Scotch tape test. To further stress the interface the samples were then annealed again at 400° C. for 4 hours in a nitrogen ambient. The SiN x film was still well adhered to the structure even after this thermal excursion. Taken in conjunction with the RBS data described in Example 1 it can be inferred that the good adhesion is related to the controlled defluorination of the near-surface region of the FDLC prior to the overcoat deposition.
[0054] Interestingly, use of a thermal anneal at 400° C. for four hours in an inert ambient alone without any UV exposure prior to annealing did not produce adhesion between the SiN 4 and the FDLC good enough to survive the rigors of a post-deposition 400° C./4 hour anneal. Use of UV exposure alone without a post-irradiation anneal yielded an even more severe loss of SiN x adhesion. We therefore conclude that the unique combination of UV exposure and thermal annealing in the correct sequence, described herein, is required to achieve the desired result.
[0055] While our UV treatments were performed in air, the ambient for the UV treatment may be selected from the group containing inert gases, such as He, Ar, and N 2 ; oxygen containing gases, such as O 2 and N 2 O; forming gases containing H 2 ; mixtures of the aforementioned gases, such as air; and vacuum. However, we speculate that the UV treatment may be more effective in an air or an oxygen containing ambient due to the possibility that UV radiation may produce reactive oxygen species that can attack and weaken C—F bonds in the near surface region of the film. Film annealing subsequent to UV exposure leads to the removal of the fluorine disrupted by the UV irradiation step, thus rendering the near-surface region of the FDLC film substantially free of reactive fluorine. Thermal annealing by itself without the first UV irradiation step may not be adequate to cause this bond scission. UV irradiation alone can lead to bond scission but can potentially leave the liberated fluorine in the near-surface region of the FDLC film without a post-irradiation thermal treatment to drive it off. In the case of thermal annealing alone or in the case of UV irradiation alone, the resulting surface of the FDLC layer can be reactive enough to form fluorine-containing compounds during subsequent semiconductor chip fabrication processing steps.
[0056] While there has been described and illustrated a method for providing a region of substantially lower fluorine content in a fluorine containing dielectric (FCD) layer and an interconnect structure using FCD with regions of low fluorine content, it will be apparent to those skilled in the art that modifications and variations are possible without deviating from the broad scope of the invention which shall be limited solely by the scope of the claims appended hereto. | A method for providing regions of substantially lower fluorine content in a fluorine containing dielectric is described incorporating exposing a region to ultraviolet radiation and annealing at an elevated temperature to remove partially disrupted fluorine from the region. The invention overcomes the problem of fluorine from a fluorine containing dielectric reacting with other materials while maintaining a bulk dielectric material of sufficiently high or original fluorine content to maintain an effective low dielectric constant in semiconductor chip wiring interconnect structures. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is related to gasoline engine cleaners and detergents, and more particularly to gasoline intake valve deposit (IVD) inhibitor additives, i.e., agents which assist in preventing and removing deposits from intake valves and related parts of a gasoline combustion engine. This invention also relates to combustion chamber deposit inhibitors, which reduce combustion chamber deposits, resulting in lower octane requirement increase and lower NO x emissions.
2. Description of Related Information
Combustion of a hydrocarbon motor fuel in an internal combustion engine generally results in the formation and accumulation of deposits on various parts of the combustion chamber as well as in the fuel intake and on the exhaust systems of the engine. The presence of deposits in the combustion chamber seriously reduces the operating efficiency of the engine. First, deposit accumulation within the combustion chamber inhibits heat transfer between the chamber and the engine cooling system. This leads to higher temperatures within the combustion chamber, resulting in increases in the end gas temperature of the incoming charge. Consequently, end gas auto-ignition occurs causing engine knock. In addition, the accumulation of deposits within the combustion chamber reduces the volume of the combustion zone, causing a higher than design compression ratio in the engine. This, in turn, can also lead to engine knocking. A knocking engine does not effectively utilize the energy of combustion. Moreover, a prolonged period of engine knocking can cause stress fatigue and wear in pistons, connecting rods, bearings and cam rods of the engine. The phenomenon noted is characteristic of gasoline powered internal combustion engines. It may be overcome by employing a higher octane gasoline which resists knocking for powering the engine. This need for a higher octane gasoline as mileage accumulates has become known as the engine octane requirement increase (ORI) phenomenon. It is particularly advantageous if engine ORI can be substantially reduced or eliminated by preventing or modifying deposit formation in the combustion chambers of the engine.
Another problem common to internal combustion engines is the formation of intake valve deposits, which is an especially serious problem. Intake valve deposits interfere with valve closing and eventually result in poor fuel economy. Such deposits interfere with valve motion and valve sealing, cause valve sticking, and, in addition, reduce volumetric efficiency of the engine and limit maximum power. Valve deposits are produced from the combustion of thermally and oxidatively unstable fuel or lubricating oil oxidation products. The hard carbonaceous deposits produced collect in the tubes and runners that are part of the exhaust gas recirculation (EGR) flow. These deposits are believed to be formed from exhaust particles which are subjected to rapid cooling while mixing with the air-fuel mixture. Reduced EGR flow can result in engine knock and in increased NO x emissions. It would therefore be desirable to provide a motor fuel composition which minimizes or overcomes the formation of intake valve deposits and subsequent valve sticking problems.
There are additives on the market which assist in the removal of deposits, particularly on the intake valves, such as OGA-472™, a product of the Oronite Co. of Wilmington, Del. These additives lack sufficient deposit cleanup activity, however, and their efficacy can be improved upon. In addition, polyisobutylene (PIB) based detergents tend to cause octane requirement increase.
Thus, it is an object of the present invention to provide a gasoline additive which will effectively remove deposits from, and prevent the formation of deposits on, the intake valves of a gasoline spark ignition engine. It is another object of the present invention to provide a gasoline additive which will perform this function without contributing to the buildup of combustion chamber deposits and, therefore, without causing octane requirement increase.
SUMMARY OF THE INVENTION
The present invention provides a novel class of compounds, useful as gasoline detergent additives, comprising hydrocarbyloxypolyether allophonate esters of 2-hydroxy ethane. These novel allophonate esters can be represented by the formula: ##STR1## where R is a C 9 -C 25 alkyl group, R 2 is a C 2 to C 4 oxyalkylene group, m is 0 or 1, and n is a number between about 5 and about 30.
The present invention also provides a motor fuel composition comprising:
(a) a major portion of a hydrocarbon fuel boiling in the range between 90° F. and 370° F.; and
(b) a minor amount, sufficient to reduce the formation of deposits on intake valves, of the hydrocarbyloxypolyether allophonate ester of 2-hydroxy ethane of FIG. 1.
A method of synthesizing the allophonate esters of the present invention is also provided.
DETAILED DESCRIPTION OF THE INVENTION
Applicant's have discovered a new class of allophonate esters which are useful as detergents in motor fuel compositions. These allophonate ester detergents are more efficacious in removing and preventing the build up of deposits on intake valves than some commercially available detergent packages. In addition, the allophonate ester motor fuel additives of the present invention will not contribute significantly, if at all, to octane requirement increase, a problem which confronts all gasoline spark ignition engines.
The allophonate esters of the present invention are represented by the formula: ##STR2## where R is a C 9 -C 25 alkyl group, R 2 is a C 2 to C 4 oxyalkylene group, m is 0 or 1, and n is a number between about 5 and about 30. In Figure II, the R group is shown located in the para position. It is probable that the R group will sometimes be located in the ortho position, and the allophonate esters of the present invention therefore include mixtures of both the para and ortho isomers. The formula of Figure II is hereinafter intended to represent both the para and ortho isomers and mixtures thereof.
Preferably, R is a C 9 to C 21 alkyl group, R 2 is an oxypropylene group, m=1, and n is a number between about 9 and about 15. In another preferred embodiment, R is a C 12 to C 21 alkyl group, R 2 is an oxypropylene group, m=0, and n is a number between about 9 and about 15
More preferably, R is a nonyl group, R 2 is an oxypropylene group, m=1, and n is about 12. This more preferred allophonate ester can be represented by the formula: ##STR3## It should be noted that the phenyl ring can contain a second nonyl substituent. In such cases the first nonyl group would be in the para position and the second nonyl group would be in the ortho position to the remainder of the molecule.
Synthesis of Allophonate Esters
The allophonate esters of the present invention are the product of the reaction of a hydrocarbyloxypolyoxyalkylene amine with urea and ethylene carbonate: ##STR4## where R is a C 9 -C 25 alkyl group, R 2 is a C 2 to C 4 oxyalkylene group, m is 0 or 1, and n is a number between about 5 and about 30.
The polyetheramine reactants useful in the present invention can be represented by the formula: ##STR5## where R is a C 9 -C 25 alkyl group, R 2 is a C 2 to C 4 oxyalkylene group, m is 0 or 1, and n is a number between about 5 and about 30. The R group can be located in the para or ortho position.
Preferably, R is a C 9 to C 21 alkyl group, R 2 is an oxypropylene group, m=1, and n is a number between about 9 and about 15. In another preferred embodiment, R is a C 12 to C 21 alkyl group, R 2 is an oxypropylene group, m=0, and n is a number between about 9 and about 15.
The most preferred polyetheramine, nonylphenoxypolyoxypropyleneamine, can be represented by the formula: ##STR6## Nonylphenoxypolyoxypropyleneamine is available from Texaco Chemical Company. It should be noted that the polyetheramines useful in the present invention can have two nonyl groups substituted onto the phenyl ring. In fact, it is likely that commercially available nonylphenoxypolyoxypropyleneamine contains at least some of the di-nonyl substituted phenyl ring versions of this compound. In such cases, the second nonyl group is located in the ortho position relative to the bulk of the molecule.
Ethylene carbonate is commercially available from the Texaco Chemical Company.
The allophonate esters of the present invention can be prepared via the following reaction. In step one a polyetheramine is heated with urea at a temperature of about 130° C. for about 6-15 (preferably about 6) hours with stirring, under a nitrogen sparge to remove the evolved ammonia. After cooling, the mixture is filtered free of unreacted urea. The cooling and filtering steps are optional.
In step two, the polyether urea product of step one is reacted with ethylene carbonate at a temperature of about 130° C. for about 1-15 (preferably about 3) hours with stirring. The reaction mixture is filtered free of unreacted reactants, and stripped under vacuum at about 80° C. for about an hour. The product is an allophonate ester of the present invention.
The synthesis can also be performed in reverse order, i.e., the ethylene carbonate can be reacted with urea in the first step and the product of this first reaction can then be reacted with the polyether amine in the second step.
All of the reactions described above can be conducted in solution in hydrocarbon type heavy oils (e.g., SNO-600, SNO-850, etc.) Preferably, the reactants are employed in the stoichiometric amount, i.e., 1:1:1.
The Motor Fuel Composition
The motor fuel composition of the present invention comprises a major portion of a hydrocarbon fuel boiling in the gasoline range between 90° F. and about 370° F., and a minor portion of the allophonate ester additive of the present invention sufficient to reduce the formation of deposits on intake valves.
Preferred base motor fuel compositions are those intended for use in spark ignition internal combustion engines. Such motor fuel compositions, generally referred to as gasoline base stocks, preferably comprise a mixture of hydrocarbons boiling in the gasoline boiling range, preferably from about 90° F. to about 370° F. This base fuel may consist of straight chain or branched chain paraffins, cycloparaffins, olefins, aromatic hydrocarbons, or mixtures thereof. The base fuel can be derived from, among others, straight run naphtha, polymer gasoline, natural gasoline, or from catalytically cracked or thermally cracked hydrocarbons and catalytically reformed stock. The composition and octane level of the base fuel are not critical and any conventional motor fuel base can be employed in the practice of this invention. In addition, the motor fuel composition may contain any of the additives generally employed in gasoline. Thus, the fuel composition can contain anti-knock compounds such as tetraethyl lead compounds, anti-icing additives, and the like.
In a broad embodiment of the fuel composition of the present invention, the concentration of the additive is about 25 to about 125 PTB (pounds per thousand barrels of gasoline base stock). In a preferred embodiment, the concentration of the additive composition is about 50 to about 125 PTB. In a more preferred embodiment, the concentration of the additive composition is about 80-100 PTB.
The additive of the present invention can also be used effectively with heavy oils such as SNO-600, SNO-850, etc., or with synthetics such as polypropylene glycol (1000 m.w.), at concentrations of 30-100 PTB, and 65 PTB in particular.
The additive of the present invention is effective in very small concentrations and, therefore, for consumer end use it is desirable to package it in dilute form. Thus, a dilute form of the additive composition of the present invention can be provided comprising a diluent e.g., xylene and about 1 to about 50 wt. % of the additive.
The preparation and advantages of the allophonate esters of the present invention are further illustrated by the following examples.
EXAMPLE 1
Preparation of N-nonylphenoxypolypropoxy Allophonate Ester of 2-Hydroxy Ethane
200 g (0.2 mole) of polyetheramine with molecular weight of about 1000 was reacted with 19.8 g (0.33 mole) urea at 130° C. for 2 hours. After 2 hours, 26.4 g (0.3 mole) of ethylene carbonate was introduced at 130° C. and reacted at this temperature an additional 6 hours. The reaction product was filtered hot and then vacuum stripped at 80° C. for 2 hours. The final clear product weighed 204.7 grams. It had the following analysis:
Nitrogen 3.50 wt %
TBN 12.78
Molecular weight (by Gel Phase Chromatography) 990
The structure, see Figure I, was confirmed by infrared spectroscopy and nuclear magnetic resonance.
EXAMPLE 2
Intake Valve Keep Clean Test
The motor fuel composition of the present invention is advantageous in that it reduces intake valve deposit formation. The advantage of the instant invention in controlling intake valve deposit formation has been shown by the comparison of the performance of motor fuel compositions of the present invention and a motor fuel containing a commercially available detergent package.
The following fuel compositions were subjected to Honda Generator - IVD "Keep Clean" testing. Fuel A contained 100 PTB of the product of Example 1 as a detergent additive and Fuel B contained 60 PTB of a commercially available gasoline additive package. The base fuel used in each fuel composition was a commercial unleaded fuel with 45% aromatics, 6% olefins, and the remainder paraffins. The octane rating, calculated as the average of research and motor octane ratings was 87. Base fuel boiling point data is listed in Table I as follows:
TABLE I______________________________________Base Fuel______________________________________initial boiling point 99° F.50% point 253° F.90% point 410° F.end point 415° F.______________________________________
The Honda Generator Test employed a Honda ES6500 generator with the following specifications:
TABLE II______________________________________Honda ES6500 Generator______________________________________Type: 4-stroke, overhead cam, 2-cylinderCooling system: Liquid-cooledDisplacement: 369 cubic cm. (21.9 cu. in)Bore × stroke: 56 × 68 mm (2.3 × 2.7 in)Maximum Horsepower: 12.2 HP/3600 rpmMaximum Torque: 240 kg-cm (17.3 ft-lb)/3000 rpm______________________________________
Each generator was equipped with an auto-throttle controller to maintain the rated speed when load was applied. Load was applied to each generator by plugging in a water heater. Various loads were simulated by changing the size of the water heaters connected to the generator.
The procedure for the Honda Generator Test is as follows. The test was started with a new or clean engine (clean valve, manifold, cylinder head, combustion chamber) and a new charge of lubricant. The generator was operated for 80 hours on the fuel to be tested following the test cycle of 2 hours at 1500 Watt load and 2 hours at 2500 Watt load, both at 3600 r.p.m. The engine was thereafter disassembled and the cylinder head stored, with valve spring and seal removed, in a freezer overnight at O° F.
IV Stickiness Test
A trained rater quantified the effort to push open the intake valves by hand. The amount of effort was correlated to valve sticking problems in vehicles: i.e., valves that could not be pushed open by hand generally correlated with cold starting problems in vehicles.
CRC IV Test
The intake system components (valve, manifold, cylinder head) and combustion chamber were rated visually according to standard Coordinating Research Council (CRC) procedures (scale from 1-10:1=dirty; 10=clean). The performance of the test fuel was measured in part by the cleanliness of the intake system components.
Fuels A and B were subjected to the Honda Generator intake valve keep clean test procedure. The results are summarized in Table III:
TABLE III______________________________________ IVFUEL CRC IV Wt., mg., IV Stickiness______________________________________A 9.6 0.013 NoB 6.03 0.269 No______________________________________
The additive gasoline of the present invention, Fuel A, demonstrated excellent CRC valve ratings, virtually no deposits on the intake valves (13 mg or less) and exhibited no stickiness. The fuel containing the commercially available additive package showed a poor CRC rating and gave 269 mg intake valve deposits. Therefore the allophonate ester of the present invention demonstrates excellent detergency and intake valve detergency keep clean properties.
EXAMPLE 6
Thermal Gravimetric Analysis (TGA)
A sample of the allophonate ester of Example 1 was analyzed for rate of thermal decomposition using TGA analysis, in order to determine whether they will increase combustion chamber deposits. The procedure used was the Chevron test method, which involves heating the additive compound in air at a rapid rate and measuring its volatility at 200° C. and 295° C. The test method is more specifically described as follows:
The sample is heated to 200° C., kept at this temperature for 30 minutes, and then heated to 295° C., where it is kept for an additional 30 minutes. The weight of the sample, (initially about 20 mg) is recorded at the start, after the first heating period and after the final heating period. The difference in weights from the start to 200° C., and from 200° C. to 295 ° C. is recorded and the percent loss, i.e., volatility, is calculated. (The final weight at 295° C. is also considered residue.) The heating is done under a flow of air at 60 cc/min.
The following results were obtained:
TABLE IV______________________________________ % Volatilized Residue (in Air) (wt. %)Run Additive 200° C. 295° C. 295° C.______________________________________1 Product of Example 1- 15 90 10 N-nonylphenoxypoly- isopropoxy allophonate ester of 2-hydroxy ethane2 OGA-472 ™ 34.5 62.8 37.2______________________________________
The test results for runs 1 and 2 show that at 295 ° C., 90% of the additive of the present invention had thermally decomposed and volatilized, compared to only 62.8% for a PIB containing derivative such as OGA-472™. These results indicate that the additives of the present invention should leave only small amounts of combustion chamber deposits during the actual engine operation, and therefore will not contribute to octane requirement increase. | The present invention provides a novel class of compounds, useful as gasoline detergent additives, comprising hydrocarbyloxypolyether allophonate esters of 2-hydroxy ethane. The present invention also provides a motor fuel composition containing the novel allophonate esters and further provides a method of synthesizing the allophonate esters of the present invention. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of cold storage systems, and more particularly to increasing density of Massive Array of Idle Disk (MAID) systems.
[0002] Cold storage systems often utilize MAID systems with multiple (e.g., hundreds to thousands) hard drives, most of which are powered down at any given time, to provide nearline storage of data. In some examples, MAID systems are used in “write once, read occasionally” applications, where increased storage density and decreased cost are traded for increased retrieval latency and decreased redundancy. Often, MAID systems are used to store cold data that is infrequently accessed. In some cases, cold data is kept for regulatory or historical reasons. In MAID applications, the increased latency, caused by waiting for an idle drive to power up, is traded for the increased density and lower power consumption of keeping most drives in an idle (i.e., unpowered) state. For example, when a hard drive is not actively being accessed, the storage device can be shut down. Once a drive is shut down it is not consuming power or generating heat, allowing the drive to begin to cool down.
SUMMARY
[0003] According to one embodiment of the present invention, a method for managing racks of an increased density MAID system is provided. The method includes identifying, by one or more processors, a first rack in a data center corresponding to a request, wherein the data center comprises a plurality of racks, and wherein the request is one of: a request to change a power status of a storage device of the first rack; or a request to service the first rack; calculating, by one or more processors, an optimal placement for the plurality of racks to satisfy a condition of the request; and moving, by one or more processors, one or more racks from a first location to a second location, based on the calculated optimal placement of the one or more racks.
[0004] According to another embodiment of the present invention, a computer program product for managing racks of an increased density MAID system is provided. The computer program product comprises a computer readable storage medium and program instructions stored on the computer readable storage medium. The program instructions include program instructions to program instructions to identify a first rack in a data center corresponding to a request, wherein the data center comprises a plurality of racks, and wherein the request is one of: a request to change a power status of a storage device of the first rack; or a request to service the first rack; program instructions to calculate an optimal placement for the plurality of racks to satisfy a condition of the request; and program instructions to move one or more racks from a first location to a second location, based on the calculated optimal placement of the one or more racks.
[0005] According to another embodiment of the present invention, a computer system for managing racks of an increased density MAID system is provided. The computer system includes one or more computer processors, one or more computer readable storage media, and program instructions stored on the computer readable storage media for execution by at least one of the one or more processors, the program instructions comprising: program instructions to program instructions to identify a first rack in a data center corresponding to a request, wherein the data center comprises a plurality of racks, and wherein the request is one of: a request to change a power status of a storage device of the first rack; or a request to service the first rack; program instructions to calculate an optimal placement for the plurality of racks to satisfy a condition of the request; and program instructions to move one or more racks from a first location to a second location, based on the calculated optimal placement of the one or more racks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a functional block diagram illustrating a computing environment, in accordance with an embodiment of the present invention;
[0007] FIG. 2 is a flowchart depicting operations for creating plenum spaces for cooling racks in a MAID system, on a computing device within the computing environment of FIG. 1 , in accordance with an embodiment of the present invention;
[0008] FIG. 3 is a flowchart depicting operations for creating plenum spaces for maintenance of racks in a MAID system, on a computing device within the computing environment of FIG. 1 , in accordance with an embodiment of the present invention;
[0009] FIG. 4 a is a block diagram of a top view of components of a MAID system, in accordance with an embodiment of the present invention;
[0010] FIG. 4 b is a block diagram of a top view of components of a MAID system, in accordance with an embodiment of the present invention; and
[0011] FIG. 5 is a block diagram of components of a computing device executing operations for creating plenum spaces between racks in a MAID system, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0012] An embodiment of the present invention recognizes a benefit in increasing density of MAID systems. Commonly, MAID systems are cooled by a combination of air flow around the storage device and powering down the storage devices, when not in use. In some instances, increasing the density of the MAID system (i.e., increasing the number of storage devices in a given physical space) can impede the air flow in the system, limiting the cooling potential within the system.
[0013] An embodiment of the present invention provides automated creation of plenum spaces for cooling and maintenance of MAID systems. In some embodiments, the automated creation of plenum spaces can accommodate an increased storage device density while sustaining cooling requirements for the system. In other embodiments, the creation of service lanes is used to provide access to hard drive stacks within the MAID system. For example, service lanes can be used to provide access to racks that require maintenance.
[0014] The present invention will now be described in detail with reference to the Figures. FIG. 1 is a functional block diagram illustrating a computing environment, in accordance with an embodiment of the present invention. For example, FIG. 1 is a functional block diagram illustrating computing environment 100 . Computing environment 100 includes computing device 102 and client device 110 connected over network 120 . Computing device 102 includes MAID control program 104 .
[0015] In various embodiments, computing device 102 is a computing device that can be a standalone device, a server, a laptop computer, a tablet computer, a netbook computer, a personal computer (PC), or a desktop computer. In another embodiment, computing device 102 represents a computing system utilizing clustered computers and components to act as a single pool of seamless resources. In general, computing device 102 can be any computing device or a combination of devices with access to client device 110 , and with access to and/or capable of executing MAID control program 104 . Computing device 102 may include internal and external hardware components, as depicted and described in further detail with respect to FIG. 5 .
[0016] In this exemplary embodiment, MAID control program 104 is stored on computing device 102 . In other embodiments, MAID control program 104 may reside on another computing device, provided that it can access and is accessible by each of user interface 106 , controller 112 , and sensor 114 . In yet other embodiments, MAID control program 104 may be stored externally and accessed through a communication network, such as network 120 . Network 120 can be, for example, a local area network (LAN), a wide area network (WAN) such as the Internet, or a combination of the two, and may include wired, wireless, fiber optic or any other connection known in the art. In general, network 120 can be any combination of connections and protocols that will support communications between computing device 102 and client device 110 , in accordance with a desired embodiment of the present invention.
[0017] MAID control program 104 operates to determine the position of racks, which house one or more storages devices, within a MAID system. In one embodiment, MAID control program 104 positions racks to define one or more plenum spaces. In some embodiments, the plenum spaces are used to increase the cooling of drives within a MAID system. In other embodiments, MAID control program 104 positions racks to define one or more service lanes. In some embodiments, service lanes allow for physical access to one or more racks for system maintenance. For example, one or more racks can be moved to create an access lane to replace or repair a drive within the MAID system.
[0018] Computing device 102 includes a user interface (UI) 106 , which executes locally on computing device 102 and operates to provide a UI to a user of computing device 102 . User interface 106 further operates to receive user input from a user via the provided user interface, thereby enabling the user to interact with computing device 102 . In one embodiment, user interface 106 provides a user interface that enables a user of computing device 102 to interact with MAID control program 104 of computing device 102 via network 120 . In various examples, the user interacts with MAID control program 104 in order to initiate movement of racks to create plenum spaces within a MAID system. In one embodiment, user interface 106 is stored on computing device 102 . In other embodiments, user interface 106 is stored on another computing device (e.g., client device 110 ), provided that user interface 106 can access and is accessible by at least MAID control program 104 .
[0019] In various embodiments of the present invention, client device 110 can be a laptop computer, a tablet computer, a netbook computer, a personal computer (PC), a desktop computer, a personal digital assistant (PDA), a smart phone, or any programmable electronic device capable of communicating with computing device 102 via network 120 . Client device 110 includes controller 112 and sensor 114 . In some embodiments, controller 112 and sensor 114 execute locally on client device 110 . In other embodiments, controller 112 and sensor 114 execute on another computing device (e.g., computing device 102 ), provided that each can access and is accessible by at least MAID control program 104 .
[0020] Controller 112 receives instructions from MAID control program 104 to move racks within the MAID system. In some embodiments, controller 112 uses MAID control program 104 instructions to move racks one dimensionally. In other embodiments, controller 112 uses MAID control program 104 instructions to move racks in two dimensions.
[0021] Sensor 114 monitors the MAID system and provides data to MAID control program 104 . In some embodiments, sensor 114 monitors the temperature of the MAID system. For example, sensor 114 can be one or more of thermometers placed throughout the MAID system. When one of the thermometers reads a temperature above a predetermined threshold, MAID control program 104 determines that one or more racks need to move to allow a hot rack to cool. For example, the hot rack may be identified based on the proximity of the hot rack to a thermometer reading a temperature above a threshold.
[0022] FIG. 2 is a flowchart depicting operations for creating plenum spaces within a MAID system for cooling MAID racks, on a computing device within the computing environment of FIG. 1 , in accordance with an embodiment of the present invention. For example, FIG. 2 is a flowchart depicting operations 200 of MAID control program 104 , on computing device 102 within computing environment 100 .
[0023] In step 202 , MAID control program 104 identifies a change to the power status of a storage device in the MAID system. In some embodiments, the identification is a result of a user attempt to access information stored on a storage device. In these embodiments, where the information is stored on a storage device that was not already powered up (e.g., due to inactivity), the storage device needs to be powered up to allow access to information stored on the storage device. In other embodiments, the identification is a result of the termination of access to a storage device. For example, when access to information on a storage device is no longer needed, the storage device can be powered down to save energy. In some embodiments, the identification is a result of an interaction with user interface 106 . For example, an operator of the MAID system indicates that a storage device needs to be powered up or powered down via user interface 106 . In still other embodiments, the identification is a result of a reading from sensor 114 . For example, a thermometer in the proximity of a hot rack reads a temperature above a threshold. Storage devices, housed in racks, within the MAID system have cooling requirements, which are satisfied, in some embodiments, by increasing the space between racks. In some embodiments, increasing the space between racks allows for greater air flow.
[0024] In step 204 , MAID control program 104 calculates the optimal placement of racks within the MAID system. In some embodiments, the optimal placement of racks is based on cooling requirements of a storage device. In these embodiments, MAID control program 104 determines the optimal placement of one or more racks based on cooling conditions. In some embodiments, optimal placement is based on industry or device standards. In other embodiments, optimal placement is based on a desired air flow. For example, MAID control program 104 determines a desired air flow for a storage device (e.g., based on the temperature of the storage device) and determines a placement of the rack based on the air flow from an air vent and the space between adjacent racks. In still other embodiments, optimal air flow is based, at least in part, on the temperatures of adjacent storage devices. In some embodiments, a cooling condition includes an air flow required to cool a storage device. In other embodiments, the cooling condition includes a requirement for amount of plenum space surrounding a rack. In some embodiments, a finite amount of space exists to accommodate space between racks. In these embodiments, MAID control program 104 may have to prioritize the cooling of one or more storage device. In some embodiments, the racks of the MAID system are arranged in a grid pattern. For example, the racks are arranged in columns and rows. In some embodiments, the racks move in one dimension. For example, a rack can move from one column to another, but stays within the same row. In some examples, rack movement is in whole integers, being multiples of the width of a rack. For example, a rack moves from one column to another column (i.e., the rack cannot reside between columns), to maintain the grid pattern. In other embodiments, rack movement can be in partial integers, being fractions of the width of a rack (e.g., racks can be placed between columns in the grid pattern), to accommodate the cooling of storage devices in multiple racks in a row at once.
[0025] In some examples, storage devices housed in more than one rack in the MAID system need to be cooled simultaneously. In these examples, MAID control program 104 may need to prioritize the cooling of one rack of storage devices over another, where space limitations prevent the racks from being fully isolated. For example, priority of cooling one rack of storage devices over another may be based on length of time each storage device has been powered up (e.g., the longer a storage device is powered up the greater the need for cooling), the temperature readings surrounding each rack (e.g., racks with a higher temperature may be given priority), temperature readings or power status of storage devices in surrounding racks (e.g., multiple hot racks in close proximity can impede rack cooling), etc. In some embodiments, priority of cooling one rack of storage devices over another is based on the cooling conditions for each storage device. In some embodiments, the optimal placement of a rack will provide plenum spaces on two or more sides of the rack. In other embodiments, the optimal placement will provide a single plenum space between two hot racks. In some embodiments, MAID control program 104 uses information from sensor 114 to determine rack placement. For example, where sensor 114 is one or more of thermometers, MAID control program 104 bases the optimal placement on the temperature readings from the thermometer(s).
[0026] In decision 206 , MAID control program 104 determines whether the optimal placement can be satisfied. In some example, MAID control program 104 may not be able to move each of the racks to the calculated optimal placement. For example, where there is a mechanical failure within the MAID system, some of the racks may not be able to move. In another example, some racks cannot move when storage devices housed within are in use. In this example, the storage devices within the racks must be powered down before the rack can be moved. If MAID control program 104 determines that the optimal placement can be satisfied (decision 206 , YES branch), then MAID control program 104 calculates the number of moves required for the optimal placement (e.g., the number of racks that need to be moved for the optimal placement). If MAID control program 104 determines that the optimal placement cannot be satisfied (decision 206 , NO branch), then MAID control program 104 returns an error. In some embodiments, in response to returning an error, MAID control program 104 returns to step 204 to calculate a new placement plan for the racks.
[0027] In step 208 , MAID control program 104 powers down storage devices in the racks. In some embodiments, MAID control program 104 prevents moving racks with a storage device that is powered up (e.g., in order to reduce the risk of damage to the storage device). In this case, MAID control program 104 powers down a storage device to be moved by issuing commands to the powered up storage devices. In some embodiments, the command to power down is issued directly to the storage device. In other embodiments, the command to power down the storage device is issued to a server or computing device that controls the power settings of the storage device. In some embodiments, the storage devices in the racks that need to be moved are already powered down. In still other embodiments, the racks can be moved while the storage devices are powered up. In embodiments where the storage devices do not need to be powered down to move, MAID control program 104 skips step 208 .
[0028] In step 210 , MAID control program 104 moves racks. MAID control program 104 sends directions to controller 112 to move one or more racks within the MAID system. In some embodiments, the racks are on wheels which move one-dimensionally along a track.
[0029] In some embodiments, moving racks includes modifying air flow through vents placed throughout the MAID system. In some embodiments, the air flow is increased or decreased. In other embodiments, the direction of the air flow is modified. For example, baffles within the air vents can be moved to change the direction of the air flow. Modifying the air flow through the vents allows the air to be directed towards racks with storage devices requiring the most cooling.
[0030] In step 212 , MAID control program 104 powers up storage devices in the racks. Racks containing storage devices with information requested by a user are powered up. In embodiments where storage devices have to be powered down before they are moved, the storage devices are powered on after they are moved to the optimal placement. Powering up storage devices allows users to access information stored on storage devices in the racks. In some embodiments, where the request is to power down a storage device, there is not a need to restore power to the storage device after the racks have been moved. In these embodiments, MAID control program 104 skips step 212 .
[0031] In step 214 , MAID control program 104 returns an error message. Where MAID control program 104 cannot move racks to satisfy the optimal placement, MAID control program 104 delivers an error message to the user via user interface 106 . In some embodiments, the optimal placement cannot be satisfied because a storage device in the rack is in use and cannot be powered down. In other embodiments, the optimal placement cannot be satisfied due to a mechanical failure within the MAID system. In still other embodiments, the optimal placement cannot be satisfied due to emergent cooling needs elsewhere in the MAID system. In some embodiments, the error message includes a description as to why the optimal placement cannot be satisfied. In some embodiments, MAID control program 104 powers down one or more storage devices to avoid overheating, where optimal placement cannot be achieved.
[0032] FIG. 3 is a flowchart depicting operations for creating plenum spaces within a MAID system for maintenance, on a computing device within the computing environment of FIG. 1 , in accordance with an embodiment of the present invention. For example, FIG. 3 is a flowchart depicting operations 300 of MAID control program 104 , on computing device 102 within computing environment 100 .
[0033] In step 302 , MAID control program 104 identifies a rack to be serviced. In some embodiments, the identification is based on a request to service a storage device located within a rack in the MAID system. In some embodiments, the identification is based on the receipt of an error message during operations 200 . For example, a request can be part of routine maintenance. In another example, a request can be made in response to an error message (e.g., in response to step 214 of operations 200 ). In other embodiments, the request is received in response to a user interaction with user interface 106 . For example, a user indicates that a rack needs to be serviced by selecting the rack on a graphical user interface.
[0034] In step 304 , MAID control program 104 calculates the optimal placement of racks for the service request. In general, a lane is created to allow a rack to be serviced. For example, the MAID system has access paths around one or more sides of the perimeter of the racks. A lane is created by creating a plenum space from the access path to the rack requiring service.
[0035] In decision 306 , MAID control program 104 determines whether the request can be satisfied. In some embodiments, storage devices within the racks need to be powered down before they can be moved. In these embodiments, a request cannot be satisfied where a storage device is in use. For example, a user may be accessing data on a storage device within a rack and powering down the storage device would disrupt the access to the information. If MAID control program 104 determines that the request can be satisfied (decision 306 , YES branch), then MAID control program 104 moves racks to create a service lane (step 314 ). If MAID control program 104 determines that the request cannot be satisfied (decision 306 , NO branch), then MAID control program 104 determines whether the request is an emergency (decision 308 ).
[0036] In decision 308 , MAID control program 104 determines whether the request is an emergency. In some cases, service to a rack may be a higher priority than a user's access to information stored on a storage device in the rack. For example, damage to a rack may prevent the rack from moving on the tracks within the MAID system. In another example, damage to a storage device within the rack can prevent retrieval of required data. If MAID control program 104 determines that the request is an emergency (decision 308 , YES branch), then MAID control program 104 calculates the minimum number of storage devices to power down (step 310 ). If MAID control program 104 determines that the request is not an emergency (decision 308 , NO branch), then a constraint is added to the next scheduled move to permit the maintenance (step 318 ).
[0037] In step 310 , MAID control program 104 calculates the minimum number of storage devices that need to be powered down to complete the service request. In some embodiments, powering down a storage device can affect a user's access to information. To minimize user interruptions, MAID control program 104 determines a rack configuration that affects the least number of powered-up storage devices. In some embodiments, user access to a storage device in one rack may take precedence over user access to other storage devices. In these embodiments, MAID control program 104 may determine a rack configuration which requires more storage devices to be powered down, allowing the user to maintain access to the needed information. Based on the calculations, MAID control program 104 determines a rack configuration. In step 312 , MAID control program 104 powers down the affected storage devices, based on the rack configuration.
[0038] In step 314 , MAID control program 104 moves racks based on the rack configuration. MAID control program 104 sends directions to controller 112 to move one or more racks within the MAID system. In some embodiments, the racks are on wheels which move one-dimensionally along a track. In embodiment where moving racks includes modifying air flow through vents, the air flow may be modified. For example, air flow to vents located near the service lane can be shut off.
[0039] In step 316 , MAID control program 104 powers up storage devices. In some embodiments, storage devices in racks unaffected by the maintenance can be powered on to provide a user to access information located on the storage devices. In other embodiments, the storage devices in the racks are not powered up until the maintenance is finished. In these embodiments, one or more racks can be moved before the storage devices are powered up.
[0040] In step 318 , MAID control program 104 adds a constraint to the next scheduled move. Where a service request is made that affects powered-up storage devices, but is not an emergency, the request is delayed. A constraint is added to the next scheduled move, allowing a rack to be serviced without disrupting a user's access to information on a storage device.
[0041] FIG. 4 a is a block diagram of a top view of components of a MAID system, generally designated 400 a , in accordance with an embodiment of the present invention. In one embodiment, MAID system 400 a is representative of a system controlled by MAID control program 104 . For example, FIG. 4 a is a block diagram of racks controlled by executing operation of MAID control program 104 .
[0042] MAID system 400 a is representative of a system where all storage devices in racks 404 are powered down. For example, MAID system 400 a represents a system where there is not a need to cool any of the storage devices. MAID system 400 a includes racks 404 and plenum space 402 . Each rack 404 includes one or more storage devices. In some embodiments, the storage devices are stored in a powered down or standby state. In these embodiments, racks 404 require less air flow to maintain a cool temperature, allowing racks 404 to be stored close to each other. In some embodiments, when storage devices within racks 404 are in the powered down state, plenum spaces 402 are located on the exterior, or perimeter, of MAID system 400 a . In other embodiments, plenum spaces 402 are located throughout MAID system 400 a . For example, plenum space 402 can be arranged in a way that creates sections of racks 404 , where plenum space 402 creates an access lane between the sections. In some embodiments, racks 404 are placed on wheels, allowing racks 404 to move. In some embodiments, rails are placed throughout MAID system 400 a , which act as tracks for racks 404 to move along. For example, the rails are attached to the floor or ceiling of MAID system 400 a and allow racks 404 to move one-dimensionally (e.g., to the left or right). Racks 404 can be moved into plenum spaces 402 . In some embodiments, racks 404 are moved to create a plenum space 402 next to a rack that needs to be cooled.
[0043] In addition to creating plenum spaces, an embodiment of the invention includes vents (e.g., in the floor or the ceiling of MAID system 400 a ) that provide air flow to racks 404 . In one embodiment, the vents include baffles that can be directed toward a rack to provide additional cooling. For example, MAID control program 104 issues instructions to controller 112 , which moves the baffles to modify the direction of the airflow. In some embodiments, MAID system 400 a includes an air handler controller that can open and close the baffles to direct and control the air flow.
[0044] FIG. 4 b is a block diagram of a top view of components of a MAID system, generally designated 400 b , in accordance with an embodiment of the present invention. In one embodiment, MAID system 400 b is representative of a system controlled by MAID control program 104 . For example, FIG. 4 b is a block diagram of racks controlled by executing operation of MAID control program 104 .
[0045] MAID system 400 b is exemplary of a system that has several hot racks 406 . MAID system 400 b also include racks 404 and plenum spaces 402 . In this example, racks 404 have been moved along rails within the system to create plenum spaces 402 around hot racks 406 .
[0046] FIG. 5 is a block diagram of components of a computing device, generally designated 500 , in accordance with an embodiment of the present invention. In one embodiment, computing device 500 is representative of computing device 102 . For example, FIG. 5 is a block diagram of computing device 102 within computing environment 100 executing operations of MAID control program 104 .
[0047] It should be appreciated that FIG. 5 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environment may be made.
[0048] Computing device 500 includes communications fabric 508 , which provides communications between computer processor(s) 502 , memory 504 , cache 506 , persistent storage 510 , communications unit 514 , and input/output (I/O) interface(s) 512 . Communications fabric 508 can be implemented with any architecture designed for passing data and/or control information between processors (such as microprocessors, communications and network processors, etc.), system memory, peripheral devices, and any other hardware components within a system. For example, communications fabric 508 can be implemented with one or more buses.
[0049] Memory 504 and persistent storage 510 are computer-readable storage media. In this embodiment, memory 504 includes random access memory (RAM). In general, memory 504 can include any suitable volatile or non-volatile computer readable storage media. Cache 506 is a fast memory that enhances the performance of processors 502 by holding recently accessed data, and data near recently accessed data, from memory 504 .
[0050] Program instructions and data used to practice embodiments of the present invention may be stored in persistent storage 510 and in memory 504 for execution by one or more of the respective processors 502 via cache 506 . In an embodiment, persistent storage 510 includes a magnetic hard disk drive. Alternatively, or in addition to a magnetic hard disk drive, persistent storage 510 can include a solid state hard drive, a semiconductor storage device, read-only memory (ROM), erasable programmable read-only memory (EPROM), flash memory, or any other computer readable storage media that is capable of storing program instructions or digital information.
[0051] The media used by persistent storage 510 may also be removable. For example, a removable hard drive may be used for persistent storage 510 . Other examples include optical and magnetic disks, thumb drives, and smart cards that are inserted into a drive for transfer onto another computer-readable storage medium that is also part of persistent storage 510 .
[0052] Communications unit 514 , in these examples, provides for communications with other data processing systems or devices, including resources of network 120 . In these examples, communications unit 514 includes one or more network interface cards. Communications unit 514 may provide communications through the use of either or both physical and wireless communications links. Program instructions and data used to practice embodiments of the present invention may be downloaded to persistent storage 510 through communications unit 514 .
[0053] I/O interface(s) 512 allows for input and output of data with other devices that may be connected to computing device 500 . For example, I/O interface 512 may provide a connection to external devices 516 such as a keyboard, keypad, a touch screen, and/or some other suitable input device. External devices 516 can also include portable computer-readable storage media such as, for example, thumb drives, portable optical or magnetic disks, and memory cards. Software and data used to practice embodiments of the present invention (e.g., software and data) can be stored on such portable computer-readable storage media and can be loaded onto persistent storage 510 via I/O interface(s) 512 . I/O interface(s) 512 also connect to a display 518 .
[0054] Display 518 provides a mechanism to display data to a user and may be, for example, a computer monitor, or a television screen.
[0055] The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
[0056] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
[0057] Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
[0058] Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
[0059] Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
[0060] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
[0061] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0062] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
[0063] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The terminology used herein was chosen to best explain the principles of the embodiment, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. | In an approach to managing racks in a MAID system, a first rack of a data center is identified. The data center comprises a plurality of racks. The first rack corresponds to a request. The request is one of (i) a request to change a power status of a storage device of the first rack or (ii) a request to service the first rack. An optimal placement of the plurality of racks is calculated to satisfy a condition of the request. One or more of the racks are moved from a first location to a second location, based on the calculated optimal placement of the one or more racks. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to the general field of airstrips for aircrafts and, in particular, to floating structures adapted for use as bases for landing and take-off.
2. Description of the Prior Art
Ever since humankind embarked in the pursuit of flight, the question of providing suitable means and places for taking off and landing has been of paramount importance. As commercial and military aviation developed, it became increasingly critical to be able to land at specific destinations safely and efficiently, so that large numbers of aircrafts could be accommodated. Thus, civil and military aviation establishments have relied over the years on thousands of airports strategically located on land around the world and on airplane carriers at sea.
Modern airports have become mazes of runways, hangars and terminals used to move millions of people and tons of cargo material every day. Problems of congestion, security, safety, noise, pollution, and distance from residential areas all contribute to sometime contradictory solutions for urban airports. The high traffic volume of a modern metropolis requires sufficient runways to take care of very frequent landings and take-offs. Therefore, even smaller airports have multiple runways spread out over several square kilometers of premium land. In addition, since the optimal direction for both take-off and landing maneuvers changes with the direction of the prevailing wind, multiple sets of intersecting runways are usually provided, creating a system of paved roads many kilometers long in all directions. This causes airplanes to taxi over long distances before and after each flight, wasting fuel and passenger time and contributing to environmental pollution.
One other aspect of urban airports is that they need to be accessible and yet far enough from residential areas to avoid unacceptable levels of noise. As a result, either they are placed tens of kilometers from town or the allowed flight patterns are adjusted to avoid maneuvers directly over populated areas. The former case complicates the logistics of travel for the average passenger who has to face a relatively time-consuming journey to and from the airport in addition to flight time. The flight pattern constraints are particularly significant in bad weather because they force the performance of suboptimal landings as a result of the restrictions, increasing the danger of mid-air collisions and problems on impact.
Various inventions have been described in the prior art to address particular air navigation needs. For example, U.S. Pat. No. 1,513,591 to Dorr et al. (1924) discloses the idea of a floating hangar for airships based on a single-hull design. The invention first introduces the concept of utilizing the unitary construction of a ship's hull to provide the buoyancy required for supporting the shed above water. Flood chambers are used to elevate or lower the bottom of the hanger to the desired elevation with respect to water level. The structure is provided with a single-point anchoring system that permits the rotation of the shed to face the wind. Although the purpose of this feature is not expressly stated, it was presumedly intended for stability and for facilitating the process of taking airships aboard.
U.S. Pat. No. 1,854,336 to King (1932) describes a floating landing strip, seemingly a precursor to modern airplane carriers. The invention relates to a runway supported by multiple submergible pontoons that permit the raising or lowering of the unit. The structure is propelled and intended for navigation and anchoring on large bodies of water.
In U.S. Pat. No. 1,753,399 (1930), Blair describes an ocean-going aircraft-carrying structure with a system of hulls designed to reduce the impact of wave motion. The bulk of the volume of the hulls is under the water level, so that the impact of surface-water motion is minimized.
In U.S. Pat. No. 2,133,721 (1938), Seidman describes an airplane terminal having a submersed rotating platform for retrieving and releasing aquatic airplanes. The invention is directed at means for coordinating passenger and cargo traffic between land and arriving or departing hydroplanes.
U.S. Pat. No. 2,342,773 to Wellman (1944) discloses a landing platform formed on the surface of a body of water adjacent to a ship. The platform is made with material carried by the ship in rolled form and reeled offboard over the water to create a landing strip when needed. Inflatable compartments are provided for buoyancy.
U.S. Pat. No. 3,191,566 to Wilken et al. (1965) shows a water-borne craft for airplanes capable of attaining the normal speed of a plane during landing. As a result of this feature, which is achieved with hydrofoil technology, the vessel is able to provide a relatively stationary target for landing airplanes and to enhance the take-off air velocity of departing aircrafts.
Finally, U.S. Pat. No. 4,744,529 to Clarke (1988) teaches a system for recovering disabled airplanes in water. It consists of a large net having sufficient size to accommodate an aircraft during landing in water and comprises floats for supporting the net and craft. The system is designed for emergency operation in conjunction with a tug boat.
None of the concepts described by the prior art address the above-mentioned problems of modern airports, nor suggest solutions to them. Therefore, there still exists a need for a new type of airport that optimizes space utilization, safety, convenience, and efficiency of operation.
BRIEF SUMMARY OF THE INVENTION
It is therefore an objective of this invention to provide a new concept in airport design based on a floating structure located on a body of water in the proximity of an urban center, providing a water buffer between airstrips and residential areas in all directions, such that landings and take-offs may occur in all directions with minimal disturbance to populated areas.
Another objective of the invention is a structure that can be rotated to face the prevailing wind, so that a single set of parallel runways is sufficient to ensure optimal landing and take-off conditions at all times.
Another goal of the invention is a method of continuously monitoring and controlling the position of the platform to ensure its stability under all weather and water conditions.
A further objective of the invention is a modular approach to the design of the airport structure that is suitable for repairs, additions and modification over a long period of operation.
Another goal of the invention is a system of supporting hulls to provided the required buoyancy that is stable under all wave conditions and nearly unaffected by surface water motion.
Finally, another goal of the invention is the utilization of known scientific principles in combination with existing technology, including sensory, computing, control, communication and other devices, for the achievement of the above-stated objectives.
Thus, in accordance with these and other objectives, the floating airport of this invention consists of a multiple-deck structure floatingly supported by a plurality of independent hulls removably attached to the underside of the structure. A system of propulsion jets is provided on all sides to permit the motion of the structure in any desired direction relative to the water. The anchoring of the structure is achieved by constantly monitoring the horizontal position of its center of gravity and by utilizing the propulsion system to avoid any significant movement with respect to a predetermined location. The structure is allowed to rotate approximately around its vertical axis in order to align the runways with the prevailing winds and minimize the winds' impact on its stability, but any translational motion of the center of gravity of the airfield with respect to the water surface is minimized. As a result of this position control strategy, the structure is prevented from ever acquiring significant linear momentum in spite of its large mass and its position can be continuously controlled with relatively minor adjustments that are within the capability of its propulsion system.
Various other purposes and advantages of the invention will become clear from its description in the specification that follows, and from the novel features particularly pointed out in the appended claims. Therefore, to the accomplishment of the objectives described above, this invention consists of the features hereinafter illustrated in the drawings, fully described in the detailed description of the preferred embodiment and particularly pointed out in the claims. However, such drawings and description disclose only some of the various ways in which the invention may be practiced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in elevational side view the general configuration of a floating airport according to this invention consisting of an upper flight deck, a lower service deck and partially-submerged modular pontoons to support the deck structure afloat.
FIG. 2 is a schematic plan view of the upper flight deck of the invention.
FIG. 3 is a schematic plan view of the lower service deck of the invention.
FIG. 4 is a schematic plan view of the airport of the invention with cut-out portions to illustrate the layout of the supporting floating hulls.
FIG. 5 is an enlarged elevational view of the floating hulls of the invention to illustrate their longitudinal arrangement to form transverse access channels therebetween.
FIG. 6 is an enlarged perspective view of the floating hulls to illustrate their transverse arrangement to form longitudinal wind channels therebetween.
FIG. 7 is an enlarged perspective view of the propulsion-jet banks in the bow of the airport structure to illustrate their aerodynamic and hydrodynamic profile.
FIG. 8 is a schematic illustration of the control method of the invention.
FIG. 9 is an elevational side view of an alternative embodiment of the modular pontoon hulls of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The idea of designing an airport as a floating structure provides a simple theoretical solution to the problems of modern airfields. In practice, though, the implementation of the idea requires a solution to many yet unresolved issues that are critical to the viability of the concept. The main issue concerns a method of stably anchoring a floating structure of the size of an airport and safely securing its position under all weather conditions. Huge ships, such as aircraft carriers, have been built and are obviously routinely secured at will by anchoring systems that tie them to fixed structures such as piers or the ocean floor. These anchoring means, though, are not deemed reliable enough for a structure that is much larger and heavier than any ship ever built and that is not designed for travel, therefore lacking sufficient self-propulsion to meet emergency situations. The floating airport of the invention is contemplated to comprise at least two decks (although a single-deck construction would also fall within the scope of the invention) and span over an area about 1,000 meters wide and 5,000 meters long. No anchoring system has ever been devised that could be relied on for such a massive structure. The main contribution of this invention is to provide a means for safely and reliably securing the position of a floating airport.
Referring to the drawings, wherein the same reference numerals and symbols are used throughout to designate like parts, FIG. 1 illustrates in elevational side view the general configuration of a floating airport 10 according to this invention. The airport comprises multiple decks (two are shown in the figures and used in this disclosure for illustration, but more could obviously be utilized in equivalent fashion) supported by a plurality of floating pontoon hulls removably attached to the bottom of the lower deck. As seen in the figure, each pontoon hull 20 is partially submerged under the surface L of the body of water supporting the airport and provides buoyancy to the structure. As also illustrated in the schematic plan view of FIG. 2, an upper flight deck 30 contains multiple longitudinal runways 32 (shown with reference to directional arrows A1), at least one flight-control tower 34, helicopter pads 36, elevators 38 connecting the top deck 30 to a lower service deck 50, and several emergency/safety areas 40. The lower deck 50, shown in schematic plan view in FIG. 3, comprises passenger ticket/baggage areas 52, aircraft maintenance and repair facilities 54, airplane parking bays 56, airplane-tow traffic lanes 58 for arrival and departure, and at least one tow vehicle lane 60. The airplanes are moved to and from the upper deck 30 by means of the elevators 38 connecting the two decks. Passenger-boat landings 62 and service-boat landings 64 are provided along the perimeter of the lower deck for accessing the airport by boat from shore.
Cut-out portions of FIG. 4 show in plan view the layout of the floating hulls 20 within the structure of the airport. Each hull 20 consists of an independent module with sufficient buoyancy to support its own weight and also a portion of the weight of the multi-deck structure in proportion to the total number of hulls used. Each hull is rigidly mounted to the bottom of the lower deck and preferably placed adjacent to another hull transversely along the width of the airport, each pair of hulls being sufficiently apart from other pairs to form transverse access channels 22 therebetween that can be used for maintenance or for removing and replacing damaged hulls. As illustrated schematically in FIGS. 5 and 6, each hull 20 is removably secured to the lower deck 50 through posts or equivalent means 24 and each pair of hulls 20 is also uniformly spaced from laterally adjacent pairs to form longitudinal wind channels 26. This modular-hull concept is greatly preferred over a very large single hull because it facilitates movement of the overall structure by providing longitudinal and lateral channels of flow for the surrounding water, thus affording much greater flexibility of operation and maintenance. It is calculated that approximately 500 modular hulls (each about 150 meters long and 30 meters wide) would be required to support a five-kilometer long airport structure; a single-hull approach would make lateral movement of such a structure virtually impossible because of the huge barrier it would provide to water flow.
Although not specifically illustrated in the drawings, large-scale construction techniques well known to those skilled in the art can be used for removably mounting each hull 20 under the airport's multi-deck structure. As shown for illustration on one of the posts 24 of FIG. 6, a hydraulic cylinder 28 can be used to provide shock absorption, so that vertical surges of the water surface are prevented from causing rapid movements of the decks and resulting stresses on the structure are reduced. Each hull 20 is independently equipped with flood chambers 21 and pumps 23 (shown only on one hull for simplicity) to control its buoyancy, so that the air field may be raised or lowered with reference to the water level as weather or other conditions may warrant. Similarly, a hull may be lowered with respect to the others to facilitate its disengagement from the structure and removal via the access channels 22.
The propulsion system of the preferred embodiment of the invention consists of a plurality of large water jets disposed preferably in the fore and aft portions of the structure below the water surface. Because of the method adopted to control the position and stability of the floating structure, only a limited number of jets is critical to provide the necessary mobility. In operation, the airport is oriented to always face the prevailing wind W, so that forward propulsion is constantly required under normal conditions to overcome the force of the wind and keep the airport stationary. Thus, banks of pump-driven stern jets 70 adapted to eject directly to the rear of the structure (as indicated by arrows A2 in FIG. 4) are used to provide forward thrust. By mounting a series of wind generators 72 in strategic positions along the flight deck or on the sides of the structure, the force of the wind can concurrently be used to generate power for operating the jet pumps. Since the forward thrust required to maintain the longitudinal position of the airport and the power generated by the wind generators will both be proportional to the force of the wind at all times, additional power requirements are minimized by this combination. Banks of smaller bow jets 74 (propelling forward in the directon of arrows A3 in FIG. 4) are similarly used to thrust the structure 10 backwards in case of a sudden reversal of wind direction. Inasmuch as the direction of the wind is to be monitored and forecast continuously and used for controlling the attitude of the airport to ensure its is windward position at all times, thereby being normally subjected to a bow head wind, it is expected that these jets would rarely be used and are provided for emergency situations only.
Steering of the structure 10 is achieved by lateral jets which may be incorporated within the banks 70 and 74 in the stern and bow portions of the airport. When the wind direction changes or the structure rotates, thereby facing the wind either at port or starboard, steering for realignment can be achieved by jets that utilize water sucked in from one side of the bank and propel it toward the opposite side. As indicated by arrows A4 in FIG. 4, the stern jets are adapted to provide thrust in either lateral direction, depending on the wind, and are used so as to eject on the windward side with intake from the leeward side. Similarly, as indicated by arrows A5, the bow jets are adapted to provide thrust in either lateral direction as well, but they are used so as to eject on the leeward side with intake from the windward side. This mode of operation of the jet banks creates a torque approximately about the vertical axis of the structure 10 and permits its longitudinal realignment with the direction of the wind simply by rotation around that axis and without translational displacement of the center of gravity.
Because of the elongated shape of the structure 10 and the presence of the wind channels 26 between the water surface and the bottom of the lower deck 50, the wind itself provides a force tending to maintain the longitudinal alignment of the airport in windsock fashion. As illustrated in schematic form in FIG. 7, the banks of jets 74 in front of the airport are preferably shaped with an aerodynamic and hydrodynamic profile in the longitudinal direction, designed to direct the wind in fin fashion into the wind channels 26. This effect is magnified by providing greater wind resistance on the portion of the structure behind its vertical axis, such as by lateral shields 76 (see FIG. 1), than on the fore portion of the airport. In fact, the front portion of the airport is purposefully largely open and wind absorbing, while the rear portion is preferably completely walled in to help its rotation.
In addition, the effect of the wind is further enhanced by controlling the rotation of the structure so that the axis of rotation R (FIG. 1) is kept in front of its vertical axis G (which, by definition, passes through the center of gravity), thus creating a torque with an arm equal to the distance h between the axis of rotation and the center of gravity with a component in the direction required to effect the longitudinal realignment of the airport. It is estimated that a distance h of 250 meters would be optimal for a 5-km long deck structure; that is, the optimal lever arm for the purposes of this invention is estimated to be about 5 percent of the length of the structure. A range of zero to 25 percent may be used under different conditions. For example, the distance h may be changed during operation as a result of a change in the load distribution on the structure 10, such as when an unusual number of heavy airplanes is stowed away in a particular area like a maintenance hanger or the like. Thus, the control stability of the floating airport can be further improved by dynamically adapting the distance h to an optimal value for given weight-distribution and wheather conditions, as one skilled in the art would be able to determine.
The position-control and anchoring system for the floating airport of the invention is not based on structural ties with stationary monuments, such as massive foundations onshore or offshore or on the bottom B of the water body; rather, it is based on the continuous dynamic control of the position of the floating structure 10 while it is free to move on the surface of the water. This freedom of motion makes it possible to always orient the structure longitudinally into the wind, so that the runways are always disposed optimally for landing and take-off irrespective of the wind direction. The stern propulsion system provides the thrust necessary to keep the airfield stationary in the longitudinal direction against the wind, the magnitude of that thrust obviously varying from time to time depending on wind conditions. The position-control system comprises means for sensing the coordinates of the chosen axis of rotation R, illustrated as passing through an imaginary rotation hub H in FIG. 4, with respect to stationary reference points M (at least three are required for triangulation purposes) at the bottom of the water body (FIG. 1) or onshore. Such a system could be based on sonar, laser or equivalent technology, as is well known in the art of navigation, and would simply involve telemetry apparatus 78 for generating and/or receiving signals representative of distances from the stationary reference monuments M and data processing apparatus (shown as combined with referenced apparatus 78) for converting the distance information so acquired into a control signal for activating the proper jets to bring the hub H to its intended position. Angular deviations from the desired longitudinal attitude (which is always determined by the direction of the prevailing wind) would similarly be measured and appropriate action taken. By continuously monitoring the position of the hub H in relation to its intended stationary location and by making adjustments as soon as deviations are measured (both linear and angular), the location and orientation of the airfield can be controlled dynamically and kept substantially fixed, such as if it were rigidly anchored. This feature makes it possible to quickly adjust the orientation of the airstrips to match the wind direction without having to first release the structure from a rigid anchoring structure.
As illustrated for example in the diagram of FIG. 8, as a result of changes in water conditions or in wind direction from W to W', the hub H will from time to time deviate from its intended stationary position H' by a measurable linear distance d and the direction of the airfield will deviate from its intended wind alignment by an angle α. Lateral thrust would then be applied to the port and stern of the structure in the direction of arrows A6 and A7 to cause it to rotate windward about the vertical axis R through the hub H. At the same time, forward thrust in the direction of arrows A8 would be applied at the stern of the structure to move the hub H toward its intended location H'. By continuously monitoring the coordinates and orientation of the hub H with respect to H' and by immediately correcting both linear and angular deviations, the structure is never allowed to deviate substantially from its intended position. The maneuverability of the structure is also enhanced by the modular hull configuration described above, which facilitates the displacement of water that is necessary to allow the structure to move swiftly. Thus, though huge in size and mass, the floating airport never develops sufficient linear and/or angular momentum to overwhelm the capacity of its jet propulsion system; rather, it can be controlled continuously within narrow perturbations that ensure a very stable and substantially stationary operation of the structure as a floating airfield.
It is understood that many equivalent systems are possible within the scope of the present invention, with different embodiments, for example, for the decks, propulsion system, and navigation apparatus. In addition, it is understood that various other features would added to the basic concept for a floating airport in order to construct a fully functional facility. Fuel tanks and lines, sewer and waste disposal apparatus, and a water supply system, which may be based on a self-contained purification plant drawing water from the surrounding body, could all be incorporated within the hull structure below the lower deck. In addition, an emergency, stationary anchor could be provided for safety in case of total failure of the onboard systems. Such an anchor would necessarily be kept inoperative under normal conditions, such as by being slack within a radius greater than the normal deviation of the hub H from its stationary target H'.
It is well known that the top few feet of water are mostly affected by adverse weather conditions over a lake or ocean, while the bottom waters tend to remain relatively calm and unaffected by high winds. Accordingly, the stability of the floating structure of the invention can be further enhanced by using a specific embodiment 25 for the supporting floating hulls according to the design shown in cross-section in FIG. 9. Each hull 25 has an approximately pear-shaped cross-section (converging to a thinner top portion) and is also independently equipped with flood chambers 21 and pumps 23 to control its buoyancy, as discussed above for hulls 20. By operating the hull 25 so that the bulk of its volume is well below the surface of the water L, the exposure of the hull to surface conditions is greatly diminished and the airport structure supported by the hulls becomes more stable in bad weather.
In all cases, the length of the posts 24 will be chosen so as to provide sufficient clearance below the lower deck 50 to allow a 20- to 30-foot wave to pass under the structure with limited impact on its stability. This feature can be enhanced by designing the hulls 20 or 25 so that they operate mostly submerged under normal conditions, thus providing minimal resistance to the motion of surface water, which is where most of the turbulence is experienced during bad weather conditions. Through the use of the flood chambers 21 and pumps 23, the position and stability of the structure 10 can be further improved by selectively changing the buoyancy of specific hulls to meet corresponding requirements to balance the weight load throughout the airport. Finally, as an emergency option, the hulls should be capable (through flooding of its chambers) of allowing the sinking of the structure to the point where the bottoms of the hulls rest on the bottom B of the water body, thus providing a stable rigid anchor for the airport that would withstand any foreseeable situation. Because of the expected proximity to shore of airports built according to this invention, they would be placed in relatively shallow waters and their hulls in most cases would contact the bottom before the airport became submerged, thus avoiding damage to it even in such cases of extreme emergency.
Thus, various changes in the details, steps and materials that have been described may be made by those skilled in the art within the principles and scope of the invention herein illustrated and defined in the appended claims. While the present invention has been shown and described herein in what is believed to be the most practical and preferred embodiment, it is recognized that departures can be made therefrom within the scope of the invention, which is therefore not to be limited to the details disclosed herein, but is to be accorded the full scope of the claims so as to embrace any and all equivalent apparatus and methods. | A floating airport that consists of a multiple-deck structure floatingly supported by a plurality of independent hulls removably attached to the underside of the structure. A system of propulsion jets is provided on all sides to permit the motion of the structure in any desired direction relative to the water. The anchoring of the structure is achieved by dynamically monitoring the horizontal position of its center of gravity and by utilizing the propulsion system to avoid any significant movement with respect to a predetermined location. The structure is allowed to rotate approximately around its vertical axis in order to align the runways with the prevailing winds and minimize the winds' impact on its stability, and any translational motion of the center of gravity of the airfield with respect to the water surface is minimized. As a result of this position control strategy, the structure is prevented from ever acquiring significant linear momentum in spite of its large mass and its position can be continuously controlled with relatively minor adjustments that are within the capability of its propulsion system. | 1 |
This is a continuation of Ser. No. 780,496, filed on Sept. 26, 1985 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to air cooling equipment for use in electronic systems such as communications systems and information processing systems.
In general, active elements such as transistors mounted on a printed circuit wiring board tend to generate heat proportional to the dissipated electric power. The heat produced has an adverse effect on characteristics of the active elements and, if too great, can result ultimately in the destruction of those active elements. For this reason, a strict environmental temperature restriction is imposed on these electronic components to ensure reliability. This temperature restriction is easily met in circuits using only a few active heat producing elements. However, recently, electronic systems need to concentrate a great number of active elements on a chip in a high density arrangement to achieve high speed operation and microminiaturization. Accordingly, an increase in the number of active elements is accompanied with the attendant increase of the electric power dissipation and the quantity of heat produced which must be dissipated. This is typically accomplished by means of cooling equipment for effectively cooling the electronic components to maintain the temperature of the electronic components below their maximum operating temperature.
One attempt for the practical use of such cooling equipment is disclosed in an air cooling system in U.S. Pat. No. 4,158,875. In the system described in that patent, a plurality of blowers are arranged with the edges of a plurality of wiring boards adjacent each other. Thus, the distance between elements connected to each other becomes longer. As a result, a high speed operation in such electric systems cannot be achieved. Furthermore, in order to obtain the air flow rate required to fully cool the electronic components, a bulky air blower is needed resulting in requiring a large area dedicated to intake and exhaust ducts. Accordingly, it is difficult operation to exchange the components for maintenance.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide cooling equipment free from the above-mentioned shortcomings in the prior art, such as the unacceptable distance between elements and the problem of difficult maintenance operations.
In accordance with this invention, in a first embodiment, a plurality of wiring boards has a plurality of heat-generating electric components mounted thereon. A first blower introduces a cooling air from the top of the equipment and a first air passage having intake ports and exhaust ports receives air from the first blower. A second blower introduces cooling air from the bottom of the equipment. A second air passage having intake ports and exhaust ports received the air from the second blower. A partition wall divides the first air passage from the second air passage.
In a second embodiment, the invention uses a plurality of wiring boards with a plurality of heat-generating electric components mounted thereon. An intake duct introduces cooling air from the bottom of the air cooling equipment into the housing. A blower moves the air from the intake duct into a path portion which receives through air from the blower. The path portion extends to the sides of the air cooling equipment. An exhaust duct exhausts air from the path portion to the top of the equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in detail with reference to the accompanying drawings, in which:
FIGS. 1 and 2 are respectively a perspective view along line II--II in FIG. 1 and cross-sectional view of a first embodiment of the invention,
FIGS. 3 to 6 are respectively a perspective front view, perspective back view and cross-sectional views along lines V--V and VI--VI in FIG. 3 of a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Throughout the drawings, arrows denote the direction of air flow passing through a duct or a flow path. Referring now to FIGS. 1 and 2, a first embodiment according to the present invention has an array of daughter wiring boards 1b each comprising a plurality of components 1a, mother boards 3 having, the daughter wiring boards 1b inserted thereon, and connectors 2 for connecting daughter wiring boards 1b to mother boards 3. Supports 7 support a plurality of mother boards 3 of the array. An upper intake unit 5 with blowers 6 is mounted in the upper position of the equipment relative to the boards 1b and 3, connectors 2, and supports 7. A lower intake unit 4 with blowers 6 is mounted in the lower position relative to the array of boards 1b and 3, connectors 2, and supports 7. Covers 8 are fixed to the supports 7 by inwardly extending flanges and have exhaust ports 9. A divider plate 8c fixed to the appropriate inner wall portion of the supports 7 separates the air flow paths from the respective blowers to prevent mixing of the air flow from the upper portion into the lower portion and also prevent mixing of the air flow from the lower portion into the upper portion. This is illustrated in FIG. 2 which is a sectional view along line II--II of FIG. 1. Guide plates 8a and 8b fixed to the cover 8 direct the warmed air in the flow path to ambient exhaust.
The air flow paths in FIG. 2 will now be explained. FIG. 2 illustrates temperatures in various zones by T0, T0', T 1 , T 2 , T 3 , and T 4 . The differentials are given by ΔT 1 , ΔT 2 , ΔT 3 , and ΔT 4 . Cool air from the lower position of the equipment is introduced by the blowers 6 of the unit 4. Next, the cooling air passes through at the position (A) in the direction of the arrow and cools the lower mounted electric components 1a mounted on the daughter wiring boards 1b. Then, the air warmed by the heat produced from the electric components 1a is delivered from position (B) into the exhaust port by guide of the guide plate 8b. In a parallel manner, cooling air from the upper position of this equipment is introduced by the blowers 6 of the unit 5. The air flow passes through position (D) in the direction of an arrow and cools the upper electronic components 1a mounted on the daughter wiring boards 1b. Then, the air warmed by the heat produced from the upper electric components 1a is delivered from the position (C) into the exhaust port 9 by guide of the guide plate 8a.
A second embodiment according to the present invention will be explained with reference to FIGS. 3 to 6. FIGS. 3 and 4 are perspective front and rear views of the second embodiment. FIGS. 5 and 6 are two sectional views taken respectively along lines V--V and VI--VI in FIG. 3. Referring to FIGS. 3 to 6, a large number of electrical components 111 are mounted on each of the wiring boards 110. The components 111 are the heat generating elements. The wiring boards 110 are fixed to a frame 112 which has a larger front shape than that of the board 111, and has a sleeve portion 112a. A front cover 113 is fixed to the sleeve portion 112a, so that an intake duct 114 is formed by the frame 112 and the cover 113. A plurality of blowers are fixed to the sleeve portion 112a, and are located beside the intake duct 114. The intake portions of the blowers are connected to an inlet portion 116 of the sleeve portion 112a and the exhaust portions of the blowers are connected to a conduit path 117 of the frame 112. The conduit path 117 is rectangular in shape when viewed in cross-section. The blowers move cooling air into and through the inlet portion 116 and exhaust cooling air to the wiring boards 110 through the conduit path 117. Seal plates 118 fixed to the wiring boards 110 and an inner cover 119 fixed to the frame 112 enclose the wiring board 110 and the conduit path 117. A path 120 (illustrated in the horizontal cross-sectional view FIG. 5) is formed which guides the cooling air in horizontal direction on the back sides along the mounting surface of the wiring boards 110 from the conduit path 117.
The path 120 is divided into two parts by a vertical separator plate 121 in the central portion of the path 120. Two outer rear covers 122 have a U-shape, and include the inner cover 119 joined together by flange portions, so that an exhaust duct 123 having a duct width M (FIG. 5) is formed by the combined outer covers 122 and the inner cover 119. The lower portion of the exhaust duct 123 is sealed and the upper portion of the exhaust duct 123 is open. The air warmed by the heat produced from the component array 111 is delivered from the path 120 into the exhaust duct 123 via an outlet portion 124. FIG. 6 also illustrates cable connectors 125 fixed to the wiring boards 110, and connect the wiring boards mounted on other equipment through signal cable 126. Wire lines 128 connect signal pins 127 mounted the wiring boards in the same equipment. Those components are also subjected to cooling air due to eddies and convection currents. The air flow passing through duct will now be explained. The cooling air introduced through the intake duct 114 flows in the direction of the arrow from the blower 115 into the zones 120 between components 111 and through the conduit path 117. The cooling air passing through the path 120 in the direction of an arrow cools the components 111 mounted on the wiring boards 110. The air warmed by the heat produced from the components 111 is delivered from the zones 120 into the exhaust duct 123 through the outlet portion 124.
Referring to vertical cross-sectional view FIG. 6, since air in the exhaust duct 123 has been warmed, the air will naturally rise and be discharged through the exhaust duct 123 in the direction of top arrow. In this second embodiment, the blowers 115 are not positioned on the side of the frame 112 and the shape of the conduit path 117 is a rectangle in the perpendicular direction, so that the location of the wiring boards can be close to each other. Accordingly, the distance between one component and another component is reduced more than that of the prior art.
The area of the exhaust duct is larger than that of ducts used in prior art devices such as in U.S. Pat. No. 4,158,875. | An air cooling equipment for use in electronic systems having a plurality of wiring boards with a plurality of heat-generating electronic components mounted thereon is disclosed. The air cooling equipment uses two blowers positioned on top and bottom of the unit and introduces cooling air in two directions into the housing. The blowers may be positioned at sides of the housing and air is directed around and through the zone where the wiring boards are disposed. | 7 |
The present invention relates to the art of packaging and, more particularly, to a transport protector for protecting an inkjet cartridge during shipping and/or handling.
INCORPORATION BY REFERENCE
The present invention relates to protecting inkjet cartridges. Scheffelin U.S. Pat. No. 5,748,216; Hattori U.S. Pat. No. 5,365,262; Denton U.S. Pat. No. 6,328,424; Cook U.S. Pat. No. 6,095,643; Baldwin U.S. Pat. No. 5,537,134; and Stathem U.S. Pat. No. 5,933,175 disclose inkjet cartridges and are incorporated by reference herein as background information for showing the same.
BACKGROUND OF THE INVENTION
The present invention is particularly applicable for use in connection with inkjet cartridges and, therefore, the invention will be described with particular reference to an inkjet cartridge. However, the invention has broader applications and may be used in connection with other products.
It is, of course, well known that a cover or protector can be used in connection with product packaging for protecting a delicate portion of a product. Further, it is also well known that the cover can be molded into a desired configuration tailored to cover and protect a desired portion of the product and to help maintain its position relative to the portion to be protected. These devices can be made from a number of different materials which provide shock absorbing qualities that protect the delicate portion of the product during the shipping and/or handling of the product. By utilizing a cover having protective qualities, a lower percentage of products are damaged during shipping and/or handling. This is especially important in relation to electronics which are easily damaged.
The problem arises in creating a protector that is inexpensive to produce and easy to position relative to the desired zone of protection. Many product protectors require separate securing items such as tape or straps to maintain the cover in the desired zone of protection.
SUMMARY OF THE INVENTION
In accordance with the present invention, a transport protector which is easy to properly install is provided for protecting the nozzle on an inkjet printer cartridge and also for preventing ink seepage from the nozzle. In this respect, a transport protector in accordance with the present invention includes a protector body having a recess shaped to at least partially receive an inkwell of the inkjet cartridge and cover the nozzle of the inkjet cartridge. The protector can further include a lid that is hingedly connected to the body and which pivots between an opened condition and a closed condition. The lid can be configured to engage the inkjet cartridge to urge the cartridge into the recess when in the closed condition and can include locking arms to releasably engage the protector body to maintain the protector in the closed condition without taping, shrink wrapping or utilize other securing methods.
A transport protector in accordance with another aspect of the present invention can include pressure ribs on the lid to evenly engage the inkjet cartridge when in the closed condition such that the nozzle evenly engages a nozzle pad in the protector.
A transport protector in accordance with yet another aspect of the invention can include
a mechanism for partially ejecting the inkjet cartridge from the protector as the protector is actuated from the closed condition to the opened condition.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features and more will in part be obvious and in part be pointed out more fully hereinafter in connection with a written description of preferred embodiments of the present invention illustrated in the accompanying drawings in which:
FIG. 1 is a rear perspective view of a transport protector for an inkjet cartridge in accordance with the present invention wherein the protector is in a closed condition;
FIG. 2 is a rear perspective view of the protector shown in FIG. 1 wherein the protector is in an opened condition;
FIG. 3 is a top plan view of the protector shown in FIG. 1 shown in the opened condition;
FIG. 4 is a right-side elevational view of the protector shown in FIG. 1 shown in the opened condition;
FIG. 5 is a bottom plan view of the protector shown in FIG. 1 shown in the opened condition;
FIG. 6 is a front elevational view of the protector shown in FIG. 1 shown in the opened condition;
FIG. 7 is a rear elevational view of the protector shown in FIG. 1 shown in the opened condition;
FIG. 8 is a front perspective view of the protector shown in FIG. 1 shown in the opened condition;
FIG. 9 is a rear bottom perspective view of the protector shown in FIG. 1 shown in the opened condition;
FIG. 10 is a rear perspective view of the protector shown in FIG. 1 with an inkjet cartridge in place wherein the protector is shown in the opened condition; and,
FIG. 11 is a rear perspective view of the protector shown in FIG. 10 wherein the protector is in the closed condition.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now in greater detail to the drawings wherein the showings are for the purpose of illustrating preferred embodiments of the invention only and not for the purpose of limiting the invention, FIGS. 1–11 illustrate a transport protector 10 having a transport or protector body 12 and a lid 14 hingedly connected to body 12 . In this respect, lid 14 is joined to body 12 at a hinge 20 wherein hinge 20 , preferably, is a live hinge. However, the hinge can be any hinge known in the art to allow pivoting or hinging movement of one component relative to another component. With respect to the invention of this application, hinge 20 allows lid 14 to pivot relative to body 12 about a hinge axis 22 . Furthermore, lid 14 includes a lid lock including locking arms 30 and 32 to maintain lid 14 relative to body 12 in a desired locked position or closed condition. By utilizing hinge 20 and locking arms 30 and 32 , lid 14 can pivoted from the opened condition shown in FIG. 2 to the closed condition shown in FIG. 1 by rotation about hinge axis 22 . Locking arms 30 and 32 maintain protector 10 in the closed condition shown in FIG. 1 which will be discussed in greater detail below. However, it should be appreciated that modifications to this locking arrangement can be made to lock lid 14 relative to body 12 without detracting from the invention. Further, as will also be discussed in greater detail below, locking arms 30 and 32 can include a ratcheting mechanism to allow the lid to lock in any one of several locking positions.
Turning to body 12 , the body is configured to receive a portion of an inkjet cartridge (see FIGS. 10 and 11 ) to retain the cartridge in a secured condition wherein the delicate components of the inkjet cartridge are protected. As can be appreciated, the shape of protector 10 is, in large part, dictated by the configuration of the particular inkjet cartridge to be protected. In the embodiment disclosed herein, the protector is configured to protect an inkjet cartridge IC. However, protector 10 can be shaped and configured differently to work in connection with other inkjet cartridges and/or multiple cartridges.
Body 12 includes a face plate 40 with side walls 42 and 44 extending rearwardly from the side edges of the face plate. Body 12 further includes a bottom 46 extending rearwardly from face plate 40 . Bottom 46 also extends between side walls 42 and 44 . As discussed above, face plate 40 , side wall 42 , side wall 44 and bottom 46 are sized and shaped in view of the configuration of inkjet cartridge IC, and further, these components are shaped to receive an ink well (not shown) of inkjet cartridge IC along with a front portion of the inkjet cartridge. Body 12 further includes a rear wall 48 extending between sides 42 and 44 to further protect the ink well components.
With special reference to FIG. 11 , rear wall 48 is a partial wall to allow a portion of the inkjet cartridge to extend outwardly from protector 10 . As can be appreciated, certain portions of the inkjet cartridge require greater protection than other portions of the cartridge. In this respect, a nozzle and flex circuits (both not shown) are a part of the operating portions of the inkjet cartridge and are generally on the ink well. The reservoir portion R is merely needed to maintain an ink supply. Therefore, cost can be reduced and the manufacturing needed to produce protector 10 can be simplified by designing protector 10 such that it is configured to provide maximum protection for only a desired group of components instead of all components of the inkjet cartridge. Protector 10 can also be utilized to help prevent ink leakage from the nozzle of inkjet cartridge IC which will be discussed in greater detail below.
Protector 10 preferably further includes reinforcing and/or protecting ribs in body 12 and/or lid 14 . In this respect, side 42 includes side ribs 50 , 52 and 53 and side 44 includes side ribs 54 , 56 and 57 . By including these ribs, protector 10 can afford a greater degree of protection for the inkjet cartridge IC by spacing sides 42 and 44 from sides S 1 and S 2 , respectively, of inkjet cartridge IC. Further, these ribs can provide a frictional engagement with sides S 1 and S 2 of the inkjet cartridge IC to produce a snug fit between the protector and the inkjet cartridge without the tendency of the inkjet cartridge IC becoming wedged in body 12 . While not shown, face plate 40 and rear wall 48 can also include similar ribs.
Sides 42 and 44 further include a locking arrangement for locking arms 30 and 32 of lid 14 . In this respect, locking arms 30 and 32 extend toward body 12 and selectively engage a pair of locking notches 60 and 62 , respectively, that are formed in sides 42 and 44 . The engagement between the arms and the notches maintains lid 14 in the locked or closed condition. More particularly, lid 14 includes side edges 70 and 72 which extend from a lid base 74 . Sides 70 and 72 are essentially parallel to one another and extend to a lid outer edge 76 . Lid 14 further includes a bottom surface 80 and a top surface 82 . Arms 30 and 32 extend downwardly from bottom surface 80 . Arms 30 and 32 are at or near sides 70 and 72 , respectively, and include inwardly facing locking protrusions 90 and 92 , respectively, that are shaped to engage a respective one of notches 60 and 62 to create the selective locking engagement. In this embodiment, locking notches 60 and 62 are open slots having an upper opened portion 100 and 102 , respectively, with one or more locking bars 104 and 106 extending transversely across the slots. The locking protrusions of arms 30 and 32 are configured to engage the bars to maintain lid 14 in the locked condition. In this respect, locking bars 104 and 106 are be spaced from one another to allow locking protrusion 90 to at least partially penetrate the opening between the bars and/or the opening between locking bar 106 and a notch base 108 . In similar fashion, notch 62 includes two locking bars 110 and 112 which are spaced from one another and are spaced from a notch base 114 . As can be appreciated, while two locking bars are shown for each notch, more or less than two locking bars can be utilized. However, by using more than one locking bar, and/or locking engagement point, a ratcheting action can be created that produces multiple locking positions which are helpful to account for manufacturing variances and to allow the protector to be used in connection with more than one inkjet cartridge. As a modification of the locking arrangement, locking notches 60 and 62 recesses (not shown) in the respective sides of body 12 as opposed to having open upper ends. The recesses of the notches are shaped to receive the locking protrusions and selectively maintain lid 14 relative to body 12 . Further, the locking action between the locking protrusions and the notches in either case can be any known locking engagement in the art.
By utilizing notches which include open portions 100 and 102 , respectively, locking protrusions 90 and 92 can be configured to penetrate these openings and engage the side walls of the inkjet cartridge IC. This configuration allows locking arms 30 and 32 to at least partially eject the inkjet cartridge from protector body 12 as the lid is opened thereby helping the end user remove the inkjet cartridge from the protector. This feature can work in connection with friction ribs such as side ribs 50 , 52 , 53 , 54 , 56 and 57 to create a packaging device that allows the user to easily remove the inkjet cartridge IC therefrom. As is stated above, ribs 50 , 52 , 53 , 54 , 56 and 57 can provide frictional engagement with the sides of inkjet cartridge IC. As protector 10 is moved from the closed condition shown in FIG. 11 to the opened condition shown in FIG. 10 , locking protrusions 90 and 92 pass through upper portions 100 and 102 , respectively, engage the inkjet cartridge sidewalls and partially lift the inkjet cartridge from the recess in body 12 . The frictional engagement of ribs 50 , 52 , 53 , 54 , 56 and 56 can then maintain the inkjet cartridge IC in the lifted position even after protrusions 90 and 92 are released from the side walls. This feature allows the user time to grasp the inkjet cartridge IC. Further, the spacing between locking bars 104 , 106 , 110 and 112 discussed above along with the spacing between the bars and notch bases 108 and 114 , can be such that locking protrusions 90 and 92 , respectively, do not engage the sides of the inkjet cartridge IC while in the locked or closed condition.
The spacing between arms 30 and 32 , and locking protrusions 90 and 92 are dictated in part by the desired function of the locking arms. As can be appreciated, if the secondary function of the arms is to lift the cartridge, the spacing of the locking protrusions must be less than the width of the cartridge. Further, even if cartridge lifting is not desired, the spacing must be calculated to create the desired selective engagement with the locking notches and to allow the remaining portions of the arm to clear the side walls of body 12 .
Preferably, as shown, notches 60 and 62 are curved and arms 30 and 32 are similarly curved to improve the locking engagement therebetween. In this respect, locking arm 30 is attached to lid 14 at a base 120 that is at or near lid side 70 . Arm 30 extends from base 120 to an end 122 and is curved with a radius generally equal to the distance between the locking arm and hinge axis 22 . By having such a curved configuration, all portions of arm 30 are at an equal distance from the pivot point of lid 14 and are maintained at the equal distance as lid 14 pivots about axis 22 . Notch 60 has a similar curved configuration. As a result, locking protrusion 90 can be maintained in transverse alignment with notch 60 and will follow the notch as the lid is pivoted relative to the body. In similar fashion, locking arm 32 can be at or near lid side 72 and can extend from an arm base 130 to an arm end 132 . Locking arm 32 also includes the same curved configuration as locking arm 30 and notch 62 includes the same curved configuration as notch 60 . However, it should be appreciated that arm 30 and notch 60 do not need to be identical to arms 32 and notch 62 , respectively. For example, arm 30 and notch 60 can be spaced differently from axis 22 than arm 32 and notch 62 based on the configuration of the inkjet cartridge.
Preferably, lid 14 further includes downwardly extending pressure ribs 140 and 142 to create even downward pressure or force on cartridge IC to produce an even engagement between the printer nozzle and a nozzle pad 144 on bottom 46 as shown in FIG. 3 . As can be appreciated, one of the functions of protector 10 is to prevent ink leakage or seepage from the nozzle during transporting and/or shipping. As can be further appreciated, leaking or seeping is better controlled if the nozzle pad fully engages the inkjet nozzle. Further, the pad will be more effective if the engagement between the pad and the nozzle is uniform. By utilizing ribs 140 and 142 , which are spaced on either side of bottom surface 80 , ribs 140 and 142 engage body top BT of the cartridge on either side. This produces an even or uniform downward engagement force between lid 14 and the inkjet cartridge when protector 10 is in the closed condition. This rib arrangement also prevents rocking of the cartridge relative to protector 10 . Pressure ribs 140 and 142 also include an arcuate engagement surface 150 and 152 , respectively, to produce precise point contact between the respective ribs and body top BT of the inkjet cartridge IC which also accounts for variations in the manufacturing processes of the inkjet cartridge and/or protector 10 . It should be appreciated that while the ribs are shown near lid sides 70 and 72 , these ribs can be spaced from the side edges of the lid. As can also be appreciated, while a wider spacing is preferred, the precise spacing may be dictated by the shape of the inkjet cartridge.
Preferably, lid 14 includes a finger grip extension 160 at or near lid outer edge 76 that at least partially extends away from inkjet cartridge IC when in the closed condition. As is best shown in FIG. 11 , by including finger grip 160 , the user can easily grasp lid 14 and move it from the closed condition to the opened condition. As can be appreciated, the shape and configuration of the finger grip can take many forms which allow the lid to be easily engaged by the user of the inkjet cartridge. Further, finger grip 160 does not need to be adjacent or near outer edge 76 . In this respect, finger grip 160 can extend from any portion of the lid which allows the user to easily actuate the lid from the closed condition to the opened condition and vise-versa.
While considerable emphasis has been placed on the preferred embodiments of the invention illustrated and described herein, it will be appreciated that other embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principals of the invention. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A transport protector is provided for an inkjet cartridge wherein the inkjet cartridge includes a cartridge body, an inkwell extending from the cartridge body and a nozzle on the inkwell. The protector includes a protector body having a recess shaped to receive an inkwell of an inkjet cartridge and cover a nozzle of the inkjet cartridge. The protector further including a lid hingedly connected to the body. The lid pivots between an opened condition and a closed condition and engages the inkjet cartridge to evenly urge the cartridge into the recess when in the closed condition. The lid also includes a lid lock for releasably engaging the protector body to maintain the protector in the closed condition. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
None.
FIELD OF THE DISCLOSURE
This disclosure pertains generally to flow control devices such as valves.
BACKGROUND OF THE DISCLOSURE
During the drilling and completion of oil and gas wells, the downhole environment can impose substantial operational stresses on downhole equipment. These harsh conditions exposure to drilling mud, contaminants entrained in well fluids, and hydraulic forces of the circulating drilling mud. Extreme pressures and temperatures may also be present. Such harsh conditions can damage and degrade downhole equipment. Valves used in sampling, drilling, and completion operations may be susceptible to the harsh downhole conditions because they require the use of seals and moving parts. For example, valves used in a downhole environment may interact with deleterious debris carried by formation fluids and encounter significant pressure drops.
The present disclosure addresses the need for sealing high differential pressure in a downhole environment, as well as in surface applications.
SUMMARY OF THE DISCLOSURE
In aspects, the present disclosure provides an apparatus for controlling a fluid flow in a borehole. The apparatus may include a tool body configured to retrieve a fluid sample from a subsurface formation, the tool body having a fluid conduit having an inlet for receiving the fluid sample and an outlet for conveying the fluid sample to a selected location; a mandrel selectively blocking flow across the fluid conduit; and a seal disposed on the mandrel, the seal including at least one chevron seal element configured to cooperate with the mandrel to selectively block flow across the fluid conduit.
In another embodiment, the apparatus may include a carrier configured to be conveyed along a borehole; a tool body positioned along the carrier, the tool body having at least one packer configured to form an isolated zone, the tool body having a fluid conduit having an inlet for receiving a fluid sample from the isolated zone and an outlet for conveying the fluid sample to a selected location; and a valve disposed in the tool body. The valve may include a mandrel configured to translate between a first and a second position to selectively block flow across the fluid conduit; and a seal disposed on the mandrel, the seal including at least one chevron seal element configured to cooperate with the mandrel to selectively block flow across the fluid conduit.
In another aspect, the present disclosure provides a method for controlling a fluid flow. The method may include retrieving a fluid sample from a subsurface formation using a tool body, the tool body having a fluid conduit having an inlet for receiving the fluid sample and an outlet for conveying the fluid sample to a selected location; selectively blocking flow across the fluid conduit using a mandrel; and isolating the inlet from the outlet using a seal positioned in a passage between the mandrel and the tool body, the seal including at least one chevron seal element.
Thus, the present disclosure provides seals that enhance control, operation, service life, reliability, and/or performance for valves and other flow control devices. The teachings may be applied to a variety of systems both in the oil and gas industry and elsewhere.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed understanding of the present disclosure, reference should be made to the following detailed description of the embodiments, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
FIGS. 1A and 1B shows sectional views of a valve according to one embodiment of the present disclosure in the open and closed positions, respectively;
FIG. 2 shows a seal in accordance with one embodiment of the present disclosure; and
FIG. 3 schematically shows a well system that uses a valve according to one embodiment of the present disclosure in a borehole formed in an earthen formation.
DETAILED DESCRIPTION
In aspects, the present disclosure provides a “dirty” fluid valve with a bi-directional Chevron type metal seal assembly for use in tool used to sample wellbore fluids and to store such fluids in a sample bottle. The valve may be pressure balanced and may be operated in varying pressures. The seals described herein provide gas tight seal for repeated operations.
Referring initially to FIGS. 1A and 1B , there is shown a valve assembly 10 that may be used to retrieve fluid samples from a formation. The valve assembly 10 may include a body or housing 20 in which a mandrel 30 and a seal 40 are disposed. The housing 20 may include a fluid inlet 22 , a fluid outlet 24 , pressure chambers 26 a, b , and pilot holes 28 a, b . The pressure chamber 26 a is positioned next to a first end 32 of the mandrel 30 and the pressure chamber 26 b is positioned next to a second end 34 of the mandrel 30 . The housing 20 may be unitary or composed of several components. Therefore, it should be understood that the depicted configuration is merely illustrative and does not limit the present disclosure.
In one embodiment, fluid communication between the fluid inlet 22 and the fluid outlet 24 may be controlled by shifting or translating the mandrel 30 in a cavity 42 of the housing 20 . The mandrel 30 may be a cylindrical member that includes a reduced diameter or “necked” portion 31 . When the mandrel 30 is set in the open position, the necked portion 31 forms an annular passage 48 in the housing that 20 that connects the fluid inlet 22 with the fluid outlet 24 . Thus, the inlet 22 , the passage 42 , and the outlet 24 may be considered as forming a fluid conduit in the housing 20 . Seals 62 , 64 between the mandrel 30 and the housing 20 isolate the passage 48 from the rest of the valve 10 . To shift the mandrel 30 to the open position, the pressure chamber 26 b is pressurized using the pilot inlet 28 b to urge the mandrel 30 in an axial direction marked with arrow 43 . To shift the mandrel 30 to the closed position, the pressure chamber 26 a is pressurized using the pilot inlet 28 a with a hydraulic fluid to urge the mandrel 30 in an axial direction marked with arrow 45 , which is directionally opposite to arrow 43 .
Referring now to FIG. 1A , the valve assembly 10 is shown in an open position wherein the fluid inlet 22 and the fluid outlet 24 are in fluid communication via a passage 48 in the housing 20 . Applying pressurized hydraulic fluid to the pressure chamber 26 a slides the mandrel 30 in the axial direction 44 until the mandrel 30 reaches the closed position shown in FIG. 1B . In FIG. 1B , the seal 40 and the mandrel 30 form a fluid seal (e.g., liquid-tight seal or gas-tight seal) that prevents fluid communication between the fluid inlet 22 and the fluid outlet 24 .
Referring to FIG. 1B , the seal 40 may be a bidirectional sealing device that includes one or more sealing elements that form a flow-blocking barrier between an outer surface 44 of the mandrel 30 and an inner surface 46 of the housing 20 . The seal 40 may be bidirectional in that the seal prevents flow therethrough in either axial direction. The seal 40 surrounds the mandrel 30 and is stationary relative to the housing 20 . For example, the seal 40 may seat on a support 47 of the housing 20 . The support 47 may be a shoulder or ledge that limits axial movement of the seal 40 . The support 47 may be integral with the housing 20 or tubular component of the housing 20 .
Referring now to FIG. 2 , there is shown a cross-sectional view of a section of one embodiment of a seal 40 in accordance with the present disclosure. In one arrangement, the seal 40 may include an upper end adapter 48 a , a first unidirectional seal stack 50 a , a center adapter 52 , a second unidirectional seal stack 50 b , and a second end adapter 48 b . The end adapters 48 a,b and the center adapter 52 may be formed of a material harder or more rigid than the material of the seal rings 54 so that pressure applied to the end adapters 48 a, b can be distributed relatively evenly through the seal stacks 50 a,b.
The unidirectional seal ring stacks 50 a, b may include one or more cylindrical seal rings 54 . The seal rings 54 may be formed as chevron-type seal rings. As used herein, a chevron seal ring is a pressure responsive sealing element that flexes to form a seal against adjacent surfaces. The chevron shape may defined by two wings 56 that are hinged at an apex 58 . The wings 56 may form an angle less than one-hundred eighty degrees. The seal ring 54 is responsive to the pressure applied on the apex 58 side (i.e., unidirectional). In one embodiment, the seal rings 54 may be “U” or “V” shaped annular elements formed of a material that allows a predetermined amount of flexure when the ring 54 is compressed. Thus, pressure applied to the upper end adapter 48 a causes the ring(s) 54 to be compressed against the center adapter 52 . This compression causes the ring(s) 54 to expand and compress the tips 60 of the wings 56 to engage and seal against the adjacent surfaces 44 , 46 .
It should be appreciated that seal 40 is pressure responsive in that the magnitude of the sealing force (or contact force) at the tips 60 varies directly with the differential pressure across the seal 40 . Thus, as this pressure differential increases, the sealing force at the tips 60 also increases. In the embodiment shown, the seal 40 includes multiple oppositely-oriented rings 54 . The use of multiple rings 54 allows the formation of multiple serially aligned sealing surfaces along the surfaces 44 , 46 . The opposite orientation of the seal rings 54 , i.e., having the apexes 58 point in opposite directions, enables the seal 40 to be bidirectional.
The rings 54 may be formed of a material that has a modulus that allows flexure at a prescribed pressure range. In some embodiments, a metal such as spring steel may be used. In other embodiments, non-metals such as elastomeric material may used. In still other embodiments, the seal stacks 50 a, b may use a combination of two or more materials. For example, seal stacks 50 a, b may include one or more rings 54 made of metal and one or more rings made of a non-metal. Also, while several rings 54 are shown for each of seal stack 50 a, b , one or more rings may be used.
Referring to FIG. 3 , in one non-limiting embodiment, the valve 10 may be used to create or diffuse a differential pressure between a fluid source in a subsurface environment and an environment in a well tool 100 . The fluid source may be fluid in a borehole 102 or a fluid reservoir residing in a formation 108 . The well tool 100 may be a bottomhole drilling assembly, a fluid sampling tool, a coring tool, or any other tool that is configured or performs one or more tasks (e.g., forming the borehole, sampling/testing formation solids or fluids, etc.) in the borehole 102 . A sample from the formation 108 may be retrieved using a packer-type probe 12 that engages a wall of the borehole 102 to isolates the fluid in the formation 108 from the borehole fluid 104 . In other embodiments not shown, one or more annular packers may be used to isolate a zone in the borehole 102 . The isolated borehole zone may fill with a formation fluid. In either case, the valve 10 may be used to convey a fluid sample retrieved from the isolated zone to a sample bottle 110 or other similar receptacle. The well tool 100 may be conveyed via a work string 106 , which may include a rigid carrier (e.g., drill string, casing, liner, etc.) or non-rigid carrier (e.g., wireline, slickline, e-line, etc.).
Referring now to FIGS. 1A and 3 , in one mode of use, the well tool 100 may be conveyed into a borehole 102 to retrieve one or more fluid samples. After being appropriately positioned, a hydraulic source (not shown) pressurizes the pressure chamber 26 a via the pilot inlet 28 a with a hydraulic fluid to urge the mandrel 30 in an axial direction marked with arrow 43 . This action sets the valve 10 in an open position and allows a retrieved fluid, which may be a liquid, a gas, or a mixture thereof, to flow to the fluid outlet 24 via the fluid inlet 22 and the passage 48 . The retrieved fluid, or fluid “sample,” may be collected in a sample receptacle 110 . It should be appreciated that during the sampling activity, the valve 10 may be considered pressure balanced. That is, the fluid pressure at the fluid inlet 22 is applied to the seal 62 above and the seal 64 below the fluid inlet 22 . This balanced pressure reduces the likelihood that the mandrel 30 will move due to pressure fluctuations.
To terminate the sampling operation, the hydraulic source (not shown) pressurizes the pressure chamber 26 b via the pilot inlet 28 b to urge the mandrel 30 in an axial direction marked with arrow 45 , which sets the valve 10 in the closed position.
Referring now to FIGS. 1B and 2 , in the closed position, fluid pressure at the fluid inlet 22 generates a pressure differential across the seal 40 . The differential between the pressure at the fluid source and the interior of the well tool 100 may approach twenty-five thousand PSI. This pressure compresses the seal 40 against the support 47 . Specifically, the upper end adapter 48 a compresses the spring stack 50 a against the center adapter 52 . The center adapter 52 communicates this pressure to the seal stack 50 b . This compression causes the ring(s) 54 to expand and compress the tips 60 of the wings 56 to engage and seal against an adjacent surfaces 44 , 46 . It should be appreciated that an increase in pressure causes a corresponding increase in the sealing force at the contact between the wings 56 and the adjacent surfaces 44 , 46 . The resulting seal may be a gas-tight seal. Moreover, in instances where multiple seal rings 54 are used, multiple independent sealing contacts are formed. It should also be appreciated that this gas-tight seal is obtained without applying a sealing agent at the contacting surfaces (e.g., grease).
It should be appreciated that when the seal 40 isolates an inflowing fluid sample from surrounding fluid during retrieval, the seal 40 prevents the inflowing fluid from leaking out of the passage 48 . When preserving a retrieved fluid sample as the tool is being returned to the surface, the seal 40 prevents the fluid sample from leaking into the passage 48 . Thus, the seal 40 has bidirectional sealing capability. However, it should be understood that if a separate seal is used to prevent either fluid leaking into or out of the passage 48 , then the seal 40 does not need to be bidirectional and only one seal stack may be used.
Also, in certain embodiments, an actuator 75 may be used to allow pressurized fluid to escape or bleed from the pressure chamber 26 b . The actuator 75 may be used to manually close the valve 10 . For instance, if the valve 10 is in the open position shown in FIG. 1A , the actuator 75 may be partially or completely removed to allow hydraulic fluid to escape, which would allow the valve 10 to shift to the closed position in FIG. 1B . In some embodiments, the actuator 75 may be a threaded body that is screwed into the housing 20 .
While the foregoing disclosure is directed to the one mode embodiments of the disclosure, various modifications will be apparent to those skilled in the art. For example, while a hydraulic source is shown for moving the mandrel, an electric motor may also be used to translate the mandrel. Also, in certain embodiments, a unidirectional seal may be used to form an adequate seal. It is intended that all variations be embraced by the foregoing disclosure. | An apparatus for controlling a fluid flow in a borehole may include a tool body that retrieves a fluid sample from a subsurface formation. The tool body has a fluid conduit having an inlet for receiving the fluid sample and an outlet for conveying the fluid sample to a selected location. A mandrel selectively blocks flow across the fluid conduit; and a seal disposed on the mandrel includes at least one chevron seal element that cooperates with the mandrel to selectively block flow across the fluid conduit. | 4 |
This application is a continuation-in-part of application Ser. No. 08/574,667 filed on Dec. 19, 1995, now abandoned.
TECHNICAL FIELD
This invention relates to an impact pad for absorbing forces, and more particularly to a method of making an impact pad for absorbing forces having improved energy absorbent materials.
BACKGROUND OF THE INVENTION
In the operation of docking a ship, because of the speed of approach, swells, currents and winds it is imperative to provide a protective docking system to reduce potential damage and impact to the ship, dock or pier. In the case of holding ships, such impact pads are used to protect both the holding ship and the smaller vessel transported therein.
Examples of fender protective structures for these types of applications can be found in commonly owned U.S. Pat. Nos. 4,923,550, 4,596,734, 4,679,517 all of which are issued to Kramer and are hereby fully incorporated herein by reference. The fender protective structures of these systems are comprised of a very hard outer plastic layer of ultra high molecular weight polyethylene (UHMWPE), a highly flexible, i.e. rubbery, intermediate elastomeric layer and a very hard base layer comprised of plastic. The base layer is necessary for installation purposes because a system with a conventional elastomeric layer bonded to a plastic layer is too flexible to work with, particularly when the elastomeric layer is partially counter bored.
Elastomer and plastic alloys are known in the marine art for utilization in the journal bearings that support the propeller shafts. More particularly, the alloy is used as stave material in the journal bearing. An example of such alloys is described in commonly owned U.S. Pat. No. 4,735,982 to Orndorff, Jr. Orndorff, Jr. teaches mixing a thermoset rubber compound and a thermoplastic, with the rubber compound having low friction as well as good oil and water resistant properties. Low friction is defined as material which develops hydrodynamic lubrication at normal shaft operating speeds. Use of low friction materials is important in bearing applications because shaft wear must be minimized. For this reason, higher friction rubber compounds are inappropriate in the alloy described in Orndorff, Jr.
Efforts to improve such fender protective systems have led to continuing developments to improve their versatility, practicality and efficiency.
DISCLOSURE OF THE INVENTION
An object of the present invention is to provide a method of making two layer bonded fender protective structures.
Another object is to provide a less expensive method to manufacture a bonded fender protective structure.
A general object is to provide an efficient and effective method of manufacturing a fender protective structure which is relatively hard, has a resilient layer with a delayed elastic response and is able to bulge upon impact for improved energy absorption.
According to the preferred embodiment of the present invention, a method of making a fender protective structure comprising the steps of providing a mold, disposing cured elastomeric spacers in the mold, pouring an alloy mix of crumb elastomer and plastic powder into the mold over said elastomeric spacers, pouring a plastic layer over the alloy mix, curing both the plastic layer (to make a very hard top layer) and the elastomer and plastic alloy mix (to thereby make a relatively hard elastomer and plastic alloy, the alloy being resilient and having a delayed elastic response) and, removing the elastomeric spacers. Removal of the elastomeric spacers creates voids in the alloy to reduce weight and to allow for expansion of the alloy upon impact. The fender protective structure thus includes an improved energy absorbing elastomer plastic alloy layer.
The present invention provides a superior method that makes fender protective structures practical, while maintaining optimum resiliency for energy absorption and return and optimum rigidity for ease of installation.
The present invention further provides a method for making a two layer fender protective structure having a relatively hard, resilient with a delayed elastic response, structure which has room to expand on impact, and which slowly returns to its original shape for receiving subsequent impacts. The structure is instantaneously low in resilience, meaning it has high energy absorbing characteristics, and has a delayed elastic response or resilience, meaning it is able to regain its original dimensions in time delay after impact upon removal of an applied impact force, the delay being between 1 second to over an hour depending on circumstances.
These and other objects, features and advantages of the present invention will become more apparent in the light of the detailed description of exemplary embodiments thereof, as illustrated by the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating the present invention wherein a larger vessel only partly shown, has fenders disposed along the water level under the vessel, with a second vessel being received in the hull of such first vessel.
FIG. 2 is a side elevational view of the back side of a fender protective structure in accordance with the present invention, taken on line 2 — 2 of FIG. 1 .
FIG. 3 is a plan view of a fender protective structure taken in cross section on line 3 — 3 of FIG. 2 .
FIG. 4 a is a is a graph illustrating the impact force versus deflection force of wood, showing a point of crushing or permanent deformation.
FIG. 4 b is a graph illustrating the impact force versus deflection force of high damping, low resiliency rubber.
FIG. 4 c is a graph illustrating the impact force versus deflection force of low damping, high resiliency rubber.
FIG. 4 d is a graph illustrating the impact force versus deflection force of the elastomer and plastic alloy of the present invention.
FIG. 5 is a schematic cross section taken through a prior art fender panel mold.
FIG. 6 is a schematic cross section taken through a mold in which the components of a fender panel embodying the concept of the present invention have been assembled prior to processing.
FIG. 7 is a graph of an impact test conducted on the alloy of the invention at one impact load.
FIG. 8 is a graph of an impact test conducted on the alloy of the invention at a second impact load.
FIG. 9 is a graph of an impact test conducted on rubber at one impact load.
FIG. 10 is a graph of an impact test conducted on rubber at a second impact load.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, wherein like reference numerals designate like or corresponding parts throughout the several views, there is shown in FIG. 1 a portion of a ship or larger vessel 10 whose hull is designated by the numeral 11 . Such vessel 10 is a docking vessel with an open hull capable of lowering a door, not shown, to allow water into the hull to receive smaller vessels 12 such as landing craft, whereby the larger vessels may transport such smaller vessels for ferrying operations close to land.
Located above and below the water line as depicted in FIG. 1, there are a plurality of impact pads or fender protective structures 15 extending in a horizontal direction and suitably attached to the hull of the larger vessel 10 . Each fender 15 is a composite member which includes a longitudinally extending, inwardly disposed (as viewed in the larger vessel 10 ) first layer of plastic material 16 and a resilient layer 17 with a delayed elastic response attached thereto. The top layer 16 of the present invention may not be necessary in certain applications of the present fender protector of the present invention.
Referring now to FIG. 2, the resilient, elastic layer 17 has a plurality of rectangular bore holes 30 provided therethrough, for providing space to allow the material of layer 17 to bulge upon impact force being applied thereto. It should be understood that resilient, elastic layer 17 is relatively inflexible; it is not rubbery and is fairly hard. It rapidly bulges upon impact, but slowly returns to its original configuration. Layer 17 also has a plurality of circular mounting bore holes 35 provided therein for the mounting of the pads. Nut and bolt connection assemblies 36 hold the pads in place. It is significant that layer 17 is hard enough to hold assemblies 36 sufficiently so that they can properly hold the fender protective structure in place in the hull. It is to be noted that holes 30 , 35 may also be any of a number of other shapes not specifically shown herein. Holes 30 are preferably molded into layer 17 . Mounting bore holes 35 are very important for isolating the fasteners (nut and bolt connectors) from impact forces. Bolt stress reduction is well over 75% due to providing the radial bulge area (elastomer compounds are not compressible like gases, at pressures less than 10,000 psi). Impact stresses on fender protective structures or impact pads are well under 5,000 psi. If there is no bulge area, the fender protective structure is virtually incompressible and might as well be made of steel. The radial bulge area allows the fastener bolts or studs to be adequately tightened or prestressed, and prevents damage to the fasteners upon impact to the fender protective structure.
Referring now to FIG. 3, the first layer or outermost layer 16 as viewed from inside the larger vessel 10 has an outer surface 20 and an inner surface 21 . First layer 16 is a very hard plastic, preferably a thermoplastic, and most preferably ultra high molecular weight polyethylene (UHMWPE) which has a melt flow index less than 0.15 measured in accordance with the test procedure of ASTM 1238-65T modified by an additional 3 kilogram load. UHMWPE is understood to be a polyolefin having an ultra high molecular weight which measured by the solution viscosity method is greater than 2.5 million. Polyolefin is understood to be a polymer or copolymer of one or more mono-olefins having no more than four carbon atoms, as well as mixtures of these polymers and/or copolymers, between themselves. It may also be a thermoplastic-rubber polymer alloy or blend comprised of UHMWPE and a low friction thermoset rubber compound. Such alloys are described in commonly owned U.S. Pat. No. 4,735,982, the disclosure of which is hereby fully incorporated herein by reference. It is to be noted that the alloy described in U.S. Pat. No. 4,735,982 can only be utilized for the top layer of the present invention. Alternatively, layer 16 may be comprised of a compression molded flame retardant high impact strength UHMWPE composition as described in commonly owned U.S. Pat. No. 5,286,576, the disclosure of which is also hereby fully incorporated herein by reference. In the finished molded or densified form, this composition is comprised of 86 volume percent UHMWPE, a minimum of 4.40 volume percent of a flame retardant compound (10 pph based on UHMWPE for ammonium polyphosphate on a weight bases) in a minimum of 6 volume percent of chopped reinforcing fiber (19.0 pph based on UHMWPE for chopped fiberglass on a weight bases). In addition, the bulk volume of the chopped reinforcing fibers used in the above composition has measured by a tapped density test described herein must be at least about 27 volume percent of the finished compression molded volume of flame retardant high impact composition. The maximum volume loadings of the flame retardant compound and chopped reinforcing fibers are only limited by the minimum requirement of 7 ft-lb/inch width of notched izod impact strength, as long as both components are present above the minimum leadings described above.
The resilient, elastic layer 17 is relatively hard compared to layer 16 , and not highly flexible or rubbery. Layer 17 has an outer surface 22 that is in abutting contact with and bonded to the inner surface 21 of the first layer 16 . To attach the fender structure 15 to the hull 11 of a vessel, the respective first and second layers have a plurality of mounting bores 35 , extending in alignment with a narrower bore 34 extending into the hull 11 . Bore 35 extends to approximately the middle to two thirds the thickness of the resilient, elastic layer, thereby defining a shoulder or bottom 38 to receive the flat base of a washer 39 and the head of a nut 40 secured to the threaded head of a bolt 41 that is suitably fastened to the hull 11 . Such bores 35 are molded into the resilient, elastic layer 17 and the top layer 16 and extend about one half to two thirds of the way through such resilient layer leaving a space 27 that facilitates the attachment of the fender to the bulkhead or hull 11 . Bore 34 is drilled through area 27 of layer 17 for receiving bolt 41 . The open area of the bores of the resilient, elastic layer to the total layer thereof is on the order of 30% to 60%, thus permitting sufficient bulging of the elastic layer so that damage to the connection assemblies 36 is avoided. In addition, the open area of the bores lightens the resilient, elastic layer.
A preferred thickness for use of the composite laminate structure as a fender protective device, the UHMWPE layer 16 is approximately 3.175 centimeters to 1.27 centimeters thick.
Although the preferred form of the present invention shows the first layer of UHMWPE as solid, it could be perforated or have bores; however, there is risk that sharp projection on the impacting vessel could catch in the bores and rip the pad if the force exceeded the strength of either the first or second layers, or the bond between.
Heretofore, it was desirable to include a third layer between the elastomeric layer and the hull in order to provide rigid integrity to the composite laminate fender structure predominantly because prior elastomeric layers were too flexible. The present invention provides an improvement to prior fender structures as will be described in further detail hereinafter. By virtue of the improvement, the elastomeric layer is eliminated and replaced by a relatively hard, resilient layer with a delayed elastic response, and the third layer between the elastomeric layer and the hull is eliminated.
The preferred material for the resilient, elastic layer 17 of the present invention consists of an elastomer and plastic blend or alloy, preferably crumb natural rubber held together by a matrix of the thermoplastic UHMWPE. An elastomer is defined as a substance that can be stretched at room temperature to at least twice its original length and, after having been stretched and the stress removed, returns with force to approximately its original length in a short time. (See Glossary of Terms as prepared by ASTM Committee D-11 on Rubber and Rubber-like Materials, published by the American Society of Testing Materials). The elastomeric or rubber material that can be used in constructing the present invention includes any of the well known elastomers, such as natural rubber, SBR rubber, copolymers of butadiene and acrylonitrile, copolymers of butadiene and styrene, copolymers of butadiene and alkyl acrylates, butyl rubber, olefin rubbers such as ethylene-propylene and EPDM rubber, fluorocarbon rubbers, fluorosilicone rubbers, silicone rubber, chlorosulfonated polyethylene, polyacrylates, polybutadiene, polychloroprene and the like. As noted before, however, natural rubber and other elastomers that have high elasticity are most preferred. Such elastomers have a shore A hardness of less than 65 before grinding. Of particular interest in the present invention is crumb rubber obtained by grinding used automotive or truck tires, because they are predominantly natural rubber and ground tire material is inexpensive. Fabric and steel wire particles originally in the tires should be removed.
The new alloy is hard, preferably having a hardness of 48 shore D, and fasteners can effectively be tightened against it. It is not “rubbery.” As explained earlier, the alloy has a delayed elastic response, and if it is impacted by a large object such as a ship it will absorb the energy imparted by the force and deform; however, it will over an extended period of time (from seconds to over an hour) recover its initial shape and dimensions.
Referring now to FIG. 4 a , wherein an impact force versus deflection curve for wood is illustrated. It can be seen that force is applied up to a maximum point 60 . When force is relaxed, the material is permanently set and does not recover. This curve illustrates that wood has high damping, low resiliency and very low recovery. The amount of energy absorption of the material is represented by the area 62 under the curve. It can be seen that wood has high energy absorption but is good for only one severe impact, after which it loses its favorable characteristics.
Referring now to FIG. 4 b , wherein an impact force versus deflection curve for a high damping, low resiliency rubber is illustrated. It can be seen that force is applied up to a maximum point 64 . When force is relaxed, the material is permanently set and does not recover. This curve is similar to the one for wood, meaning that the material has high damping, low resiliency, low recovery, and that it has high energy absorption (area 66 ) but is good for only one severe impact, after which it loses its favorable characteristics.
Referring now to FIG. 4 c , wherein an impact force versus deflection curve for a low damping, high resiliency rubber is illustrated. It can be seen that force is applied up to a maximum point 64 . When force is relaxed, the material returns reasonably close to its original shape, meaning the material has low permanent set. This material is therefore good for multiple severe impacts. Energy absorption (represented by hysteresis area 70 ) is, however, quite low, meaning that the material has high rebound and produces a slingshot effect, which is highly undesirable.
Referring now to FIG. 4 d , wherein an impact force versus deflection curve for the elastomer and plastic alloy of the present invention is illustrated. It can be seen that force is applied up to a maximum point 72 . When force is relaxed, the material returns close to its original shape, meaning the material has low permanent set. In addition, energy absorption is high, since hysteresis area 74 is large. It can be seen that a factor contributing to the high energy absorption is that the top curve 76 for the present invention is convex, whereas the top curves 78 , 80 for the materials for FIGS. 4 b and 4 c , respectively, are concave. It is to be noted that the hysteresis area 74 is about twice as large as that of FIG. 4 c.
FIG. 4 d therefore illustrates that the elastomer plastic alloy of the present invention provides the favorable characteristics for a fender protective structure without the drawbacks of prior materials. That is, the present elastomer plastic alloy has high damping, high resiliency, low permanent set, high energy absorption and a delayed elastic response. The material is good for multiple severe impacts and does not give a sling shot effect due to the delayed response.
As mentioned in the Background of the Invention section, commonly owned U.S. Pat. No. 4,735,982 to Orndorff, Jr. teaches mixing a thermoset rubber compound and a thermoplastic for use as staves in journal bearings. Low friction is critical property in the Orndorff, Jr. application. The friction properties of the alloy of the present invention are not necessarily as important as high elasticity, low hardness and high energy absorption. However, highly elastic, soft elastomers with high energy absorption inherently have high friction properties. The low friction elastomers of U.S. Pat. No. 4,735,982 inherently have low elasticity, high hardness and low energy absorption. The teachings of Orndorff, Jr. are therefore not compatible with the requirements of the present invention.
Manufacture of the fender protective structure of the present invention is as follows. For the elastomer used in the present alloy, a rubber compound is cured and, (in order to mix the two components), is ground to a suitable size to make a crumb rubber. Conventional grinding methods can be utilized, such as mechanical or cryogenic grinding. The crumb rubber is thoroughly dry mixed with a UHMWPE powder until a generally uniform random dispersion of the rubber is achieved. The particle size of the rubber and UHMWPE preferably pass through a Tyler mesh screen below 35, with the 20 mesh particles being more preferable. Because of the free flowing nature of the UHMWPE, the rubber and UHMWPE powder mix very easily. The preferred ratio of constituents is on the order of 30% UHMWPE powder and 70% crumb rubber by weight. Thus a elastomer plastic mixture 94 is created.
Referring now to FIG. 5, heretofore molds 84 were provided for curing fender protective structures. Projections 86 were provided integrally therewith for displacing the rubber compound for creating expansion bores in the cured resilient layer. The projections 86 had to be treated with a mold release material and had to have tapered sides 88 in order to facilitate separation of the mold from the material after the curing cycle. The necessary tapers and large number of projections 86 unduly increased tooling costs for producing fender protective structures. Even with the tapered projections and mold release preparation, though, it is still difficult to separate the mold and finished product, resulting in increased manufacturing costs due to time and labor.
Referring now to FIG. 6, a mold 90 , having the desired shape of the fender panels is provided. In accordance with another aspect of the present invention, a plurality of cured rubber blocks, plugs or projections 92 (having the desired shape of the bores 30 in FIG. 2) are placed in the mold at the desired locations for the bores 30 . Other cured rubber projections are provided for bores 35 . The rubber and UHMWPE mix 94 is then poured into the mold body over the rubber blocks 92 and the blocks for bores 35 . The rubber and UHMWPE mix 94 is then covered with a layer 96 of UHMWPE powder. A mold cover 98 is then secured onto the mold body and sufficient pressure and heat are applied thereto to mold the elastomer and rubber together and melt the polyethylene powder. The heating temperature must be above the glass transition temperature (Tg) of the plastic. Desirable heating temperatures range from about 290° F. to about 360° F. and preferably between 310° and 350° F. After the melted polyethylene powder has: a) coalesced to form a top polyethylene layer 16 ; and b) sufficiently bonded the crumb rubber particles together, the mixture is cooled under pressure (at least 600 psi and desirably more than 1000 psi) to ambient temperature in order to prevent cracking or strain failure of the alloy. The mold is then opened, and the finished composite is removed. This procedure makes for a very even and high quality molded article because the flow distortions problematic of conventional thermoplastic compounds are eliminated.
It is to be noted that the rubber projections 92 are preferably made of the same elastomeric material as defined above for use in the elastomer plastic alloy, such as a nitrile rubber. The rubber projections 92 are easy to manufacture and inexpensive to make, regardless of the required shape. Rubber projections or spacers 92 shrink more than the rubber plastic alloy during cooling, and therefore are easy to remove. That is the coefficient of thermal expansion of the rubber projections is greater than the very low coefficient of thermal expansion for the rubber plastic alloy and the rubber projections are more elastic than the alloy (after molding). These characteristics facilitate easy removal of the projections from the alloy after the fender protective structure is cooled. To this end, it has been found that the rubber projections “pop” out of the cured alloy when urged slightly. Sometimes the projections 92 simply fall out. It is now apparent that use of the removable rubber projections 92 reduces manufacturing costs of the fender protective structure of the present invention. It should be noted that spacers in prior versions of fender protectors were made from steel, which did not shrink at all during cooling—and whose removal was extremely difficult.
A way to improve the notoriously poor thermal conductivity (heat transfer) of the cured rubber void forming projections 92 involves increasing the slightly greater coefficient of thermal expansion of the rubber projections 92 so that they will shrink dimensionally even more than the UHMWPE/rubber polymer alloy. This should assure an easy release of the rubber projections 92 at the cooled-down temperature. One could not advantageously add powdered aluminum to the uncured rubber compound, similar to what is often done in tires for high speed (Mach 2) aircraft bombers, because this would decrease the coefficient of thermal expansion, causing the rubber projections 92 to be tightly locked in place instead of easily releasing. The inventor has determined that aluminum metal cylinders can be inserted into circular holes spaced periodically across the plan (top) view of the projections 92 and the projections for bores 35 . Aluminum has roughly 1000 times the thermal conductivity of rubber. Replacing only ten percent of the rubber plan view area with the aluminum cylinders would significantly increase the heat flow through the blocks as shown in the Table discussed below, without noticeably reducing the coefficient of thermal expansion.
Since the metal cylinders are not adhered to the rubber (inserted after cure), the cylinders will not affect the elastic deflection. Copper cylinders (2,000 times the thermal conductivity of rubber) or heat pipes (over 100,000 times the thermal conductivity of rubber) would work even better, but at a significant increase in cost.
Accordingly, high thermal conductivity materials 99 are combined with projections 92 to increase their coefficient of thermal or heat conductivity. Materials 99 can be cylindrical aluminum containers as shown in FIG. 6 . Materials 99 increase the heat flow to the alloy being cured. Upon cooling, the bore-producing projections shrink more than the plastic/elastomer alloy due to their higher coefficient of thermal expansion, to make the separation of the projections expedient. The following Table and calculations show how to determine the number of plugs required if made from aluminum or copper.
TABLE I
Thermal Conductivity, k
Material
(BTU-ft/Hour-ft 2 -° F.)
Nitrile Rubber
0.098
Aluminum
117
Copper
224
Steel
26
Heat Pipes
100,000+
Heat conducted through 1 ft 2 of area=k (1 ft 2 )
A. Nitrile Rubber=0.098 (1)=0.098 BTU-ft/Hour-° F.
Replacing 10% of area with aluminum plugs:
Conducted Heat
=0.098 (0.9)+117 (0.1)
=0.088+11.7
=11.788 BTU-ft/Hour-° F.
Conducted Heat Ratio=aluminum plugs/nitrile rubber=11.788/0.098=120.3
B. Replacing 10% of area with copper plugs:
Conducted Heat
=0.098 (0.9)+224 (0.1)
=0.088+22.4
=22.488 BTU-ft/hour-° F.
This is not quite as good as for steel.
Heat conducted through 1 ft 2 of area Steel=26 (1)=26 BTU-ft/hour-° F.
C. Replacing 20% of area with copper plugs:
Conducted Heat
=0.098 (0.8)+224 (0.2)
=0.0784+44.8
=44.88 BTU-ft/hour-° F.
Conducted Heat Ratio=copper plugs/steel=44.88/26=1.73 (an improvement)
D. No. of 1″ diameter copper plugs required for 20% coverage:
=0.2 (144)/Π(1) 2 /4=0.2 (144) (4)/Π=36.67
=37 Plugs
It should also be noted that the present alloy shows no loss of adhesion to the top plastic layer or other plates. No adhesives or other special materials or procedures are needed to cause the top layer to bond to the resilient layer.
The preferred characteristics of the elastomer/plastic alloy of the present invention are a shore A hardness of 95, an elastic or Young's modulus in compression of on the order of 5,469 psi for a shape factor=0.381, and a specific gravity of 1.09 (30% UHMWPE). It has been discovered that the present elastomer and plastic alloy as a unique combination of high damping, low resiliency and high recovery not found in conventional materials utilized before.
Immediate resiliency is defined herein as the percentage of impacting energy that is returned to the impacting object on the immediate rebound (ASTM-D-2632). In the case of a fender protective structure, a low resilience percentage is desired in order to eliminate the possibility of sling shot or whiplash occurring to the occupants of impacting vessels. To this end, the present alloy has similar deflection values and similar resiliency percentages (23-25%) of prior elastomeric compounds used in fender protective structures. An advantage of the present alloy though, because of its delayed elastic response, is that it return within several minutes to very near its original thickness whereas former high damping elastomeric compounds exhibited considerable permanent set, because conventional elastomeric compounds having high damping (low resilience) invariably have high permanent set.
The present alloy permits a lower cost fender protective structure which because a third layer is unnecessary and the present alloy is less than half the cost of prior elastomeric compounds.
Energy absorption of the present invention is also maximized because of the greater thickness of the elastomer alloy layer compared with former three layer designs. The result is that the bolts/studs are better isolated from impact forces while reducing the complexity of the system. The bonded two layer design of the present invention also has a much larger circumferential area (for the rubber to bulge upward) between the washer OD and the hole ID then is the case with conventional three layer designs. This helps to better isolate the bolts from impact forces.
EXAMPLE
Tests were conducted to determine the relative energy absorption valves between an EPDM rubber (S-401) developed by The B.F. Goodrich Company for bonded 3-layer impact pads (or batterboard) use with the 2-layer batterboard incorporating crumb rubber (such as made from ground up truck tire rubber). The S-401 rubber cannot be bolted against a rigid support because it is a relatively soft elastomer, and could not be used in the bonded 2-layer design.
In the graphs of test plats shown in FIGS. 7-10, the area shown between the load and unload (or rebound) curves shows the absorbed energy. The experiments were conducted to show and compare the absorbed energy.
It has been determined that high speed drop test impacts on batterboard could be simulated with equivalent damage by subjecting the test samples to very high compressive loads at much slower speeds using a large, conventional physical property test machine. 50,000 pounds has been found to be a high load, and 100,000 pounds has been found to be an extremely high load. (The impact energy is the same on both the drop test and the compressive test.)
TABLE II
UHMWPE/CRUMB RUBBER ALLOY
EPDM RUBBER (S-401)
50,000 LBS
100,000 LBS.
50,000 LBS
100,000 LBS
Overall Dimensions
4 × 4 × 3.3125 in.
4 × 4 × 3.3125 in.
4 × 4 × 3.563 in.
4 × 4 × 3.563 in.
(Plan View and Thickness)
Elastomer Thickness
2.625 in.
2.625 in.
2.325 in
2.325 in.
Elastomer Hardness
75
75
65
65
Overall Dimensions (Plan View)
4.625 in. × 4.625 in.
5.25 in. × 5.25 in.
4.125 × 4.125 in.
4.313 × 4.5 in
(After Test)
Overall Thickness Minutes After
2.875 in.
2.5 in.
3.313 in.
3.063 in.
Testing
Recovery After 5 Minutes
85.3%
75.5%
91.0%
86.0%
Recovery After 1.5 Hours and 2.0
(1.5 Hours)
(2 Hours) 91.0%
Hours
85.3%
Comments
No cracks or
Started cracking
splits
at 70,000 lbs.
Amount of Energy Absorbed
25,769 in. - lbs.
47,692 in. - lbs.
13,461 in. - lbs.
30,769 in. - lbs.
(The same sample in each case was consecutively tested at 50,000 and 100,000 lbs.)
The results of the tests are significant. The bonded 2-layer with the alloy absorbed 91.4% more energy than the S-401 rubber (25,769 vs. 13,461 in.-lbs.) when exposed to the 50,000 lb. force, and absorbed 55.5% more energy than the S-401 rubber (47,692 vs. 30,769 in.-lbs.) when exposed to the 100,000 lb. force. The S-401 rubber compressed more and returned much more energy on the rebound (sling-shot effect). The destructive reaction pressure on the back-up metal supporting structure would also be significantly reduced with the bonded 2-layer because of its greater energy absorption.
The results of the tests are shown for multiple or repeated impact capability. The test shown in FIG. 4C shows immediate elastic recovery for the S-401 rubber, whereas the new alloy's tests shown in FIG. 4D shows a delayed elastic response or resiliency.
The test results shown on the foregoing Table and FIGS. 7-10 indicate that the new alloy was recovering its thickness at a faster rate than the S-401 rubber (see both “Recovery” rows in Table II).
Although the invention has been shown and described with exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto without departing from the spirit and scope of the invention. | A method of making a fender protective structure having a layer of resilient plastic/elastomer alloy having a delayed elastic response, comprising providing a mold, placing elastomer spacers in the mold, adding the plastic and elastomer to the mold under heat and pressure, and opening the mold and removing the spacers to create voids the alloy. | 8 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
The present invention relates to eyeglass structures, and more particularly to eyeglass structures having a pair of temple members whereto mounting supports are attached to secure the eyeglass structure on the ridges of the temporal process of the zygomatic bone of the wearer.
Heretofore, most eyeglass structures have rested and been supported on the nose and the temple members of the eyeglass structures have rested on the ears and engaged both sides of the head behind the ears. Such eyeglass structures have the major portion of the weight thereof concentrated on the nose of the person wearing same and, therefore, tend to bear on and slide down the nose. Constant wearing of these conventional eyeglass structures often results in unsightly creases in the skin and tissue on both sides of the nose. This pressure on the sensitive part of the face can become irritating to the wearer and can even cause permanent creases in the areas of contact upon wearing of these conventional eyeglass structures over an extended period of time. The pressures on both sides of the nose can also cause discomfort to the wearer, e.g., headaches, eye congestions, etc. Traditional eyeglass structures can not be used by many people after nose surgery due to the pressures exerted by conventional frame members. Also, some people have such nose shapes that are difficult and, in some instances, practically impossible to fit with conventional eyeglass structures that will remain in position thereon. It is, of course, understood that a person who is handicapped due to the loss of a nose can not be accommodated by these conventional eyeglass structures.
Attempts have been made to secure eyeglass structures to the head of the wearer using other securing means to avoid fatiguing support on the nose. Such eyeglass structures often require additional components such as headband, suction cups, adhesive devices, and magnetic devices. These additional components may lead to an increase in the production cost of these special eyeglass structures. Head-mount type eyeglass structures are large or have tight headbands or members extending over the top of the head are unsightly and the hairstyle of the wearer could be damaged badly. Furthermore, the shapes and styles of these eyeglasses are quite different than the conventional eyeglasses that are commonly used in nowadays.
While these eyeglass structures may be suitable for the purposes for which they were designed, still there is a need for eyeglass structures that utilize other area than the nose as a supporting base for the eyeglass structure and yet to suffice consumers in convenience, cost, and style.
BRIEF SUMMARY OF THE INVENTION
The present invention is eyeglass structures having a pair of temple members whereto mounting supports are attached to secure the eyeglass structure on the ridges of the temporal process of the zygomatic bone of the wearer.
The principal object of the present invention is to provide an eyeglass structure that overcomes the aforementioned problems and that can be worn without discomfort while avoiding any contact with the nose of the wearer.
One aspect of the present invention is eyeglass structure having a pair of mounting supports and each mounting support is attached to the corresponding temple member. The pad of the mounting support provides a wide contact area with the wearer and distributes the weight of the eyeglass structure throughout the contact area. Each mounting support is located in the closest distance to the ridge of the temporal process of zygomatic bone of the wearer.
Another aspect of the present invention is a method of adjusting the position of the pad of the mounting support to have a proper contact along the ridge of the temporal process of zygomatic bone to secure the eyeglass structure on the head of the wearer. The pad position of the mounting support can be adjusted by bending the C-shaped arm of the mounting support toward the desired direction using a tool such as a plier.
These and other features, advantages and objects of the present invention will become apparent from the following description taken in connection with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The drawings constitute a part of the specification and include exemplary embodiments illustrating various objects and features of the eyeglass structure of the present invention.
FIG. 1 is a lateral view of a human head showing relevant bone structures.
FIG. 2 is an anterior view of a human head showing relevant bone structures.
FIG. 3 is a perspective view of the eyeglass structure embodying features of the present invention.
FIG. 4 is a top perspective view of the eyeglass structure embodying features of the present invention.
FIG. 5 is an exploded perspective view of the mounting support, an exemplary embodiment of the present invention.
FIG. 6 is an enlarged sectional view of the mounting support taken on line 1 — 1 , FIG. 4 .
FIG. 7 is a side view of the eyeglass structure with straight temple members, a typical embodiment of the present invention.
FIG. 8 is a side view of the eyeglass structure with curved temple members, an alternative embodiment of the present invention.
FIG. 9 is a side view of the eyeglass structure with straight temple members and straight temple covers, an alternative embodiment of the present invention.
FIG. 10 is a side view of the eyeglass structure with curved temple members and straight temple covers, an alternative embodiment of the present invention.
FIG. 11 is a perspective view of a person wearing the eyeglass structure embodying features of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following discussion describes in detail one embodiment of the invention and several variations of that embodiment. This discussion should not be construed, however, as limiting the invention to those particular embodiments because the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for claims and as a representative basis for teaching one skilled in the art to employ the present invention in any detailed structure.
As shown in FIGS. 1 and 2 , there are two zygomatic bones 11 in each human head 10 . Each zygomatic bone 11 has a process extending toward the backside of the head along the temple area and is called as the temporal process of the zygomatic bone 12 . On the top of the temporal process of the zygomatic bone 12 , there is a ridgeline that further extends towards backside of the head through the zygomatic process of the temporal bone 13 . This ridge of the temporal process of the zygomatic bone 12 provides a rigid base for the pad 221 of the mounting support 22 of the eyeglass structure 20 . Although the ridgeline on the temporal process of the zygomatic bone 12 is an excellent place for the mounting support 22 , the ridgeline on the zygomatic process of the temporal bone 13 could be an alternative place for the mounting supports 22 to secure the eyeglass structure 20 to the wearer.
FIG. 3 is an illustrative view of the eyeglass structure design, a typical embodiment of the present invention. In this design, the eyeglass structure 20 is comprised of a pair of lenses 21 , a pair of mounting supports 22 , one bridge 23 , a pair of eyewire barrels 24 , a pair of end pieces 25 , a pair of temple members 26 , and a pair of temple covers 27 . A top perspective view of the eyeglass structure 20 is shown in FIG. 4 . A mounting support 22 is attached firmly to the temple member 26 through soldering or welding. The mounting support 22 is comprised of a pad 221 , an arm 222 , a stem 223 , and a screw 224 as shown in FIGS. 5 and 6 . The arm 222 of the mounting support 22 is attached to the temple member 26 such that the pad 221 could be rested at the closest distance to the ridge of the temporal process of the zygomatic bone 12 when the eyeglass structure 20 is worn by the wearer. The C-shaped arm 222 of the mounting support 22 can be bended toward any direction whenever necessary to position the pad 221 on the ridge area of the temporal process of the zygomatic bone 12 of the wearer. The arm 222 and temple member 26 should be made of metals that can be easily welded or soldered. The pad 221 can be coupled to the metal stem 223 by pushing the stem 223 into the opening hole of the pad 221 . In this case the pad 221 is made of elastic material so the metal stem 223 can be pushed into the smaller opening hole of the elastic pad 221 . Injection molding could be an alternative way of coupling the pad 221 with the stem 223 when plastic material is selected for pad 221 .
FIG. 7 is a side view of the eyeglass structure 20 with straight temple members 26 and curved temple covers 27 . The temple cover 27 is bended downward and engaged the side of the head behind the ear. In this design, most part of the mounting support 22 can be seen from the side.
FIG. 8 is a side view of the eyeglass structure 30 with curved temple members 36 and curved temple covers 27 . The temple cover 27 is bended downward and engaged the side of the head behind the ear. In this design, only a fraction of the mounting support 22 can be seen from the side.
FIG. 9 is a side view of the eyeglass structure 40 with straight temple members 26 and straight temple covers 47 . The temple cover 47 is engaged along the side of the head behind the ear. In this design, most part of the mounting support 22 can be seen from the side.
FIG. 10 is a side view of the eyeglass structure 50 with curved temple members 36 and straight temple covers 47 . The temple cover 47 is engaged along the side of the head behind the ear. In this design, only a fraction of the mounting support 22 can be seen from the side.
FIG. 11 is a perspective view of a person wearing the eyeglass structure 20 of the present invention.
The eyeglass structures of the present invention provide a comfortable way to secure the eyeglass structures to the head of the wearer without having any contact with nose. The eyeglass structures of present invention are versatile and can be adjusted to fit a wide range of sizes, and can be made using a variety of different styles.
The above description is considered that of the preferred embodiment only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents. | Eyeglass structures having mounting supports in temple members are provided. This design eliminates conventional nose pads and is free from any physical contact with nose. It provides a comfortable and stylish eyeglass structure to the wearer. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from Japanese Patent Application No. 2011-286379, filed on Dec. 27, 2011 and Japanese Patent Application No. 2012-096788, filed on Apr. 20, 2012, which are incorporated herein by reference.
FIELD
The disclosure relates to an image-reading device that reads a document, and more specifically, to an image-reading device that controls power supply to reduce power consumed by reading components used for document reading.
BACKGROUND
In order to achieve power savings, a known image-reading device, for example, a scanner, is configured to enter a power saving mode to reduce power consumed by reading components used for document reading while the scanner is not in an operating condition.
A known scanner, as an example of an image-reading device that controls power, includes a retractable document mount that is capable of opening and closing with respect to a main body of the known scanner. The known scanner is configured to turn itself on or off in accordance with the opening or closing of the document mount.
SUMMARY
The known scanner is configured to turn itself on or off in accordance with opening or closing of the document mount. When the document mount is changed to an unused position during document reading, the known scanner turns itself off during the document reading and this may detrimentally influence image reading quality. The configuration in which turning on or off of power of the known scanner is controlled by the opening or closing of the document mount provides usability. Thus, the scanner not having such a configuration may reduce user convenience.
According to aspects of the disclosure, an image-reading device configured to control power supply and achieve image-reading quality and user convenience may be accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure and the features and advantages thereof, reference now is made to the following descriptions taken in connection with the accompanying drawing.
FIG. 1 depicts a scanner in an illustrative embodiment according to one or more aspects of the disclosure, wherein a document feed tray is closed.
FIG. 2 depicts the scanner in the illustrative embodiment according to one or more aspects of the disclosure, wherein the document feed tray is opened.
FIG. 3 depicts an internal configuration of the scanner of FIG. 1 in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 4 depicts the internal configuration of the scanner of FIG. 2 in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 5 is a block diagram depicting an electric configuration of the scanner in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 6 is a perspective view depicting a power supply control system in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 7 depicts a relationship between each mode and a condition of power supply to each component in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 8 is a flowchart depicting a mode switching process in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 9 is a flowchart depicting a second power-saving mode executing process in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 10 is a flowchart depicting a power saving mode switching process in the illustrative embodiment according to one or more aspects of the disclosure.
DETAILED DESCRIPTION
Hereinafter, an illustrative embodiment in which an image-reading device according to the aspects of the disclosure may be implemented is described in detail with reference to the accompanying drawings. In the illustrative embodiment, the aspects of the disclosure may be applied to a scanner that may have a power saving mode for reducing power consumption in the scanner.
As depicted in FIGS. 1 and 2 , a scanner 100 may comprise a housing 6 , a document holding portion such as a document feed tray 91 , and a document discharge tray 92 . Housing 6 may cover a main body of scanner 100 . Document feed tray 91 may be configured to cover or uncover an upper surface 6 A of housing 6 and be opened or closed with respect to scanner 100 . Document discharge tray 92 may be disposed at a lower part of scanner 100 . In FIG. 1 , the side on which document discharge tray 92 may be disposed may be defined as the front of scanner 100 . The right, left, front, and rear of scanner 100 may be defined when scanner 100 is disposed in an orientation in which it is intended to be used, and the defined directions may be applicable to the drawings of FIGS. 2-4 .
Document feed tray 91 may be supported by housing 6 so as to be pivotable about a rotation axis X that may be located at a rearwardly upward position with respect to housing 6 to extend along a right-left direction. When document feed tray 91 is pivoted about rotation axis X to be opened from a position where document feed tray 91 may cover upper surface 6 A as depicted in FIG. 1 , document feed tray 91 may be changed to a position where document feed tray 91 may allow a document holding surface 91 A to face upward at a rearward part of housing 6 as depicted in FIG. 2 . In the illustrative embodiment, the position where document holding surface 91 A may be exposed as depicted in FIG. 2 may be referred to as a “used position” of document feed tray 91 and the position where document holding surface 91 A may not be exposed as depicted in FIG. 1 may be referred to as an “unused position” of document feed tray 91 . In the used position, document feed tray 91 may be configured to hold one or more documents that have not been read yet. In the unused position, document feed tray 91 may be configured not to hold any documents because document feed tray 91 may not allow document holding surface 91 A to appear in the unused position.
Document discharge tray 92 may be disposed at the lower part of housing 6 and may be configured to be inserted into or be drawn from housing 6 along a front-rear direction. As depicted in FIG. 2 , document discharge tray 92 may be configured to be drawn forward with respect to housing 6 . In the illustrative embodiment, the position where document discharge tray 92 may be drawn forward with respect to housing 6 as depicted in FIG. 2 may be referred to as a “used position” of document discharge tray 92 and the position where document discharge tray 92 may be accommodated in housing 6 as depicted in FIG. 1 may be referred to as an “unused position” of document discharge tray 92 . Similar to document feed tray 91 , in the used position, document discharge tray 92 may be configured to hold one or more documents that have been read. In the unused position, document discharge tray 92 may be configured not to hold any documents.
As depicted in FIG. 2 , housing 6 may comprise an operating panel 40 that may comprise a keypad 41 and a display unit 42 at upper surface 6 A. Keypad 41 may comprise various buttons (e.g., a start key, a stop key, and numeric keys). Display unit 42 may comprise a liquid crystal display. When document feed tray 91 is located in the unused position, input operations on operating panel 40 by a user may be limited because document feed tray 91 covers operating panel 40 (see FIG. 1 ). When document feed tray 91 is located in the used position, operating panel 40 may appear to allow all input operations by the user.
FIGS. 3 and 4 depict an internal configuration of scanner 100 . FIG. 3 depicts scanner 100 in which both the document feed tray 91 and document discharge tray 92 are located in their unused positions. FIG. 4 depicts scanner 100 in which document feed tray 91 and document discharge tray 9 are located in their used positions.
Scanner 100 may comprise a feed roller 62 , a first conveyor roller 63 , image sensors 21 , 22 , and a second conveyor roller 64 in its inside. In this illustrative embodiment, the reading components, for example, feed roller 62 , first conveyor roller 63 , image sensors 21 , 22 , and second conveyor roller 64 , used for document reading may be collectively called an image reading unit 20 . Image reading unit 20 may be configured to read a color image or read a monochrome image only.
One of image sensors 21 , 22 may be configured to read an image on one side of a document and the other of image sensors 21 , 22 may be configured to read an image on the other side of the document. In each of image sensors 21 , 22 , optical elements may be arranged in line along the right-left direction (a direction perpendicular to the drawing surface of FIG. 4 ). Each of image sensors 21 , 22 may be configured to convert light reflected from the document into electronic signals and output the electronic signals. For example, a contact image sensor (“CIS”) or a charge-coupled device (“CCD”) may be employed as image sensors 21 , 22 .
Scanner 100 may convey one or more documents 9 held on document feed tray 91 along a direction indicated by an arrow D depicted in FIGS. 2 and 4 from document feed tray 91 to document discharge tray 92 . More specifically, in scanner 100 , document feed tray 91 may be located in the used position for setting one or more documents 9 on document feed tray 91 . As depicted in FIG. 4 , the user may set one or more documents 9 on document feed tray 91 . The one or more documents 9 held on document feed tray 91 may move toward feed roller 62 by their own weight. Then, feed roller 62 may convey documents 9 , one by one, downstream along a conveying path 61 . Image reading unit 20 may read one or both sides of document 9 that is moving in conveying path 61 when document 9 passes image reading unit 20 . After that, scanner 100 may discharge document 9 onto document discharge tray 92 . That is, document feed tray 91 and document discharge tray 92 may constitute a part of conveying path 61 .
As depicted in FIG. 3 , in scanner 100 , when document feed tray 91 is located in the unused position, conveying path 61 may be curved in a substantially U-shape manner at rotation axis X of document feed tray 91 . Therefore, when document feed tray 91 is located in the unused position, scanner 100 may be configured to not perform document reading by image reading unit 20 .
Scanner 100 may further comprise a control device 10 and a power supply control system 50 in its inside as well as image reading unit 20 . Control device 10 may be configured to control image reading unit 20 . Power supply control system 50 may be configured to control power supplied to each unit or component of scanner 100 . Control device 10 and power supply control system 50 will be described in detail later.
An electric configuration of scanner 100 is now described. As depicted in FIG. 5 , scanner 100 may comprise image reading unit 20 , a detector such as sensor 30 , operating panel 40 , power supply control system 50 , control device 10 , a Universal Serial Bus (“USB”) interface (“I/F”) 15 and a network interface (“I/F”) 16 . Sensor 30 may be configured to detect the position of document feed tray 91 in the used position or in the unused position. Power supply control system 50 may be configured to control power supplied to each unit or component of scanner 100 . Control device 10 may be configured to control operations of image reading unit 20 . USB interface 15 and network interface 16 may be communication interfaces for establishing connections between scanner 100 and an output destination device, for example an external device.
Control device 10 may comprise a central processing unit (“CPU”) 11 , a read-only memory (“ROM”) 12 , a random-access memory (“RAM”) 13 , and a nonvolatile RAM (“NVRAM”) 14 . ROM 12 may store firmware that may control programs for controlling scanner 100 and various settings as well as certain setting values. RAM 13 may be used as a workspace for temporarily storing the control programs read from ROM 12 or as a storage area for temporarily storing image data.
A reading control device, for example CPU 11 , may control functions of each unit or each component of scanner 100 . CPU 11 may store processing results in RAM 13 or NVRAM 14 , in accordance with the control programs read from ROM 13 and signals sent from sensors.
USB interface 15 may be configured to allow scanner 100 to communicate with the external device. For example, when an USB memory is connected to USB interface 15 , scanner 100 may output read image data to the USB memory. USB interface 15 may not always be connected with the USB memory but also can be connected with, for example, a personal computer (“PC”). When USB interface 15 is connected with a PC, scanner 100 may be configured to receive various instructions, for example, a scanning instruction or a setting instruction, from the PC via USB interface 15 .
Similar to USB interface 15 , network interface 16 may be configured to allow scanner 100 to communicate with the external device. Scanner 100 may be configured to output read image data to an external device connected thereto via network interface 16 . Scanner 100 may receive instructions from the external device via network interface 16 .
The connection between scanner 100 and the external device may be established via other devices as well as USB interface 15 and network interface 16 . For example, when scanner 100 comprises a wireless communication interface, scanner 100 may be connected with the external device via wireless communication.
Image reading unit 20 may be configured to read an image on a document and output the read image as image data, for example, in PDF format. Image reading unit 20 may be further configured to perform a correction process on the image data as required. Image reading unit 20 may output the image data to, for example, the external device that may be connected with scanner 100 via USB interface 15 or network interface 16 .
Sensor 30 may be configured to output a signal identifying whether document feed tray 91 is in the used position (an opened state) or in the unused position (a closed state). Sensor 30 may comprise, for example, a light-emitting element and a light-receiving element. When document feed tray 91 is located in the used position, sensor 30 may be configured such that the light-receiving element may receive light from the light-emitting element. When document feed tray 91 is located in the unused position, sensor 30 may be configured such that the light-receiving element may not receive light from the light-emitting element due to an interruption.
The power supply control performed in scanner 100 is described below. As depicted in FIG. 6 , scanner 100 may comprise a power source device 51 (an example of a supply device), a switch circuit 52 , and a power supply control device 53 , collectively forming a power supply control system 50 . Switch circuit 52 may be configured to distribute the power supplied from power source device 51 to each unit or each component of scanner 100 . Power supply control device 53 may be configured to control making and breaking of each switch of switch circuit 52 .
Power source device 51 may comprise a circuit that may be configured to be connected with, for example, a main electricity grid or a battery, and convert the power to an appropriate level to supply to each unit or each component of scanner 100 . Switch circuit 52 may be configured to switch a power supply condition between supplying or not supplying power to each unit or each component of scanner 100 in accordance with a signal outputted from power supply control device 53 . More specifically, scanner 100 may comprise a power source system for image reading unit 20 , a power source system for control device 10 , and a power source system for an external interface (for example, USB interface 15 and network interface 16 in this embodiment). Switch circuit 52 may be configured to switch the power supply condition between supplying or not supplying power to each power source system. Power source device 51 may supply power to sensor 30 and operating panel 40 all the time by bypassing switch circuit 52 .
A plurality of power-supply modes are now described below. The plurality of power-supply modes may be realized by the switching of the power supply condition by switch circuit 52 between supplying or not supplying power to each power source system. The power-supply modes may include a power saving mode for reducing power consumed by one or more of image reading unit 20 and the other units and components, and a non-power saving mode for not reducing power consumed by image reading unit 20 and the other units and components.
More specifically, the non-power saving mode may include a ready mode. In the ready mode, scanner 100 may be allowed to perform image reading from a document and data transmission or reception and to receive user operations through operating panel 40 . The power saving mode may include a first power-saving mode and a second power-saving mode. In the first power-saving mode, scanner 100 may be allowed to perform data transmission or reception via USB interface 15 , network interface 16 , or other interfaces and to receive user operations through operating panel 40 but may not be allowed to perform image reading from a document. In the second power-saving mode, scanner 100 may not be allowed to perform image reading from a document and data transmission or reception while operating panel 40 , sensor 30 , and power supply control system 50 may be allowed to operate.
FIG. 7 depicts a relationship between each mode and a condition of power supply to each unit or each component. In FIG. 7 , “SUPPLIED” may represent that power is supplied to the unit or the component and “NOT SUPPLIED” may represent that power is not supplied to the unit or the component. As depicted in FIG. 7 , in the ready mode, power is supplied to all of image reading unit 20 , control device 10 , operating panel 40 , the external interface, and sensor 30 , and scanner 100 may be allowed to perform a scanning operation. Immediately after scanner 100 is up, scanner 100 may operate in the ready mode. When a condition for shifting to the first power-saving mode is met during the ready mode, the mode may be changed to the first power-saving mode. When a condition for shifting to the second power-saving mode is met during the ready mode or during the first power-saving mode, the mode may be changed to the second power-saving mode.
In the first power-saving mode, switch circuit 52 may interrupt the power supply to image reading unit 20 . That is, switch circuit 52 may interrupt the power supply to image sensors 21 , 22 , which may consume a larger amount of power, to reduce the power consumption in scanner 100 . However, switch circuit 52 may not interrupt the power supply to control device 10 , operating panel 40 , and the external interface to receive user operations. When a condition for shifting to the ready mode is met, the mode may be changed to the ready mode.
In the second power-saving mode, switch circuit 20 may interrupt the power supply to control device 10 and the external interface in addition to image reading unit 20 . That is, scanner 100 may not be allowed to perform data transmission or reception to or from the external device. This power supply control may further reduce the power consumption in scanner 100 as compared with the power consumption in scanner 100 in the first power-saving mode. However, switch circuit 20 may not interrupt the power supply to sensor 30 . That is, sensor 30 may be controlled by a circuit different from control device 10 , and thus, sensor 30 may be configured to detect the position of document feed tray 91 in the used position or in the unused position when scanner 100 is in the second power-saving mode. When document feed tray 91 is changed to the used position during the second power-saving mode, scanner 100 may determine that the document feed tray 91 has been changed from the unused position to the used position based on the detection result of sensor 30 and may shift to the ready mode. In the second power-saving mode, operating panel 40 may be supplied with power. That is, operating panel 40 may be controlled by a circuit different from control device 10 and may be configured to receive user operations when scanner 100 is in the second power-saving mode.
More specifically, power supply control device 53 may store a threshold time period (e.g., a waiting period) that may be a time at which the mode may be changed to the power saving mode. When the elapsed time measured by a timer exceeds the threshold time period since a time period during which the document reading may be performed has elapsed or a user operation (for example, an input through operating panel 40 or an instruction inputted from the external device) has been completed, the mode may be changed to the power saving mode. When document feed tray 91 is located in the used position at the time the elapsed time being measured exceeds the threshold time period, the mode may be changed to the first power-saving mode. When document feed tray 91 is located in the unused position at the time the elapsed time being measured exceeds the threshold time period, the mode may be changed to the second power-saving mode. After the mode is changed to the second power-saving mode, the timer may stop because the power supplied to control device 10 that can control the timer is interrupted.
Power supply control device 53 may be configured to output, to switch circuit 52 , a signal for supplying or not supplying power to each power source system, in accordance with the current mode. Power supply control device 53 may be directly supplied with power from power source device 51 and configured to work while scanner 100 is in the second power-saving mode. Therefore, power supply control device 53 may control switch circuit 52 by monitoring an output signal from sensor 30 while scanner 100 is in the second power-saving mode.
A mode switching process for switching among the above-described modes is described with reference to FIG. 8 . The mode switching process may be performed by power supply control device 53 when power source device 51 is connected to the main electricity grid or the battery and power is supplied to power supply control device 53 from power source device 51 .
As the mode switching process starts, first, power supply control device 53 may operate in the ready mode in an initial state (step S 101 ). It may be expected that scanner 100 will probably be used immediately after scanner 100 is up. Therefore, the mode may preferably be the ready mode immediately after scanner 100 is up.
After step S 101 , power supply control device 53 may start the timer to measure time (step S 102 ). The time being measured by the timer may be used for a mode switching determination. The measured time of the timer may be reset to an initial value when document reading is started. The timer may stop measuring time during document reading, and the timer may restart measuring time when the document reading is completed. The measured time of the timer may be reset to the initial value when control device 10 detects a user operation through operating panel 40 or receipt of a signal from the external device.
Then, power supply control device 53 may determine whether communication is available between scanner 100 and an external device (step S 151 ). The external device may be the USB memory connectable to scanner 100 via USB interface 15 or the PC connectable to scanner 100 via network interface 16 .
When communication is available between scanner 100 and an external device (step S 151 : YES), power supply control device 53 may specify a time period T 1 (for example, 15 minutes) as the threshold time period for shifting to the power saving mode (step S 152 ). When communication is not available between scanner 100 and an external device (step S 151 : NO), power supply control device 53 may specify a time period T 2 (for example, 3 minutes) as the threshold time period to further reduce the power consumption in scanner 100 (step S 153 ). Time period T 2 may be shorter than time period T 1 . After step S 152 or step S 153 , the routine may move to step S 103 .
Then, power supply control device 53 may determine whether document feed tray 91 has been changed from the used position to the unused position (step S 103 ). Power supply control device 53 may determine the position of document feed tray 91 based on the output signal sent from sensor 30 . In step S 103 , when sensor 30 detects the position change of document feed tray 91 from the used position to the unused position, power supply control device 53 may make a positive determination (step S 103 : YES). From then on, power supply control device 53 may not make the positive determination in step S 103 until sensor 30 detects again the position change of document feed tray 91 from the used position to the unused position.
When document feed tray 91 has been changed from the used position to the unused position (step S 103 : YES), power supply control device 53 may determine whether the elapsed time measured by the timer has exceeded the threshold time period (step S 104 ). When the elapsed time measured by the timer has exceeded the threshold time period (step S 104 : YES), power supply control device 53 may perform a second power-saving mode executing process by shifting to the second power-saving mode (step S 105 ).
FIG. 9 depicts details of the second power-saving mode executing process in step S 105 . In the second power-saving mode executing process, first, power supply control device 53 may change the mode to the second power-saving mode (step S 181 ). In step S 181 , power supply control device 53 may output the signal for supplying or not supplying power to each power source system with respect to switch circuit 52 to control switch circuit 52 for changing the power-supply mode. This may be realized by the switching of the power supply condition by switching switch circuit 52 between supplying and not supplying power to each power source system in the second power-saving mode. That is, when document feed tray 91 is located in the unused position, the user may not be allowed to operate operating panel 40 or to set one or more documents 9 on document feed tray 91 . Therefore, it may be conceivable that the user may not intend to use scanner 100 . Thus, power supply control device 53 may change the mode to the second power-saving mode for more effectively reducing the power consumption in scanner 100 .
Then, power supply control device 53 may determine whether document feed tray 91 has been changed from the unused position to the used position based on the output signal from sensor 30 (step S 182 ). While document feed tray 91 is located in the unused position (step S 182 : NO), the routine may wait until document feed tray 91 is changed from the unused position to the used position.
When document feed tray 91 has been changed to the used position (step S 182 : YES), power supply control device 53 may change the mode to the ready mode (step S 183 ). In step S 183 , power supply control device 53 may output the signal for supplying or not supplying power to each power source system with respect to switch circuit 52 to control switch circuit 52 for changing the power-supply mode. This may be realized by the switching of the power supply condition by switch circuit 52 between supplying and not supplying power to each power source system in the ready mode, because it may be conceivable that the user will use scanner 100 . Then, power supply control device 53 may reset the measured time of the timer to the initial value and restart the timer to measure time (step S 184 ). After step S 184 , power supply control device 53 may exit the second power-saving mode executing process.
Back to the mode switching process of FIG. 8 , after performing the second power-saving mode executing process in step S 105 , the routine may move to step S 151 .
When the elapsed time measured by the timer has not exceeded the threshold time period (step S 104 : NO), power supply control device 53 may determine whether scanner 100 is currently performing document reading (step S 131 ). The measured time of the timer may be reset when document reading is started and the timer may stop measuring time during document reading. Therefore, the elapsed time measured by the timer does not exceed the threshold time period when scanner 100 is currently performing document reading. Thus, the case where the elapsed time measured by the timer has not exceeded the threshold time period may include a case where scanner 100 is currently performing document reading and a case where the elapsed time has not exceeded the threshold time period since the document reading was completed.
When scanner 100 is currently performing document reading (step S 131 : YES), power supply control device 53 may cancel the reading of one or more documents following the current target document after a time period during which the current target document is read is over (step S 132 ). That is, when scanner 100 stops the current document reading in the middle of reading the current target document, scanner 100 may not obtain completely-read image data. Even when scanner 100 restarts the reading of the current target document, the quality of an image may be degraded due to variations in the reading speed. Accordingly, scanner 100 may continue the reading of the document being currently read to complete the reading of the current target document. However, scanner 100 may not perform reading of any documents following the current target document because a problem may arise during the conveyance of the following documents. After the completion of step S 132 , the current document reading is completed. Therefore, power supply control device 53 may restart the timer, which has stopped, to measure time. After step S 132 or when scanner 100 is not currently performing the document reading (step S 131 : NO), the routine may move to step S 151 .
Back to step S 103 , when document feed tray 91 has not been changed from the used position to the unused position (step S 103 : NO), power supply control device 53 may determine whether document feed tray 91 has been changed from the unused position to the used position (step S 111 ). In step S 111 , when sensor 30 detects the position change of document feed tray 91 from the unused position to the used position, power supply control device 53 may make a positive determination (step S 111 : YES). From then on, power supply control device 53 may not make the positive determination until sensor 30 detects the position change of document feed tray 91 from the unused position to the used position.
When document feed tray 91 has been changed from the unused position to the used position (step S 111 : YES), power supply control device 53 may change to the ready mode (step S 112 ). In step S 112 , power supply control device 53 may output the signal for supplying or not supplying power to each power source system with respect to switch circuit 52 to control switch circuit 52 for changing the power-supply mode. This may be realized by switching the power supply condition by switch circuit 52 between supplying and not supplying power to each power source system in the ready mode. That is, power supply control device 53 may control switch circuit 52 to supply power to each unit or each component of scanner 100 and thus scanner 100 may be allowed to perform document reading. When scanner 100 is in the ready mode at the time of the position change of document feed tray 91 from the unused position to the used position, power supply control device 53 may not need to perform step S 112 . After step S 112 , power supply control device 53 may reset the measured time of the timer to the initial value and restart the timer to measure time (step S 113 ). After step S 113 , the routine may move to step S 151 .
When document feed tray 91 has not been changed from the unused position to the used position (step S 111 : NO), power supply control device 53 may perform a power saving mode switching process for determining whether an automatic mode change to the first or second power-saving mode is performed (step S 121 ).
FIG. 10 depicts details of the power saving mode switching process in step S 121 . In the power saving mode switching process, first, power supply control device 53 may determine whether the elapsed time measured by the timer has exceeded the threshold time period (step S 201 ). When the elapsed time measured by the timer has exceeded the threshold time period (step S 201 : YES), power supply control device 53 may determine whether document feed tray 91 is located in the used position (step S 202 ).
When document feed tray 91 is located in the used position (step S 202 : YES), power supply control device 53 may change the mode to the first power-saving mode (step S 203 ). In step S 203 , power supply control device 53 may output the signal for supplying or not supplying power to each power source system with respect to switch circuit 52 to control switch circuit 52 for changing the power-supply mode. This may be realized by switching the power supply condition by switch circuit 52 between supplying and not supplying power to each power source system in the first power-saving mode. In the first power-saving mode, power supply control system 50 may control switch circuit 52 to stop supplying power to image reading unit 20 while continuing to supply power to operating panel 40 , the external interface, and control device 10 that may control operating panel 40 and the external interface. Therefore, in the first power-saving mode, scanner 100 may be allowed to receive an input through operating panel 40 or an input from the external device. When scanner 100 has already been in the first power-saving mode at the time of step S 203 , power supply control device 53 may not need to perform step S 203 .
When document feed tray 91 is located in the unused position (step S 202 : NO), power supply control device 53 may perform the second power-saving mode executing process (step S 221 ). In the second power-saving mode, power supply control system 50 may control switch circuit 52 to stop supplying power to image reading unit 20 , the external interface, and control device 10 that may control operating panel 40 and the external interface. Therefore, in the second power-saving mode, scanner 100 may not be allowed to receive an input from the external device. The processing of step S 221 may be the same as the processing of step S 105 . After completing step S 221 , power supply control device 53 may exit the power saving mode switching process.
After step S 203 or when the elapsed time measured by the timer has not exceeded the threshold time period (step S 201 : NO), power supply control device 53 may determine whether scanner 100 has received a user operation (step S 204 ). The user operation to scanner 100 may be, for example, an input operation on operating panel 40 , an issue of a scanning instruction from the PC, or an access to data from the PC. When scanner 100 has not received a user operation (step S 204 : NO), power supply control device 53 may exit the power saving mode switching process.
When scanner 100 has received a user operation (step S 204 : YES), power supply control device 53 may change the mode to the ready mode (step S 205 ). In step S 205 , power supply control device 53 may output the signal for supplying or not supplying power to each power source system with respect to switch circuit 52 to control switch circuit 52 for changing the power-supply mode. This may be realized by the switching of the power supply condition by switch circuit 52 between supplying and not supplying power to each power source system in the ready mode for performing processing corresponding to the user operation. That is, power supply control system 50 may control switch circuit 52 to supply power to each unit or each component of scanner 100 and this scanner 100 may be allowed to perform document reading. When scanner 100 has already been in the ready mode at the time of step S 205 , power supply control device 53 may not need to perform step S 205 . After step S 205 , power supply control device 53 may reset the measured time of the timer to the initial value and restart the timer to measure time (step S 206 ). After step S 206 , power supply control device 53 may exit the power saving mode switching process.
Back to the mode switching process of FIG. 8 , after performing the power saving mode switching process of step S 121 , the routine may move to step S 151 .
As described above, in scanner 100 according to the illustrative embodiment, while scanner 100 does not perform reading of a document 9 , the user convenience may be ensured by the mode change to the power saving mode (in particular, the second power-saving mode in this illustrative embodiment) performed in accordance with the position change of document feed tray 91 from the used position to the unused position document 9 . When document feed tray 91 is changed from the used position to the unused position during document reading, the mode may not be changed to the first power-saving mode or the second power-saving mode while at least reading of the current target document is performed. By doing so, the currently-performed reading may be completed and thus the degradation in the image quality may be reduced. Accordingly, scanner 100 according to the illustrative embodiment may achieve image-reading quality and the user convenience.
While various aspects of the disclosure has been described in detail with reference to the specific illustrative embodiments thereof, it would be apparent to those skilled in the art that various changes, arrangements and modifications may be applied therein without departing from the spirit and scope of the invention. For example, the image-reading device may not be limited to the scanner but may be applied to any devices having a reading function, for example, multifunction peripheral devices or facsimile machines.
In the above-described illustrative embodiment, the mode may be changed to the first or second power-saving mode on condition that document feed tray 91 is located in the used position or in the unused position, respectively. The condition may not be limited to the specific illustrative embodiment. In other illustrative embodiments, for example, the mode may be changed to the first or second power-saving mode on condition that document discharge tray 92 is located in the used position or in the unused position, respectively. That is, in the above-described illustrative embodiment, the power supply may be controlled in accordance with the position (the used position or the unused position) of document feed tray 91 . Nevertheless, in other illustrative embodiments, for example, the power supply may be controlled in accordance with the position (the user position or the unused position) of document discharge tray 92 .
In the above-described illustrative embodiment, there may be three modes, for example, the ready mode, the first power-saving mode, and the second power-saving mode. Nevertheless, in other illustrative embodiments, for example, the mode may be changed between two modes, for example, the ready mode and the second power-saving mode (or the first power-saving mode). There may be other modes (for example, a third power-saving mode in which power supply control system 50 may control switch circuit 52 to stop supplying power to the external interface while continuing the power supply to control device 10 for a duration of the mode shifting from the first power-saving mode to the second power-saving mode).
In the above-described illustrative embodiment, power source device 51 may supply power to operating panel 40 at all times. Nevertheless, in other illustrative embodiments, for example, power supply control system 50 may control switch circuit 52 to stop supplying power to operating panel 40 in the second power-saving mode.
In the above-described illustrative embodiment, when document feed tray 91 is located in the unused position (step S 103 : YES), power supply control device 53 may change the mode to the second power-saving mode after the elapsed time measured by the timer exceeds the threshold time period (step S 104 : YES). However, it may be unnecessary to wait at all times until the elapsed time measured by the timer exceeds the threshold time period. In other illustrative embodiments, for example, power supply control device 53 may change the mode to the second power-saving mode immediately after document feed tray 91 is changed from the used position to the unused position (or immediately after document reading is completed when scanner 100 is performing the document reading). The immediate mode change to the second power-saving mode after the position change of document feed tray 91 from the used position to the unused position may achieve further power savings.
In the above-described illustrative embodiment, power supply control device 53 may change the threshold time period based on whether communication is available between scanner 100 and an external device. Nevertheless, in other illustrative embodiments, for example, the threshold time period may not change.
In the above-described illustrative embodiment, when document feed tray 91 is changed from the used position to the unused position, scanner 100 may continue the reading of the document being read. Nevertheless, in other illustrative embodiments, for example, scanner 100 may be configured to perform reading of all of the following documents placed on document feed tray 91 when document feed tray 91 is changed to the unused position. However, the following documents may be damaged because it may be difficult to convey the documents from document feed tray 91 that may be located in the unused position. Accordingly, it may be preferable to complete the reading of the current target document only and not to perform reading of the following documents.
In the above-described illustrative embodiment, the threshold time period for shifting to the first power-saving mode and the threshold time period for shifting to the second power-saving mode may be commonly used. Nevertheless, in other illustrative embodiments, for example, these threshold time periods may be individually specified. In this case, for example, the threshold time periods may be individually specified based on whether communication is available between scanner 100 and an external device.
In the above-described illustrative embodiment, when scanner 100 is in the first power-saving mode, power supply control device 53 may control switch circuit 52 to stop supplying power to image reading unit 20 to reduce the power consumption in scanner 100 . Nevertheless, in other illustrative embodiments, for example, power supply control device 53 may decrease the power supplied to image reading unit 20 to reduce the power consumption in scanner 100 , instead of stopping the power supply. In the above-described illustrative embodiment, when scanner 100 is in the second power-saving mode, power supply control device 53 may control switch circuit 52 to stop supplying power to control device 10 and the external interface in addition to image reading unit 20 . Similarly, power supply control device 53 may decrease the power supplied to at least one of image reading unit 20 , control device 10 , and the external interface to reduce the power consumption in scanner 100 .
While the disclosure has included various example structures and illustrative embodiments, it will be understood by those skilled in the art that other variations and modifications of the structures and embodiments described above may be made without departing from the scope of the disclosure. Other structures and embodiments will be apparent to those skilled in the art from a consideration of the specification or practice of the embodiments disclosed herein. It is intended that the specification and the described examples are illustrative. | An image-reading device is provided that includes a reading component configured to read a document, a document holding portion, a detector detecting a position of the document holding portion, a power supply device that supplies power to the reading component, and a power supply control device that controls power supplied by the power supply device to the reading component. The power supply control device determines whether a change in the position of the document holding portion has occurred based on the position of the document holding portion detected by the detector. When a change in position is detected and the image reading device is not performing document reading, the power supplied to the reading component is reduced. If a change in position is detected while the image reading device is performing document reading, the power supplied to the reading component is maintained. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to G.B. provisional application, 0515071.9, filed Jul. 22, 2005, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a non-return valve and particularly to a non-return injection valve for use downhole.
BACKGROUND OF THE INVENTION
[0003] Injection valves are used where an operator wishes to inject a fluid into a pressurized downhole environment. The fluid may, for example, be water or gas which is to be injected into the formation to maintain reservoir pressure.
[0004] Some conventional injection valves comprise a plug biased by a spring to a position in which the valve outlet is sealed closed. To inject fluid through the valve, the fluid is pressurized against the plug until there is sufficient fluid pressure to overcome the closing force of the spring, permitting the valve to open.
[0005] There are disadvantages associated with this type of arrangement. For example, when the fluid pressure has built up sufficiently to overcome the spring closing force, and the plug moves to open the outlet, there is an immediate release of pressure as fluid flows through the valve. In this situation the fluid pressure can drop sufficiently to permit the valve to close under the action of the spring. The pressure then builds up behind the plug and an oscillation cycle of valve opening and closing can be established. This oscillation cycle causes vibration in the string and can lead to damage of the sealing interface between the plug and the valve housing. Additionally, as the plug is opened, and the pressurized fluid passes between the plug and the housing, the movement of the fluid can erode the valve and the surrounding components such as the bore casing or tubing.
[0006] It is an object of the present invention to obviate or mitigate at least one of the aforementioned disadvantages.
BRIEF DESCRIPTION OF THE INVENTION
[0007] Disclosed herein is a device that relates to a non-return valve. The valve comprising, a valve seat, a valve piston in operable communication with the valve seat. The valve further comprising, a first seal disposed at the piston to interact with the valve seat, and a second seal positioned at the piston to interact with the valve seat temporally after the first seal.
[0008] Further disclosed herein is a downhole non-return valve. The non-return valve comprising, a housing defining a valve inlet and a valve outlet, a plug moveable between an open position and a fully sealed position. Additionally comprising a biasing member urging the plug towards the fully sealed position wherein the urging force of the biasing member is sufficient to move the plug to a partially sealed position but is selected to be insufficient to move the plug to a fully sealed position.
[0009] Further disclosed herein relates to a downhole non-return valve. The valve comprising, a housing defining a valve inlet and valve outlet, and a plug moveable between an open position and a fully closed position. The valve further comprising a sacrificial member adapted to divert fluid injected through the valve axially along an external surface of the valve housing.
[0010] Further disclosed herein is a method that relates to injection fluid into a well bore through a non-return valve. The method comprising, injecting fluid into a non-return valve the valve being in a fully sealed configuration, pressurizing the fluid sufficiently to overcome a closing force comprising a combination of a biasing force and well pressure to open a valve outlet. The method further comprising, injecting fluid through the valve outlet into a well and ceasing injection of the fluid thereby permitting the closing force to fully seal the valve outlet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0012] FIG. 1 is a perspective view of a non-return injection valve in the run-in configuration according to an embodiment of the present invention;
[0013] FIG. 2 is a cross-sectional side view of the valve of FIG. 1 in the run-in configuration;
[0014] FIG. 3 is a partially cut-away perspective view of the valve of FIG. 1 shown in the run-in configuration;
[0015] FIG. 4 is a partially cut-away perspective view of the valve of FIG. 1 in a partially open configuration;
[0016] FIG. 5 is a partially cut-away perspective view of the valve of FIG. 1 in an open configuration;
[0017] FIG. 6 is a partially cut-away perspective view of the valve of FIG. 1 in a partially sealed configuration;
[0018] FIG. 7 is a partially cut-away side view of the valve of FIG. 1 in a partially sealed configuration;
[0019] FIG. 8 is an enlarged closed-up view of the seals and part of the housing of FIG. 7 ;
[0020] FIG. 9 is a partially cut-away perspective view of the valve of FIG. 1 in a fully sealed configuration; and
[0021] FIG. 10 shows a partially cut-away side view of the valve of FIG. 1 in a fully sealed configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0022] A detailed description of several embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0023] Referring firstly to FIG. 1 , there is shown a perspective view of a non-return injection valve generally indicated by reference numeral 10 in a run-in-configuration according to an embodiment of the present invention. The internal arrangement of the injection valve 10 can be seen more clearly with reference to FIG. 2 , a cross-sectional side view of the non-return injection valve 10 of FIG. 1 in the run-in-configuration.
[0024] The valve 10 comprises a housing 12 having an upper housing portion 14 and a lower housing portion 16 . The housing 12 defines a housing inlet 18 and a housing outlet 20 . The housing outlet 20 is partially covered by a sacrificial shield 44 .
[0025] Contained within the housing 12 is an injection valve plug 22 and a spring 24 . The plug 22 comprises a shaft 25 , a packing mandrel 26 and an end cap 27 . The packing mandrel 26 and the end cap 27 are fixed to the shaft 25 by means of rivet pins 28 .
[0026] The plug 22 further comprises a shear screw ring 30 defining a groove 32 , which is adapted to receive a number of shear pins 34 of which only one is shown for clarity. The shear pins 34 secure the valve 10 in the run-in-configuration during transit and location downhole and permit a pressure application to a pre-determined rate to test the correct placement and setting of the hanging device.
[0027] The valve 10 is sealed by means of a metal-to-metal seal 44 , V-packing seals 36 and a wiper seal 38 . The metal-to-metal seal 44 is made by a plug seal surface 46 engaging a complementary seal seat 48 defined by the upper housing portion 14 .
[0028] Finally, the lower housing portion 16 defines well fluid inlet ports 40 , the purpose of which will be discussed in due course.
[0029] Referring now to FIG. 3 , there is shown a partially cut away perspective view of the non-return injection valve 10 of FIG. 1 shown in the run-in configuration. As can be seen from this Figure, the plug 22 is located in the fully sealed position in that the plug 22 is preventing fluid from flowing between the housing inlet 18 and the housing outlet 20 . In this configuration, both the wiper seal 38 and the V-packing seal 36 engage an internal surface 42 of the upper housing portion 14 and the seal surface 46 engages the seal seat 48 . Additionally, the shear screws 34 are shown engaged with the shear screw ring 30 .
[0030] As fluid is pumped into the valve 10 , the pressure being applied to the plug face 50 increases to a point when the pressure is sufficient to shear the screws 34 and move the plug 22 .
[0031] Referring now to FIG. 4 , there is shown a partially cut-away view of the valve of FIG. 1 in a partially open configuration. In this Figure, fluid pressure acting on the plug face 50 has increased sufficiently to overcome the combination of the pressure applied by the spring 24 , the external well pressure and the force retaining the plug 22 in the run-in position by the shear screws 34 . To get to this point, the shear screws 34 shear freeing the plug 22 to move in the direction of the arrow.
[0032] FIG. 5 shows a partially cut-away perspective view of the valve 10 of FIG. 1 in an open configuration. In this configuration, the outlet ports 20 are fully open and fluid can flow through the outlet 20 in the direction indicated by the small arrows. The plug 22 is held in the open configuration by the fluid pressure, indicated by the large arrow.
[0033] The sacrificial shield 44 diverts the flow of fluid from the outlets 20 axially along the external surface of the lower housing portion 16 . This prevents erosion of the surrounding bore casing (non-shown) and ensures that any erosion which occurs will take place on the sacrificial shields 44 .
[0034] In this fully open configuration, it will be seen that the shear screw ring 30 has moved under gravity from the position shown in FIG. 3 to a position on which it is abutting the end cap 27 . The purpose of this movement will be discussed in due course.
[0035] It will also be noted that the well fluid inlet ports 40 are covered by a lower end portion of the packing mandrel 26 , preventing well fluids entering the lower housing portion 16 and acting on the plug 22 .
[0036] When the plug 22 is in this open configuration, the wiper seal 38 and the V-packing seal 36 are contained within the lower housing portion 16 . The lower housing portion 16 has a slightly larger internal bore than the upper housing portion 14 such that the V-packing seal 36 does not rub and wear on the internal surface of the lower housing portion 16 . The wiper seal 38 does engage the lower housing portion 16 protecting the V-packing seal 36 from the injected fluid and any circulating debris.
[0037] Referring to FIG. 6 , a partially cut-away perspective view of the valve of FIG. 1 in a partially sealed configuration. In this Figure, the pressure applied by the well fluid has been removed, and the plug 22 has moved in the direction of the arrow towards a partially sealed configuration under the action of the spring 24 . The partially sealed configuration is better seen in FIG. 7 , a partially cut-away side view of the valve 10 of FIG. 1 in the partially sealed configuration and FIG. 8 an enlarged close-up view of the seals and part of the housing 12 of FIG. 7 .
[0038] Referring to FIGS. 7 and 8 , it can be seen that in the partially sealed configuration, the plug 22 has been moved sufficiently by the spring 24 for the wiper seal 38 to engage the internal surface of the upper housing portion 14 . In this configuration, the valve outlet 20 is sealed sufficiently by the wiper seal 38 to prevent ingress of well fluid and the well fluid inlet ports 40 (visible on FIG. 7 ) are no longer covered by the packing mandrel 26 , permitting well fluid to enter the lower housing portion 16 and act on the packing mandrel 26 .
[0039] FIG. 9 shows the plug 22 of FIG. 1 in the fully sealed configuration. The plug 22 has moved from the partially sealed configuration shown in FIGS. 7 and 8 to the fully sealed configuration shown in FIG. 9 by the action of well pressure. As indicated by the arrows, well fluid has entered the well fluid inlet ports 40 and the valve outlet 20 and is acting on the packing mandrel 26 . In the absence of a counter pressure on the plug face 50 , the well pressure is sufficient to move the plug 22 to the fully sealed configuration in which both the wiper seal 38 and the V-packing seal 36 are engaged with the upper housing portion internal surface 42 , and the seal surface 46 is engaged with the seal seat 48 .
[0040] As the plug 22 moves from the partially sealed configuration to the fully sealed configuration, the wiper seal 38 cleans the upper housing portion internal surface 42 ensuring a good seal is created between the internal surface 48 and the V-packing seal 36 .
[0041] It can be also seen from FIG. 9 that the shear screw ring 30 has not re-entered the housing 12 . This can be more clearly seen in FIG. 10 .
[0042] FIG. 10 shows a partially cut-away side view of the valve 10 of FIG. 1 in the fully sealed configuration. In this Figure the position of the shear screw ring 30 on the plug 22 outside of the housing 12 can most clearly be seen. This arrangement is adopted to prevent the stubs of the shear screws 34 fouling on the plug 22 as it moves to the fully sealed configuration. If the shear screws 34 did foul on the plug 22 , which may occur if a moveable shear screw ring 30 was not used, the fouling may be sufficient to prevent the metal seal 44 , the wiper seal 38 and the V-packing seals 36 from obtaining their optimum sealing position to fully seal the valve 10 .
[0043] Various modifications may be made to the described embodiment without departing from the scope of the invention. For example, it will be understood that although the seal surface and the seal seat are shown machined respectively into the surface of the plug and the housing, they could equally be formed on separate elements which are inserted into the surface of the plug and/or the housing. Similarly, although the valve is shown with the sacrificial shields, these are not essential to the smooth running of the valve and could be omitted. Furthermore, the V-packing seals may be replaced with a Zertech™ Deformable Z-seal which could be energized due to the effect of piston and pressure differential.
[0044] Those of skill in the art will recognize that the above described embodiment of the invention provides a non-return valve which permits fluid to be injected into a downhole environment at a reduced pressure and with a reduced possibility of oscillation cycles being established within the valve.
[0045] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. | Disclosed herein is a device that relates to a non-return valve. The valve comprising, a valve seat, a valve piston in operable communication with the valve seat. The valve further comprising, a first seal disposed at the piston to interact with the valve seat, and a second seal positioned at the piston to interact with the valve seat temporally after the first seal. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to automated tile-laying apparatus and more particularly to the specific improvement in existing tile-laying machines of eliminating gaps between tiles as they are laid.
Porous clay tiles have long been used to draw excess water from a field or to disperse fluids to a field, for example, their use in septic tank drain lines where the liquid effluent from a septic tank is dispersed over a large ground area. To properly utilize the tiles, a trench up to several feet deep, is normally dug, lined with gravel and the cylindrical tiles are laid end to end such that a long porous pipe is formed. This is covered with a layer of gravel and then the trench is filled in. The fluid flows into the pipe which is essentially horizontal, stands and seeps through the porous sides of the pipe to be dispersed into the similarly porous ground. Early methods of constructing such a drain field required hand laying of the clay tiles which is a long arduous back-breaking chore. Machinery has been developed to automatically dispense the clay tiles in a closely connected end to end relationship to form the required porous pipe. However, occasionally the ceramic tile will jam up in the dispensing chute with the result that a substantial gap is formed between the end of the preceding cylinder and the beginning of the subsequent cylinder. These gaps if uncorrected would allow the pipe to be stopped up by dirt or allow the effluent in the operational pipe to train out through the gap rather than disperse slowly through the porous clay tile wall. This draining would allow a high concentration of effluent at one point in the ground resulting in seepage to the surface providing a health hazard or the possibility of erosion underground resulting in a collapse of the ground immediately above the gap. In the past, eliminating the gaps has been a manual operation necessitating either an additional operator on the machine to insure the clay tiles are correctly positioned in the dispensing chute or an operator following along behind the machine to slide the clay tiles into correct position. The ability to correct the tile positions in the chute would be highly desirous and would improve existing machinery and eliminate the necessity for extra personnel during the tile-laying operations.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to eliminate gaps which may occur between clay tiles in an automatic dispensing chute.
It is a further object of the present invention to provide an inexpensive compact degapping apparatus to eliminate gaps occurring between clay tiles in an automatic tile-laying apparatus.
A still further object of the instant invention is to provide a degapping apparatus adaptable to be retrofitted to present tile-laying machinery.
In the present invention two sensing switches are placed in series, one of which is actuated by the presence of tiles coming down the dispensing chute and the other is actuated when a gap appears between two tiles. When both switches have been closed, an electrical solenoid is operated which actuates positioning levers where one releases the misaligned tile while the other urges the tile into the correct alignment position. After the tile moves past the switches further along the dispensing chute, the switch which sensed the gap is opened and thus the solenoid is deactivated. The apparatus is constructed such that it can be mounted along any substantially vertical portion of the railed dispensing chute.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an operational side view of the normal tile-laying operations.
FIG. 2 is an operational side view of tile-laying operations showing incorrect positioning of tiles.
FIG. 3 is a side view of the tile-laying apparatus showing the mounting arrangement of the degapping apparatus.
FIG. 4 is a side view, partially in section, of the degapping apparatus as shown in FIG. 3.
FIG. 5 is a cross-sectional front view of the degapping apparatus.
FIG. 6 is a side view, partially in section, of the stretch spring of FIG. 5 along the section lines 6--6.
FIG. 7 is a section view along the lines 7--7 of FIG. 5 showing the sensing switch arrangement.
FIG. 8 is a section view along the lines 8--8 in FIG. 5 showing the spring return of the sensing switch levers.
FIG. 9 is a schematic view showing the electrical circuit interconnected with the mechanical sensing switches.
FIGS. 10A, B, C, D and E are side views showing the operation of the applicant's invention.
FIG. 11 is a side view of a further embodiment of the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference numerals designate identical or corresponding parts through the several views, and more particularly to FIG. 1 wherein a typical automated clay tile-laying operation is depicted. Ceramic tiles 10 are fed into the top of the dispensing chute 12 made up of rails 14 and cross braces 16 such that each tile overlaps the end of the preceding tile. FIG. 2 illustrates the problem when one tile 20 is underlapped, that is, its front edge is actually under the trailing edge of the preceding tile. This misaligned tile when laid on the ground at the end of the dispensing chute will have a large gap 22 between it and the preceding tile.
FIG. 3 illustrates the mounting and operational relationship of the tile degapper 30 on the dispensing chute 12 by welding cross bars 31 on the chute rails 14. FIG. 4 is a cutaway view of the degapper 30 showing the misalignment switch lever 32 and the gap switch lever 34. Solenoid coil 36 operates in conjunction with the solenoid slug 38 with flexible link 40 connected between the slug 38 and rod 42. When the solenoid coil 36 is energized, the slug 38 is drawn into the coil pulling down on rod 42 through the flexible link 40. Rod 42 has three stops 44 with arms 48 and 50 positioned therebetween as shown. Arms 48 and 50 are rigidly connected through pivot points 52 and 54 to repositioning arm 56 and detaining arm 58, respectively. Arms 48 and 50 are biased towards the lower stops 44 by springs 60 and 62, respectively. It can be seen that if the coil is energized and the rod 42 moves downward, detaining arm 58 will rotate about pivot point 54 and move in towards the rod whereas repositioning arm 56 will move outward away from the rod 42. The solenoid and internal rod and arms are sealed in a dustproof, waterproof housing 64 to prevent premature deterioration of the mechanical and electrical parts. In this view, a stretch spring connected between arms 48 and 50 has been excluded for clarity of understanding.
FIG. 5 shows the pivot points 52 and 54 from which arms 48 and 50, and 56 and 58 protrude, respectively. Misalignment switch lever 32 and gap switchlever 34 are connected to switches 70 and 72, respectively, through pivots 66 and 68. Springs and stops (not shown) bias these levers in the position shown such that switches 70 and 72 are normally in the off and on positions respectively. The degapper apparatus and housing are mounted on chute rails 14 such that repositioning and detaining arms 56 and 58 respectively are essentially in the center of the pathway of the clay tiles as they move down the chute 12.
FIG. 6 is a view of FIG. 5 along section lines 6--6 showing the details of stretch spring 74, attachment point 76 and adjustment bolt 78. Stretch spring 74 is tensioned between arms 48 and 50 such that it retains arm 50 against spring 62. This stretch spring is necessary to allow detaining arm 58 (more clearly seen in FIG. 5) to be deflected inward by the side of a correctly aligned tile as it passes along the distribution chute while positioning the arm to engage misaligned tiles. The tension of spring 74 is adjusted by tightening or loosening nut 78 on threaded shaft 80.
FIGS. 7 and 8 along section lines 7--7 and 8--8, respectively, show the details of the location and operation of switches 70 and 72. FIG. 7 shows the tabs 80 and 82 which strike microswitches 70 and 72, respectively, to maintain switch 70 in an OFF position and switch 72 in an ON position as shown. FIG. 8 shows the details of the switch lever biasing springs 84 and 86 which pull down on lever extensions 88 and 90 thus biasing misalignment switch lever 32 and gap switch lever 34 against stops 92 and 94, respectively.
FIG. 9 illustrates the electromechanical relationship of the switch levers 32 and 34 to the solenoid coil 36. Actuation relay 96 is electrically connected in series with switches 70 and 72 and power supply 98 such that when both switches 70 and 72 are closed, power is supplied through relay coil 100 causing contacts 102 to supply current through solenoid coil 36. As shown in FIG. 4, energizing coil 36 pulls slug 38 downward causing repositioning arm 56 to move outward and detaining arm 58 to move inward, thus repositioning a misaligned tile.
FIGS. 10A, B, C, D and E show how a misaligned tile moving down the distribution chute is repositioned into correct alignment. Misaligned tile 20 has forward end 104 lapped under rear end 106 of the preceding tile 10. As shown in FIG. 10A, the passage of tile 10 causes gap switch lever 34 to be depressed thus opening switch 72 while misalignment switch lever 32 is undepressed thus maintaining switch 70 in an open condition also. As the misaligned tile 20 moves down the distribution chute it depresses misalignment switch lever 32 turning on switch 70. However, because gap switch lever 34 is still depressed the gap switch 72 is still turned OFF precluding operation of the solenoid actuation relay 96. In FIG. 10C, the misaligned tile 20 has progressed far enough down the distribution chute 12 to catch on detaining arm 58. Switches 70 and 72 are in the same condition as in 10B thus precluding solenoid actuation. However, in FIG. 10D, aligned tile 10 has continued moving down the distribution chute 12 allowing switch 34 to move towards the ON position. Misaligned tile 20 is still detained by detaining arm 34 and continues to actuate switch 70 in the ON position by depressing misalignment switch lever 32. When gap switch lever 34 has moved under the influence of spring 86 (as more clearly seen in FIG. 8), the switch 72 is also closed causing the actuation relay to be energized. This causes energization of the solenoid coil with the resultant clockwise movement of arms 56 and 58 rotate from the dotted line position to the solid line position. Misaligned tile 20 (shown in its previous position) is bumped toward the position of tile 20' in the solid black line by lever 56. Detaining lever 58 is simultaneously withdrawn allowing the repositioned tile 20' to fall into a correct alignment, that is where forward end 104 laps over rear end 106 of the previous tile 10. The use of springs 60 and 62 tend to cushion the potentially violent action of the solenoid such that the movement of arms 56 and 58 do not damage the clay tiles. Similarly the distance that repositioned tile 20' falls is not sufficient to cause damage to itself or the previous tile 10.
FIG. 11 discloses a further embodiment of the degapping apparatus in which the repositioning arm 56, shown in FIGS. 1-10, has been eliminated. As in previous embodiments, a misaligned tile 20 is retained on arm 58 when in the dotted line position. When both switches (not shown) are closed, the energization of the solenoid coil forces arm 58 to move in a clockwise direction releasing tile 20. The tile then drops over the previous tile 10 such that leading edge 104 laps over the trailing edge 106 of the preceding tile. The use of deformation 110 in the rear chute rail 14 allows the rear end of the preceding tile to fall immediately under the misaligned tile such that when it is released by the detaining arm 58 the misaligned tile drops into correct position. A similar switch and solenoid arrangement as in FIGS. 1-10 can also be employed in the embodiment shown in FIG. 11. This embodiment has the advantage of reducing the number of arms that the solenoid is required to move thus reducing the power drain and complexity of the apparatus. However, it requires the rear rail of the tile-laying chute to be deformed to allow the trailing edge of the previous tile to fall directly under the center of the detained tile 20. This deformed chute rail is not as easily retrofitted into the current tile-laying machinery although it could be readily incorporated in the design of new equipment.
Clearly, those skilled in the art could devise modifications and varying arrangements to accomplish the same results in view of the above teachings. Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described therein. | Disclosed is an apparatus to detect misaligned clay tiles in the chute of a tile-laying machine and realign any tiles incorrectly aligned. The apparatus is capable of being retrofitted onto existing tile-laying machinery as well as being incorporated into improved future designs. The apparatus is comprised of alignment sensing switches which in turn control solenoid operated repositioning levers. The levers realign the ceramic tiles such that they are properly positioned to avoid gaps in the tile field. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a room temperature vulcanizable polyorganosiloxane composition. More specifically, this invention relates to a room temperature vulcanizable polyorganosiloxane composition whose cured product will not soil other substrates which have been brought into contact with the composition after the composition has been cured.
2. Background Information
Various room temperature vulcanizable polyorganosiloxane compositions which cure into resins or rubbers are conventionally used as electrical insulating materials, adhesives, coating materials, for sealing containers, and as a sealing material.
In particular, a so-called oxime-liberating room temperature vulcanizable polyorganosiloxane composition, which cures with the production of a ketoxime, is widely used as a single-package curable composition because it can be stored uncured in a sealed container for long periods of time and is rapidly cured by atmospheric moisture upon exposure to the atmosphere while seldom corroding other substrates which are brought into contact with it.
However, the above room temperature vulcanizable polyorganosiloxane composition suffers from the drawback of soiling other substrates which come into contact with the cured product when it is employed in the applications cited above. For example, when the composition is employed as an electrical insulating material, it causes poor contact by neighboring electrical contacts. When it is employed as a coating agent, it hydrophobicizes the underlying substrate. When it is employed as a construction sealing material, it soils the sealing joint and its surrounding areas. When it is employed to seal a container, polyorganosiloxane will elute into the sealed liquid.
Various methods were examined by the present inventors in investigating the causes of the above defects in ketoxime-liberating room temperature vulcanizable polyorganosiloxane compositions with the goal of improving these compositions and this invention was thus developed as a result.
SUMMARY OF THE INVENTION
The purpose of this invention is to provide a room temperature vulcanizable polyorganosiloxane composition whose cured product will not soil substrates brought into contact with it after it has been cured.
This invention relates to a room temperature vulcanizable polyorganosiloxane composition consisting essentially of the product obtained by mixing (A) 100 parts by weight of a polyorganosiloxane which has a viscosity at 25° C. of 0.001 to 0.2 m 2 /s, has at least two terminal silanol groups per molecule, contains ≦2 weight percent components with a polystyrene-based molecular weight of ≦5,000 according to the gel permeation chromatogram, and has organic radicals selected from the group consisting of monovalent hydrocarbon radicals and halogenated monovalent hydrocarbon radicals, (B) 0.5 to 30 parts by weight of ketoxime silicon compound selected from silane of the general formula
RSi (O--N═X).sub.3
or its partial hydrolysis product wherein R represents a radical selected from the group consisting of alkyl, alkenyl, and phenyl, X represents ═CR 2 ' or ═CR 2 , each R' represents a monovalent hydrocarbon radical, and each R 2 represents a divalent hydrocarbon radical, and (C) 0.005 to 2 parts by weight of an organotitanate ester.
DETAILED DESCRIPTION OF THE INVENTION
Component (A) is a principal component of the room temperature vulcanizable polyorganosiloxane composition produced by the method of this invention. The molecular configuration of component (A) is straight chain or branched chain; however, it is preferably straight chain. In the case of a branched chain, the number of branch points must be ≦1% of the total number of silicon atoms in component (A) from the standpoint of an efficient production process. At least 2 terminal silanol groups are present per molecule in order to produce a three-dimensionally crosslinked structure after curing. Examples of silicon-bonded organic groups in the polyorganosiloxane of component (A) are monovalent hydrocarbon radicals such as alkyl, such as methyl and ethyl; alkenyl such as vinyl and allyl; aryl such as phenyl and tolyl; and halogenated monovalent hydrocarbon radicals such as haloalkyl such as 3-chloropropyl and 3,3,3-trifluoropropyl. One to three different species of these organic groups may be present in a single molecule. Among these groups, the usual case is methyl only or a mixture of °50 mol % methyl with other organic groups. The viscosity of component (A) at 25° C. is specified as 0.001 to 0.2 m 2 /s for the following reasons. When the viscosity falls below the above range, the cured product has poor mechanical strength, a modulus of elasticity which is too high, and its applicability is limited. On the other hand, when the viscosity exceeds the above range, the processability is extremely poor.
Furthermore, component (A) may be a mixture of compounds with different viscosities and organic groups. When a mixture of compounds with different viscosities is employed, the viscosity of each individual compound need not be in the range specified above, but the average viscosity must be in the above range.
A method for producing the polyorganosiloxane comprising component (A) is as follows.
(I) Cyclic diorganosiloxane oligomer and/or silanol group-terminated linear diorganosiloxane oligomer as starting materials are equilibration polymerized with cleavage and reformation of siloxane bond in the presence of an acid or basic catalyst. Alternately, only a silanol group-terminated linear diorganosiloxane oligomer as the starting material is polymerized by dehydropolycondensation in the presence of an acid or basic catalyst.
(II) The low molecular weight polyorganosiloxanes are subsequently removed by thin film stripping or a solvent wash, preferably by a solvent wash. The solvent to be used in the solvent wash is a compound which can selectively dissolve low molecular weight polysiloxanes of less than 5,000. The most desirable examples of poor solvents for polydimethylsiloxane are ethanol and acetone.
The molecular weight distribution of component (A) is verified by gel permeation chromatography (GPC). The GPC column must be usable for verification into the principal polymer range (for example, G4000H/G5000H) and the calibration curve may be constructed from a monodisperse polysiloxane which has been obtained by partial sedimentation. However, verification by comparison with the Q values for monodisperse polystyrene is the more usual method. Detection in GPC is usually carried out using the solution index of refraction. The molecular weight dependence of the solution index of refraction becomes almost negligible at a molecular weight of about 5,000, which is the important limit in this invention, and the GPC chart may be divided into higher and lower molecular weight regions at a polystyrene-based molecular weight of 5,000 and the areas of the two regions may be compared with each other in order to determine the quantity of components with molecular weights ≦5,000.
Component (B) reacts with the silanol groups of component (A) to form a crosslinked structure, that is, it is indispensable for the production of a cured composition. Component (B) is ketoxime silicon compound which is selected from an organotriketoximesilane with the general formula RSi (O--N═X) 3 , wherein R and X retain their definitions from above or its partial hydrolysis product. The R in the organotriketoximesilane is an alkyl such as methyl, ethyl, or propyl or an alkenyl such as vinyl or allyl. The R 1 is a monovalent hydrocarbon radical such as an alkyl such as methyl, ethyl, or propyl; an alkenyl such as vinyl or allyl; or an aryl such as phenyl or tolyl. The R 2 is a divalent hydrocarbon group such as an alkylene such as ##STR1##
Among these, dialkyl ketoxime groups and particularly the dimethyl ketoxime group and methyl ethyl ketoxime group are preferred from the standpoints of economical silane production as well as their high reactivity with silanol groups. Examples of the organotriketoximesilane are methyltri(dimethyl ketoxime)silane, methyltri(methyl ethyl ketoxime)silane, and vinyltri(methyl ethyl ketoxime)silane. Component (B) can be a single compound or a mixture of 2 or more compounds. The total quantity of component (B) is 0.5 to 30 parts by weight and preferably 2 to 20 parts by weight per 100 parts by weight of component (A). When the quantity of component (B) falls below the above range, curing will be incomplete. When the quantity of component (B) exceeds the above range, the curing rate is reduced and it is also economically disadvantageous.
The organotitanate ester comprising component (C) is indispensable for completing the curing reaction of component (A) with component (B). Examples of component (C) are tetraisopropyl titanate, tetra-n-butyl titanate, bis(acetylacetonate)titanium diisopropoxide, bis(acetylacetonate) titanium di-n-butoxide, and bis(ethyl acetoacetate) titanium diisopropoxide. Component (C) is added at 0.005 to 2 parts by weight per 100 parts by weight of component (A). When the quantity of component (C) falls below the above range, the curing reaction cannot be completed. On the other hand, when the quantity of component (C) exceeds the above range, the storage stability after component (A) has been mixed with component (B) is reduced.
The order of mixing of components (A) to (C) is arbitrary; however, component (C) is preferably mixed with component (A) simultaneously with the mixing of component (B) or after the mixing of component (B). When the added number of moles of component (B) exceeds the combined number of equivalents of silanol groups and water in the system, the produced composition is a so-called single-package room temperature vulcanizable polyorganosiloxane composition which will remain uncured as long as exterior moisture is excluded and which will cure when brought into contact with water.
The room temperature vulcanizable polyorganosiloxane composition produced by the method of this invention may optionally contain an inorganic filler (D). Examples of inorganic reinforcing fillers are fumed silica, surface-hydrophobicized fumed silica, surface-hydrophobicized wet-process silica, carbon black, colloidal calcium carbonate, and fumed titanium dioxide.
Examples of inorganic extender fillers are diatomaceous earth, finely pulverized quartz, finely powdered calcium carbonate, and clays.
If necessary, the room temperature vulcanizable polyorganosiloxane composition produced by the method of this invention may contain pigments such as titanium dioxide, zinc white, and iron red oxide; flame retardants such as platinum compounds and metal carbonates; thermal stabilizers such as cerium oxide and cerium hydroxide; adhesion promoters such as silane coupling agents; antisoiling agents such as polyethers, sorbitol derivatives, and fluorine surfactants, and antimolds.
The resulting composition of this invention cures at room temperature into a resin or rubber in such a way that the post-cure quantity of uncrosslinked polysiloxane is extremely small. For this reason, the polysiloxane component will not migrate from the cured product to another substrate brought into contact with the cured product. Due to this, the composition can be widely used in applications such as electrical insulating materials, adhesives, coating materials, and sealing materials.
This invention will be explained using demonstrational examples. "Parts" in the examples denotes "parts by weight" in all cases and the various values, such as the viscosity, were measured at 25° C. in all cases.
REFERENCE EXAMPLE 1
Production of silanol group-terminated polydimethylsiloxane:
Silanol group-terminated polydimethylsiloxane oligomers (pentameric on the average) were polymerized in the presence of an extremely small amount of potassium hydroxide to obtain a silanol group-terminated polydimethylsiloxane (visosity 0.0135 m 2 /s denoted as "polymer A" below.
Octamethyltetracyclosiloxane was polymerized in the presence of a solid acid catalyst and then stripped at 150° C./10 mmHg to produce a silanol group-terminated polydimethylsiloxane (viscosity 0.0112 m 2 /s) denoted as "polymer B" below.
Polymer B was stripped by a thin film technique at 200° C./10 -4 mmHg to obtain a silanol group-terminated polydimethylsiloxane (viscosity 0.0156 m 2 /s) denoted as "polymer C" below.
Polymer B (300 g) was combined with acetone (600 g) and this was mixed at 45° C. to homogeneity and then allowed to cool for 1 day. The separated acetone phase was then removed. This process was repeated 5 times. Acetone in the polymer layer was stripped to obtain a silanol group-terminated polydimethylsiloxane (viscosity 0.0123 m 2 /s) denoted at "polymer D" below.
The proportion of components with molecular weights ≦5,000 in the polymers was determined by GPC and is reported in Table 1.
TABLE 1______________________________________ % Components with MolecularPolymer Weights ≦ 5000, wt %______________________________________A 0.5B 5.2C 1.8D 0.4______________________________________
EXAMPLE 1
Polymer A (100 parts), methyltri(methyl ethyl ketoxime)silane (4.0 parts), and the organotitanate ester given in Table 1 were charged to a mixer. The resulting mixture was thoroughly mixed and defoamed. The resulting composition was poured into a groove (width 20 mm, depth 2 mm) which had been milled in white granite (40 cm×40 cm×4 cm) and then was allowed to stand in the ambient for 14 days for curing into a rubbery material. The granite was then placed in a perpendicular position outdoors, 50 cm above the ground, for exposure. Soiling of the granite surface was inspected after 3 and 6 months and the results are reported in Table 2. In the table, NS represents no soiling, IS represents insignificant soiling, SS represents significant soiling and ESS represents extremely significant soiling (these criteria are also applicable below).
The above composition was also poured into a mold and subsequently allowed to stand in the ambient for 14 days for curing into a 2.0 mm thich rubber sheet. The rubber sheet was cut into 1 mm square pieces and 5 g of these pieces were then extracted with chloroform 4 times. The percent extraction is reported in Table 2.
COMPARISON EXAMPLE 1
Experiments were conducted by the methods of Example 1 with the exception that organotin compounds were used as catalysts instead of titanate esters. The results are also reported in Table 2.
The above results demonstrate that the extent of soiling and the degree of curing both significantly depend on the nature of component (C) comprising the catalyst even with the use of the same types of components (A) and (B). Organotitanate esters were thus found to be excellent catalysts.
TABLE 2__________________________________________________________________________ Catalyst SoilingSample Amount After After ExtractionNo. Compound (Parts) 3 months 6 months (%)__________________________________________________________________________Example 1 ##STR2## 0.1 NS NS 0.62 Ti(OCH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3).sub.4 0.1 NS NS 0.63 Ti(OCH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3).sub.4 0.02 NS NS 0.74 ##STR3## 0.02 NS NS 0.65 ##STR4## 0.5 NS NS 0.6ComparisonExample 16 none -- SS SS 3.77 Dibutyltin diacetate 0.1 ESS ESS 4.38 Dibutyltin diacetate 0.02 ESS ESS 4.09 Dibutyltin dioctoate 0.1 ESS ESS 4.4__________________________________________________________________________
EXAMPLE 2
Polymer A, C or D (100 parts), methyltri(dimethyl ketoxime)silane (3.5 parts), and tetrabutyl titanate (0.1 part) were charged to a mixer. The resulting mixture was thoroughly mixed and defoamed. Soiling by the compositions was inspected under the same conditions as in Example 1 and the results are reported in Table 3.
COMPARISON EXAMPLE 2
An experiment was conducted by method of Example 2 with the exception that dibutyltin dilaurate (0.2 part) was used as the catalyst instead of tetrabutyl titanate and the results are also reported in Table 3.
COMPARISON EXAMPLE 3
An experiment was conducted by the method of Example 2 with the exception that polymer B was used instead of polymer A, C or D and the results are also reported in Table 3.
TABLE 3______________________________________ Soiling Sample Poly- Extraction After AfterType No. mer (%) 3 months 6 months______________________________________Example 2 10 A 0.7 NS NS 11 C 2.1 NS IS 12 D 0.5 NS NSComparison 13 A 3.5 SS ESSExample 2 14 C 5.0 ESS ESS 15 D 3.8 ESS ESSComparison 16 B 5.2 ESS ESSExample 3______________________________________
EXAMPLE 3
Polymer A (100 parts) was thoroughly mixed with fumed silica (specific surface area 200 m 2 /g, 10 parts) and vinyltri(methyl ethyl ketoxime)silane (8 parts) in a mixer under nitrogen, combined with tetrabutyl titanate (0.2 part) and again mixed thoroughly, defoamed in vacuo and then filled into an aluminum tube.
EXAMPLE 4
Polymer A (100 parts) was thoroughly mixed with fumed silica (10 parts), methyltri(methyl ethyl ketoxime)silane (8 parts), n-propyl silicate (1 part), and tetrabutyl titanate (0.2 part) in a mixer under nitrogen, defoamed in vacuo and then filled into an aluminum tube.
EXAMPLE 5
Polymer D (100 parts) was thoroughly mixed with fine light calcium carbonate (100 parts) in a mixer in vacuo followed by mixing with methyltri(methyl ethyl ketoxime)silane (12 parts) and diisopropoxybis(acetylacetate) titanium (0.5 part) with careful attention to avoid introducing bubbles and this was then filled into an aluminum tube.
Soiling by the compositions of Examples 3 to 5 was inspected by the method of Example 1 with the exception that the depth of the groove in the granite stone was 10 mm. The compositions remaining after application were sealed in the aluminum tubes and stored at room temperature for 3 months in order to examine their extrudabilities and curabilities. The test results are reported in Table 4 where a G denotes "good".
TABLE 4______________________________________Exam- Soiling Storage stability inple Sample After After in tube for 3 monthsNo. No. 3 months 6 months Extrudability Curability______________________________________3 17 NS NS G G4 18 NS NS G G5 19 NS NS G G______________________________________
The examples above demonstrate that a room temperature vulcanizable polyorganosiloxane composition which has been produced by the method of this invention exhibits insignificant soiling around the periphery of the cured product because the post-cure quantity of uncrosslinked polysiloxane is extremely small.
REFERENCE EXAMPLE 2
Octamethylcyclotetrasiloxane (100 parts), tetramethyltetraphenylcyclotetrasiloxane (20 parts), potassium hydroxide (0.013 part) and water (0.36 part) were charged to a polymerization reactor, reacted at about 150° C. for 5 hours, neutralized with dimethyldichlorosilane, cooled, filtered and then stripped at 150° C./10 mmHg in order to obtain a silanol group-terminated dimethylsiloxanemethylphenylsiloxane copolymer which is denoted as "polymer E" below (viscosity 0.00384 m 2 / s, methylphenylsiloxane unit, 10.0 mol %).
The polymer was washed with acetone by the method used for polymer D in order to remove low molecular weight components to obtain a silanol group-terminated dimethylsiloxane-methylphenylsiloxane copolymer denoted below as "polymer F" (viscosity 0.00413 m 2 /s). The percentages of components with a molecular weight ≦5,000 in these polymers are 5.7 wt. % for polymer E and 0.7 wt. % for polymer F.
EXAMPLE 6
Room temperature vulcanizable polyorganosiloxane compositions were produced by the method of Example 3 with the exceptions that polymer E or F was used instead of the polymer A used in Example 3 and a fumed silica (specific surface area 130 m 2 /g) which had been surface-hydrophobicized with dimethyldichlorosilane was used instead of the fumed silica.
The soiling and storage stability (in a tube) of the room temperature vulcanizable polyorganosiloxane composition were examined by the same method as in Example 3. The results for polymer F were identical to the results in Example 3. On the other hand, while the storage stability of polymer E in a tube was identical to that of Example 3, the stone was quite soiled both after 3 and 6 months. | A room temperature vulcanizable polyorganosiloxane composition which cures to products, such as silicone rubber, which do not soil easily are made from mixing silanol containing polyorganosiloxane, ketoxime silicon compounds such as organotriketoximosilanes, and organotitanates. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional patent Ser. No. 60/783,184, filed Mar. 16, 2006 by the present inventor.
Other filings: Disclosure Document No. 550014, Mar. 29, 2004
COMPUTER PROGRAM LISTING
This application includes a computer program listing appendix submitted on compact disc. The total number of compact discs submitted is 2. The two discs are identical with the following content:
Copy 1: windchime.asm, Jan. 14, 2006, 41,179 bytes
Copy 2: windchime.asm, Jan. 14, 2006, 41,179 bytes
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to wind chimes, specifically to an improved device employing solid-state electronics for the detection of air movement and programmed electronic generation of sounds.
2. Description of Related Art
Many improvements and modifications have been made to the traditional wind chime. Many design patents have been issued for unique wind chime designs. Also several utility patents have been issued for alternative methods of detecting wind or generating sounds.
Various devices have been disclosed that have a power means to drive mechanical chimes in the absence of wind. U.S. Pat. No. 6,559,367 uses a magnetic arrangement to provide movement of a striking device towards chime rods. U.S. Pat. No. 5,744,736 has an electric powered pendulum that strikes chime rods in a preset sequence. It also has an auxiliary pendulum to strike the rods in the presence of natural wind. U.S. Pat. No. 6,640,742 has a motor-driven element that strikes mechanical chime tubes in a desired sequence. It also uses tubes with different diameters to save space. U.S. Pat. No. 6,525,248 also describes a space saving design using a rod with a folding joint. It is driven by natural wind. The current invention improves on these devices by not requiring any powered mechanical means.
Several devices have been disclosed that use electrical contacts that are moved together by wind to trigger a chime generating circuit or other device. U.S. Pat. No. 6,124,782 consists of a sound-generating circuit that is triggered by a wind switch having multiple contacts. In U.S. Pat. No. 5,315,909, music generation is triggered by a wind control switch using a circular conductor, and a conductive rod. U.S. Pat. No. 6,504,471 describes a transducer apparatus to trigger a chime or other device in response to air movement and acceleration, consisting of multiple contacts. The current invention detects airflow directly and does not require exposed electrical contacts.
Two other disclosures describe methods of striking chimes using unique mechanical arrangements. U.S. Pat. No. 5,334,797 uses a propeller which drives hammers for striking chime tubes in a predetermined sequence. U.S. patent application Ser. No. 10/236,236 describes a specific mechanical arrangement using a baffle and a tether for striking chime rods in response to wind. The current invention improves on these devices by not requiring any moving parts.
U.S. Pat. No. 6,604,691 describes a support for a wind driven device, but does not contain a specific wind detection design.
A meteorological instrument company in The Netherlands, Mierij Meteo, produces a solid state wind speed and direction sensor, model MMW05. The sensor uses a ceramic material that is maintained at a constant temperature. Wind causes small temperature changes that can be measured with thermocouples on various points on the ceramic. This information is used to derive very accurate wind speed and direction information. While this device provides accurate measurements, the present invention provides an inexpensive means of approximating wind speed.
BRIEF SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention there is provided a device for measuring wind intensity and generating sounds consistent with the wind intensity. The device consists of a wind-detection means and a processing means.
The wind detection means includes a differential pressure transducer and a specially-shaped enclosure. The pressure transducer can provide a pressure-difference signal indicating the difference in pressure at its two ports. The specially-shaped enclosure provides different-length paths for the airflow past two holes provided in the enclosure. Airflow is forced to travel faster along the path with the greater length. The pressure transducer ports are coupled to the two holes such that the difference in pressure, due to the difference in wind speed, can be measured.
The processing means samples the pressure-difference signal and stores a plurality of signal values. The signal values are used to calculate a variable trigger signal that represents the relative wind intensity. The processing means can use the variable trigger signal to generate chimes or other sounds with properties that are dependent on wind speed. The processing means can also be programmed to perform other tasks or control other devices.
A principle objective of this invention is to provide a wind chime that is more versatile and robust than a traditional wind chime, employing solid state electronics for detection of air movement.
Another objective of this invention is to provide a wind chime that responds only to air movement and not to movement of the device itself, allowing the device to be attached to a fixed surface in any orientation or used in a moving vehicle, while minimizing unwanted chimes and potential damage.
Another objective of this invention is to provide programmed chime generation that can be customized to provide a variety of sounds with adjustable sensitivity to wind activity.
These and other objectives and advantages of the present invention will become apparent upon consideration of the ensuing detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an example enclosure used for the preferred embodiment;
FIG. 2 is a cross-sectional view taken along line 2 - 2 ′ of FIG. 1 showing the differential pressure transducer mounted in the enclosure;
FIG. 3 is a schematic diagram of an electrical circuit in accordance with the principles of the present invention; and
FIGS. 4 , 5 and 6 are flowcharts illustrating the programming associated with the device and implemented with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
An enclosure in accordance with the preferred embodiment of the present invention is shown in FIG. 1 . The enclosure is made from a tube with a specialized cross-sectional shape. Custom tubing made from plastic or other materials can be obtained with arbitrary cross-sections from several suppliers. The cross section shown is roughly shaped like the letter “D” with rounded edges. Alternate embodiments may use tubing with other cross-sectional shapes including but not limited to circular, oval, triangular or rectangular. Other embodiments may be completely contained in a spherical or egg-shaped enclosure. Two small holes, 1 A and 1 B are made in opposite sides of the tube surface, A. These holes provide air pressure sample locations for the differential pressure transducer. One side is curved outward slightly presenting a large radius near hole 1 A. The other side is elongated, creating a smaller radius near hole 1 B. The modified shape enhances the difference in pressure at the two holes. Alternatively, appendages can be added to a circular tube to modify the outer surface shape. The tube may be left open at one or both ends. The tube can be approximately 10 cm. long and 2.5 cm. in diameter to accommodate the pressure transducer, battery and other circuitry.
As shown in FIG. 2 , the holes interface with the two ports of differential pressure transducer, PT. The PT can be mounted on a circuit board inside the tube with other circuitry. The ports may be modified or extended as needed to provide an air-tight seal with the holes. For most directions of air flow, there will be a longer path across hole 1 B compared to the path across hole 1 A. Since the path lengths of the airflow are different, the air velocities will be different. The different velocities will cause a pressure difference between the two sample locations. This effect is due to the Bernoulli Principle of Fluids, which states that the pressure of a compressible fluid is related to its velocity. Another cause of pressure differences at the two holes is random turbulence of the airflow as it passes by the tube at various angles. If air flow is facing directly toward one of the holes, the pressure will generally be higher at the facing port. In addition, the surface may employ a texture to increase the amount of laminar air flow across the surface. The effect is similar to that of dimples used on golf balls. A laminar air flow would reduce the effect of turbulence, giving a pressure difference related more to air velocity. The present invention uses these pressure differences to generate a variable trigger signal that is proportional to the relative intensity of airflow.
The following discussion refers to the schematic diagram shown in FIG. 3 . The differential pressure transducer (PT), such as a Honeywell 24PCAFA6D, is normally biased by a supply voltage on one pin and a corresponding ground connection on another pin. A pressure signal voltage appears across the other two pins that is related the difference in pressure between Port 1 A and Port 1 B. The transducer is manufactured such that pressure differences in either direction can be measured. The pressure signal is fed in a differential manner through resistors R 1 and R 2 to an amplifier, A 1 . This is a common operational amplifier providing large gain and low bandwidth, such as one quarter of a National LM324 quad op amp. Two resistors R 3 and R 4 complete a high gain amplifier to increase the amplitude of the pressure signal. The pressure signal is AC-coupled through capacitor C 2 to the next stage. The amplifier A 2 , which may be another quarter of the LM324, along with resistors R 7 and R 8 provide more amplification of the pressure signal to obtain the desired sensitivity to pressure changes. Resistors R 5 and R 6 and capacitor C 1 create a voltage reference at approximately one half of the supply voltage, so that the output of A 2 will be centered between 0 volts and the supply voltage. The resulting signal is fed to an Analog-to-Digital Converter ADC, which is incorporated in the processor, Z 1 . The processor may be a low power, 8-bit device with a built in ADC unit, such as the Microchip PIC16F873. The processor can be programmed to sample the ADC input voltage corresponding to the magnitude of the pressure signal.
In the disclosed embodiment, the processor Z 1 also generates data values at regular time intervals that correspond to audio waveform samples. Three signal lines are used to send the data values to a Digital-to-Analog Converter (DAC), Z 2 . This is an integrated circuit such as the Maxim MAX550A. The data interface conforms to the commonly used SPI format by Motorola, Inc. One signal selects the DAC as the data recipient. Another signal provides a clock signal to synchronize the data. Another signal is used for the actual data.
Z 2 will create output voltages that correspond to the provided data. When supplied with appropriate data at regular intervals, the DAC can create analog waveforms in the audible frequency range. The output voltage values must be output at a rate at least twice that of the highest audio frequency to be produced. In accordance with the Nyquist Theorem, this assures that unwanted frequency components can be filtered out.
The voltage output from Z 2 is fed through capacitor C 3 to remove any DC offset voltages that are present. Resistors R 9 and R 10 create a voltage divider to reduce the signal level. The signal is fed through a unity gain amplifier, A 3 . This can be the third quarter of the LM324 device. This amplifier does not increase signal amplitude, but it isolates the DAC from the following stage to maintain signal characteristics.
Amplifier A 4 , the fourth quarter of the LM324 device, provides an active low-pass filter in the Sallen-Key configuration. The components R 13 , R 14 , C 4 and C 5 are chosen to create a resistors R 11 , R 12 and capacitor C 4 provide a one-half supply voltage reference for the filter circuit. The resulting signal is a low-level audio waveform. Another amplification stage, A 5 , is used to give the signal sufficient energy to drive a speaker so the sound can be heard at a distance. A common single chip amplifier device such as the National LM386, provides enough power to drive a small speaker. The output of the low-pass filter is fed through C 6 to remove any DC offsets. A variable resistor, R 17 is configured as a volume control that provides a constant load for the filter stage. The wiper of R 17 selects an input voltage to the final audio amplifier, A 5 . The LM386 device is configured as a constant gain amplifier to minimize external component requirements. Capacitor C 8 and resistor R 18 provide necessary filter components recommended by the LM386 manufacturer. Capacitor C 7 couples the amplified audio signal to a speaker, SP. The speaker SP is mounted inside the enclosure near an open end.
A button, B 1 is connected to an input of the processor, Z 1 to provide for user control of the device. Various modes of operating this and/or additional buttons are provided to select on and off states, as well as various sound options.
The circuit is powered by a battery that is carried inside the enclosure. The circuit is designed to maximize the life of the battery, for example by removing power from certain components when they are not needed. The device may have an automatic shut-off feature to limit the operation periods. If used outdoors, a solar panel integrated onto the enclosure can help extend the battery life.
The processor, Z 1 contains a computer program to control several functions. The exact implementation may vary, however the required software functions are described in the flow charts of FIGS. 4 , 5 and 6 . A computer program implemented with the principles of the present invention is listed in the appendix of this specification. Other implementations of a computer program could be used.
FIG. 4 is the flow chart of a routine that is entered by various interrupt triggers of Z 1 . This routine takes priority over other operations the processor may be handling at the time. One interrupt trigger of Z 1 occurs at regular intervals based on an internal hardware timer. The timer interval is based on an external crystal and programmed parameters. The crystal frequency and parameter values can be chosen to cause the routine to be accessed approximately 10,000 times per second. The measurement of the pressure signal and calculation of output samples are based on this rate. The sample values for creating audio waveforms must be output at reliable intervals, interval is based on an external crystal and programmed parameters. The crystal frequency and parameter values can be chosen to cause the routine to be accessed approximately 10,000 times per second. The measurement of the pressure signal and calculation of output samples are based on this rate. The sample values for creating audio waveforms must be output at reliable intervals, however the period for sampling the pressure signal may be adjusted to modify the performance of the air movement detection.
In step S 1 , the processor determines if the routine has been accessed due to the timer expiration or one of other possible interrupt reasons. If the timer has expired, it is reset for the next timeout and step S 2 is accessed. If not, the routine is exited.
In step S 2 , the processor checks a software flag to determine if Chime # 1 is currently in progress. Since each chime sound may last up to 3 seconds, there are approximately 30,000 samples to be output while the chime is in progress. If the chime is in progress, step S 3 is accessed. Otherwise, step S 4 is accessed.
Step S 3 determines the next sample value for Chime # 1 . The routine used is described in association with FIG. 5 . Whether or not step S 3 was accessed, control continues to step S 4 .
Step S 4 is similar to step S 2 . The processor checks the status of Chime # 2 and if active, step S 5 is accessed. Otherwise, step S 6 is accessed.
Step S 5 determines the next sample value for Chime # 2 . Steps S 3 and S 5 both use the routine of FIG. 5 , except for operating on a different set of variables. Additional chimes may be generated in the same way. Whether or not step S 5 was accessed, control continues to step S 6 .
In step S 6 , all of the active samples are combined using a signed summation to mix the chime sounds. The resulting sample value is sent over the SPI interface to the DAC as described in association with FIG. 3 . After step S 6 , control continues to step S 7 .
Step S 7 keeps a count of how many times the timer interrupt routine has been called. This effectively divides the time base by a desired value. A typical divide value is 256, so that the counter completes each 0.0256 seconds. The counter value must be reset in this step if the count is completed. This less frequent event is used to trigger the internal analog to digital converter (ADC) to read a new pressure signal value. When the divide count is complete, step S 8 is accessed. If not, control continues to step S 11 .
In step S 8 , the latest value from the ADC is read. In the preferred processor, this is a 10-bit binary value between 0 and 1023, inclusive. To improve consistency of the results, a plurality of sample values are added to a 16-bit accumulator register. When a constant number of samples have been summed, the total will be divided by the number of samples to provide an average. Alternatively, a continuous average can be obtained by adding the new value and subtracting the oldest value before dividing by the number of samples. This step always continues to step S 9 .
In step S 9 , the number of samples added to the accumulator is compared to a predetermined number. The number chosen determines the length of the accumulated average. In the disclosed embodiment a value of 16 is used, although different length averages can be used. If the predetermined number of samples have been accumulated, the processor proceeds to step S 10 , otherwise control proceeds to step S 11 .
In step S 10 , the ACCUM_FULL flag bit is set. This flag signals the routine of FIG. 6 that the accumulator is full and ready for examination. After this step, control proceeds to step S 11 .
Step S 11 is accessed during each timer interrupt, whether or not chime samples or pressure samples were processed. In the disclosed embodiment, this will occur approximately each 0.0256 seconds. A counter, TRIG_DECAY_TIME, is decremented to divide this time to a slower interval. This is a non-critical timer since the period will depend on what processing was done during the interrupt. This counter may use a value between 2 and 5, to cause an event to occur a few times per second. If the counter decrements to zero, it is reset to the starting value and step S 12 is accessed. Otherwise control proceeds to step S 13 .
In step S 12 , the value of the VAR_TRIG signal is decremented by one. The VAR_TRIG signal represents the current amount of wind activity. The VAR_TRIG signal will decay to zero if no new, higher value is set in step S 30 of FIG. 6 . This allows the VAR_TRIG signal to track increases in the pressure measurements, but lag behind them as they decrease. The amount of lag can be adjusted by the selecting the value of TRIG_DECAY_TIME used in step S 11 . After this step, control is transferred to step S 13 .
In step S 13 , another non-critical timer, CHIME_DELAY is maintained. The timer value is decremented each time until zero is reached. CHIME_DELAY can be set to an arbitrary value in other parts of the program. When the value reaches zero, various events can be triggered.
FIG. 5 is a flow chart describing the process of creating one output sample value. The process is valid for each waveform that will be generated. It is initiated in steps S 3 and S 5 of FIG. 4 . The disclosed embodiment generates chime sounds based on the value of the VAR_TRIG signal. Alternate embodiments could use the VAR_TRIG signal for other purposes. The chime sound is approximated with a Double-Sideband Suppressed-Carrier (DSB-SC) waveform. The waveform can be created by multiplying together two sinusoidal (sine) waves, or by modulating the frequency of one sine wave with another. The disclosed embodiment implements the later method using a digital algorithm to create the DSB-SC waveform. The result contains a mix of frequencies that has the metallic sound of a ringing chime. Since the algorithm is under programmed control, it allows easy modification and adjustment of the sound parameters.
Each chime is specified by two PHASE_INC values, which determine the frequencies of the two sine waves used. To create a sine wave, the PHASE_INC value is added to the current phase, CURR_PHASE, at regular intervals. The new CURR_PHASE value is used as the offset into a table. The table contains amplitude values for one full cycle of a sine wave. Each table entry represents the amplitude at a particular phase step. If a 16-bit value is maintained for the CURR_PHASE, the complete 360 degree sinusoidal wave is separated into 65,536 different phase values (i.e. approximately 0.0055 degrees per CURR_PHASE value). When CURR_PHASE goes beyond the maximum number of steps, it is wrapped around to the beginning of the table to begin the next cycle of the waveform. Since the sinusoidal wave is symmetrical, the table can be reduced to one quarter of a cycle if proper inversions are made depending on the current phase quadrant.
The frequency of a sine wave can be modulated by using a varying phase step. The software uses a constant PHASE_INC to create one sine wave. The scaled amplitude of this wave is used to modify the constant PHASE_INC of the second wave. The second wave is therefore frequency modulated by the first wave.
The modulated waveform is then amplitude limited by an exponentially decaying envelope to simulate the natural attenuation of a mechanical chime after it is struck. A table of scaling factors is used with an incrementing index, ATTEN_INDEX. This index can start at zero, or at a later point in the table. This way, the initial loudness and the duration of the chime can be adjusted. The decaying envelope can also encode some low-frequency amplitude modulation that is common in chimes. Multiple decay envelope tables may used to vary the chime sounds.
In step S 14 , the phase increment value PHASE_INCR_ 1 is added to the current phase for sine wave # 1 , CURR_PHASE_ 1 . The value is wrapped around to the beginning of the table if needed.
In step S 15 , the new phase value is used as the index to the sine table. The value obtained from the table is saved as the next sample of sine wave # 1 , FREQ_ 1 .
In step S 16 , the constant phase increment value, PHASE_INCR_ 2 , is modified by the new sample value for FREQ_ 1 , obtained in step S 15 . The value of FREQ_ 1 is first scaled to a smaller, proportional value which may be positive or negative. When it is added to the constant PHASE_INCR_ 2 value, the value is slightly increased or decreased. The modified PHASE_INCR_ 2 is then added to the current phase value for sine wave # 2 , CURR_PHASE_ 2 . This will effectively modulate the frequency of sine wave # 2 .
In step S 17 , the new CURR_PHASE_ 2 is used as the index to the sine table. The value obtained from the table is the resulting frequency modulated sample for FREQ_ 2 .
In step S 18 , the current ATTEN_INDEX is used to look up the scaling factor, ATTEN_VALUE for the current sample. ATTEN_VALUE will be used to reduce the amplitude of the current sample of the modulated waveform.
In step S 19 , the current value of FREQ_ 2 is multiplied by ATTEN_VALUE.
In step S 20 , the result of step S 19 is saved. It will be combined with any other chimes in progress in step S 6 of FIG. 4 .
In step S 21 , ATTEN_INDEX is incremented by one.
In step S 22 , the ATTEN_VALUE is checked for a value of zero, meaning that the amplitude of the waveform has faded to zero. This occurs at the end of the table. If the value is zero, control proceeds to step S 23 . Otherwise, the routine exits.
In step S 23 , the CHIME_IN_PROGRESS flag is cleared, indicating that the current chime has completed. After this step, the routine exits.
The main routine of the software is described by the flowchart in FIG. 6 . This routine is entered when the device is turned on. This routine runs continuously unless it is interrupted by a higher-priority task.
In step S 24 , the processor is initialized for operation including enabling various interrupts and setting initial memory values. The processor then reads a plurality of pressure samples, and calculates a reference value. This value will be used for comparing future samples. Ideally, this reference value represents the nominal pressure signal, when there is no air movement. Slow changes in the nominal pressure signal may occur due to component variations, temperature, barometric pressure, humidity, etc. Therefore, the preferred embodiment occasionally performs a recalibration by adjusting the reference value to match the long-term average pressure signal. This way, new pressure signals will accurately represent short-term changes in air flow.
In step S 25 , a state machine determines if various user controls are activated. One or more buttons may be used to control device features. The state machine may determine the duration and number of button presses to expand the control functions. For example, a short press (less than one second) may select a different set of chime sounds, and a long press may turn the device on or off. If a control action is required, control is transferred to step S 26 . If no control action is indicated by button presses, control is transferred to step S 27 .
In step S 26 , the appropriate control action is executed. If a new chime set is selected, the phase increment values for the chime set can be read from a table and stored for current use. A sensitivity value may be adjusted to set the amount of chime activity desired. If the user selects to turn off the device, this routine is exited and the device is turned off. After any other control action is completed, control is transferred to step S 27 .
In step S 27 , a turn-off timer is checked. This timer is started when the device is turned on, and reset when a control action is executed. If the device is left on for the pre-determined time without control actions, this routine is exited and the device will be turned off to save power. The duration of this timer may be several hours. If the time has not expired, control is transferred to step S 28 .
In step S 28 , the ACCUM_FULL flag state is checked. This flag is set in step S 10 ( FIG. 4 ) when the required number of pressure samples have been added to the accumulator. If the flag is set, control is transferred to step S 29 ; if not, control is transferred to step S 33 .
In step S 29 , the accumulated value is divided by the number of samples to provide an average value of the accumulated samples. Control is then transferred to step S 30 .
In step S 30 , the value DP is calculated as the magnitude of the difference between the new accumulated average and the reference value. The direction of the deviation may also be noted for various purposes such as chime selection. Control is then transferred to step S 31 .
In step S 31 , the current VAR_TRIG value is compared to the new DP value. If VAR_TRIG is less than DP, VAR_TRIG is set to the new DP value. This way, VAR_TRIG will immediately track the highest values of DP. If no new higher values occur, VAR_TRIG will slowly decay to zero due to step S 12 of FIG. 4 . Control is then transferred to step S 32 .
In step S 32 , the sample accumulator is reset to zero and the ACCUM_FULL flag is cleared to prepare for a new accumulation of samples. Control then transfers to step S 33 .
In step S 33 , the CHIME_DELAY timer is check for expiration. This timer is started at the beginning of each chime to provide a minimum time between chimes. When the timer expires, a new chime is allowed and control is transferred to step S 34 . If the timer has not expired, control loops back to step S 25 for continuous operation.
In step S 34 , the value of VAR_TRIG is used in an algorithm to determine if a new chime should start. If so, the new PHASE_INC values, CHIME_DELAY and initial ATTEN_INDEX for the new chime are determined. After this step, control loops back to step S 25 for continuous operation.
When the algorithm starts a chime, it selects from a table of predetermined pairs of PHASE_INC values. Each pair defines a chime sound. The selection has a random component and can be modified according to parameters such as estimated wind direction. The algorithm also sets a minimum duration, CHIME_DELAY, to wait before allowing the next new chime to start. The duration has a random component, and can be modified according to parameters such as estimated wind intensity, indicated by VAR_TRIG. The algorithm also sets the initial ATTEN_INDEX value. This value normally starts at zero, but it can be increased to start the chime at a lower attenuation envelope value. Generally, higher values of VAR_TRIG will cause the creation of louder and more frequent chimes. If the VAR_TRIG value is below a predetermined threshold, no new chime is generated but any chimes in progress are allowed to complete.
The maximum number of simultaneous chimes is limited by the resources and performance of the processor. The samples for all chimes must be calculated within one sample period. Each waveform is generated independently and they are mixed together to form the final output. When a new chime starts, the selected PHASE_INC, CHIME_DELAY and ATTEN_INDEX values are assigned to one set of chime resources. A resource is freed when the chime completes or it can be reassigned with new parameters before the chime completes.
Obviously, many modifications and variations of the present invention are possible in light of the above teaching. It is therefore to be understood that the invention may be practiced otherwise than specifically described. | This device has a detection means to measure the relative amount of air movement in its vicinity. The detection means is coupled to a processing means for creating a variable trigger signal that is proportional to detected air movement. The detection means consists of a differential pressure transducer mounted inside a specially-shaped enclosure. The pressure transducer is arranged to measure the air pressure difference between two holes in the enclosure. The shape of the enclosure causes air to flow at different velocities near the holes, creating a differential air pressure. The processing means consists of a microprocessor that periodically samples the signal from the differential pressure transducer. A programmed algorithm calculates a variable trigger signal value based on a plurality of sampled signals. The processing means can also incorporate an algorithm for digitally generating audio signals that have attributes based on the value of the trigger signal. | 6 |
FIELD OF THE INVENTION
This invention relates generally to methods of knitting pile jacquard fabric on a circular knitting machine, and more particularly to methods of knitting such fabric which involve feeding the ground and pile yarns while selectively operating the needles and sinkers to selectively form pile loops of different pile loop yarns in adjacent groups of sinker wales in side-by-side relationship in each course to provide a dense velour type jacquard pattern fabric after the loops are cut in the finishing process.
BACKGROUND OF THE INVENTION
It is generally known to provide a pile loop jacquard pattern fabric on a circular knitting machine by utilizing sinker pattern wheels for knitting this type of pile jacquard fabric. This known method of knitting a pile loop jacquard fabric is illustrated in FIGS. 29-31. As shown in the sinker pattern diagram of FIG. 29, first spaced-apart groups of four sinkers (solid circles) are advanced inwardly during the knitting of alternate courses while second spaced-apart groups of four sinkers (cross hatched circles) are advanced inwardly during the knitting of intervening courses to form vertical stripes of adjacent groups of four pile loops. Thus, during the knitting of the first course of the fabric at the first yarn feeder (FIG. 30), the sinker pattern wheel advances the sinkers associated with the knitting of the four adjacent wales A so that pile loops are formed by placing the first pile loop yarn over the sinkers while the ground yarn is fed beneath the sinker noses. At the same time, the four sinkers associated with the knitting of the wales B are not advanced so that the first pile loop yarn forms plain stitch loops in plated relationship with the ground yarn. During the knitting of the second course of fabric at the second feeder, the sinker pattern wheel advances the sinkers associated with the knitting of the four adjacent wales B so that pile loops are formed by placing the second pile loop yarn over the sinkers while the ground yarn is fed beneath the sinker noses. The sinkers in the wales A are not advanced so that both the pile loop yarn and the ground yarn form plain stitch loops without pile loops. FIG. 31 illustrates the pile loops, knit in accordance with the prior art of FIG. 30, being cut or sheared to provide a velour type of fabric. As shown in FIGS. 30 and 31, the pile loops forming adjacent walewise stripes are not formed in the same course but are formed in alternating courses. Thus, the density of pile loops is one-half of the density of the stitch loops formed of the ground yarn, resulting in a pile or velour patterned fabric having less than the desired density of pile loops.
SUMMARY OF THE INVENTION
In contrast to the above-described type of pile jacquard knit fabric, the knitting methods of the present invention provide a pile jacquard pattern fabric in which each of the pattern pile loop yarns forms corresponding groups of pile loops in a side-by-side manner and in every course to provide a density of pile loops which is the same as the density of ground stitch loops.
Generally, groups of adjacent pile loops are formed of different pile loop yarns in a side-by-side manner and in the same course, in accordance with the knitting methods of the present invention. This is accomplished by feeding the ground yarn to all of the needles, feeding a first pile loop yarn to selected spaced-apart groups of needles raised to tuck level to form pile loops over corresponding advanced sinkers, feeding a second pile loop yarn to the remaining spaced-apart groups of needles raised to tuck level to form pile loops over corresponding advanced sinkers, and then simultaneously knitting the ground yarn along with the first and second pile loop yarns. The portions of the first pile loop yarn between the first groups of pile loops extend as elongate floats above the second groups of pile loops while the portions of the second pile loop yarn between the second groups of pile loops extend as elongate floats above the first groups of pile loops.
In accordance with the present invention, a two-color jacquard pattern fabric can be produced by either a repeated three-feeder knitting procedure or by a repeated two-feeder knitting procedure. In the three-feeder knitting procedure, all needles are raised to latch clearing or knitting level and fed the ground yarn at the first yarn feeder. All needles are then lowered to the welt or float level where the old loops which are about to be cast off are retained on the outside of the closed latch of the needles. At the second yarn feeder, certain groups of adjacent needles remain at this welt level while other groups of adjacent needles are raised to the tuck level and fed a first pile loop yarn. The sinkers associated with these needles ar advanced inwardly beneath the first pile loop yarn. These needles with the first pile loop yarn are then lowered to a level where the top of the needle hook is slightly higher than the surface of the sinker nose so that the first pile loop yarn is positioned above the sinker nose. At the third yarn feeder, the needles which were raised to tuck level at the second feeder remain at the welt level while the needles which remained at the welt level at the second feeder are raised to tuck level and are fed a second pile loop yarn. The sinkers associated with these needles are advanced inwardly beneath the second pile loop yarn. These needles with the second pile loop yarn are then lowered so that the second pile loop yarn is positioned above the sinker nose. The inward movement of the sinkers at the second and third feeders positions the floating portions of both the first and second pile loop yarns on the inside of the needles. All needles then are lowered to stitch drawing level so that the required lengths of the first and second pile loop yarns are drawn over the sinker nose while the ground yarn is drawn over the sinker knitting face. As the old loops are cleared from the needles, the first and second pile loop yarns form corresponding groups of adjacent first and second pile loops in a side-by-side position in this single course of fabric. As this three-feeder sequence is continued, vertical stripes of pile loops are formed.
In a second embodiment, the jacquard pattern fabric is produced by a two-feeder procedure in which the ground yarn is fed to all needles at the first yarn feeder while a first pile loop yarn is also fed to selected groups of adjacent needles and the other needles pass the first yarn feeder at welt or float position and do not receive the first pile yarn therein. The sinkers associated with these needles which pick up the first pile loop yarn are advanced inwardly beneath the first pile loop yarn. The needles are then lowered at the first yarn feeder to a welt level to retain the old loops about to be cast off the needle on the outside of the closed latch of the needles. At the second yarn feeder, the second pile loop yarn is fed to the remaining needles as they are raised to tuck level while the needles which picked up the first pile loop yarn at the first feeder are maintained at the welt or float level so that they do not pick up the second pile loop yarn. The sinkers associated with the needles selected for picking up the second pile loop yarn are advanced inwardly so that the second pile loop yarn extends above the sinker nose. The inward movement of the sinkers at the second yarn feeder positions the extended floats of the first pile loop yarn on the inside of the corresponding needles. After the second pile loop yarn is fed at the second feeder, all needles are lowered to the knitting or stitch drawing level so that the old loops are cleared from the needles and the pile loops of the first and second pile yarns are formed in a side-by-side position in the same course.
In both the described three-feeder and two-feeder knitting procedures, four wale wide vertical stripes of pile loops are formed of different pile loop yarns in side-by-side position in each course of the fabric. However, it is to be understood that additional feeds can be employed so that more than two separate pile loop yarns may be used to form corresponding pile loops in the same course. Also, the needle selection and sinker operation may be varied to produce various other types of loop pile patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages will appear as the description proceeds when taken in connection with the accompanying drawings, in which--
FIG. 1 is a schematic developed view looking outwardly from inside of the needle cylinder and showing the operation of the needles and sinkers at each of the three yarn feeders;
FIGS. 2A through 13B are successive vertical sectional views illustrating the relative positions of the needles and sinkers during a three-feeder knitting procedure, being taken along the respective lines 2--2 through 13--13 of FIG. 1;
FIG. 14 is a view similar to FIG. 1 but schematically illustrating the two-feeder knitting procedure;
FIGS. 15A through 25B are successive vertical sectional views illustrating the relative positions of the needles and sinkers during a two-feeding knitting procedure, being taken along the respective lines 15--15 through 25--25 of FIG. 14;
FIG. 26 is a sinker pattern diagram illustrating the manner in which the sinkers are advanced during the knitting of each course in the knitting of a two-color pile jacquard pattern fabric in accordance with the present invention;
FIG. 27 is a perspective view of one course of the present two-color pile jacquard pattern fabric;
FIG. 28 is a view similar to FIG. 27 but showing the pile loops being cut or sheared;
FIG. 29 is a sinker pattern diagram illustrating the manner in which the sinkers are operated in alternate courses in the knitting of the prior art type of jacquard knit pattern fabric;
FIG. 30 is a perspective view of a pair of adjacent courses, illustrating the manner in which the pile loops are formed in successive courses in the knitting of the prior art type of two-color pile jacquard pattern fabric; and
FIG. 31 is a view similar to FIG. 30 but illustrating the pile loops being cut or sheared.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The knitting of the two-color jacquard pattern fabric will be described in connection with FIGS. 1-13B in which a repeated three-feeder knitting procedure is utilized, in accordance with the present invention. After all needles 3 are raised to the latch clearing or highest position, a ground yarn 7 is fed to all needles at the first feeder X by a yarn carrier 10 (FIG. 1). As the needles 3 are lowered, the ground yarn 7 is caught in hooks 3a of each of the needles 3, as shown in FIGS. 2A and 2B. At this time, sinkers 5 begin retreating or moving outwardly. As the needles 3 are further lowered, old or previously formed ground needle loop 7a and pile needle loop 9a slide upwardly on the needle stem 3c, as shown in FIGS. 3A and 3B, to raise the latch 3b to close the hook 3a. The sinkers 5 then retreat or move outwardly to the outermost position, as shown in FIGS. 3A and 3B.
The needles 3 then further move downwardly to the welt position, as shown by the one-dot chain line 1 in FIG. 1. As the needles 3 move down to the welt position, the old loops 7a and 9a are retained on the outer part of the needle latch 3b without being shed or cleared off of the needles, as shown in FIGS. 4A and 4B. The needles 3 then move along the one-dot chain line 1 to the second feeder Y, retaining the old loops on the latches 3b. At this time, the sinkers 5 are advanced inwardly and position the ground yarn 7 retained by the lowered needle hook 3a in the sinker throat 5b.
Selection of the needles 3 is then made at needle selection position A to either tuck or welt as they approach the second feeder Y. The needles 3 which have been selected for tuck level at the second feeder Y are raised upwardly and the ground yarn 7 opens the latch 3b (FIG. 5A) so that a first pile loop yarn 8 is caught in the needle hook 3a. The first pile loop yarn 8 is fed through a yarn feeder 11 (FIG. 1). After these needles have picked up the first pile yarn 8, they are lowered until they reach the one-dot chain line 2 (FIG. 1) with the top of the hook slightly higher than the upper sinker nose face 5c (FIG. 6A). Thus, the ground yarn 7 and the pile yarn 8 are in the needle hook 3a with the latch 3b in a closed position and with the first pile yarn 8 being supported above the upper sinker nose face 5c and the ground yarn 7 being supported on the knitting face or surface 5a of the sinker, as shown in FIG. 7A. The yarns are supported in this manner until the selected needles reach the third feeder Z, as illustrated in FIG. 8A.
On the other hand, the needles 3 which have not been selected for movement to the tuck level at the first needle selection position A, remain in the welt position and below the level of the first pile yarn 8, as shown in FIGS. 4B through 6B. In this position, these needles 3 at welt position retain the ground yarn 7 in the hooks 3a and old loops 7a and 9a on the outside of the latch 3b.
At the third feeder Z, the needles 3 are selected to either tuck or welt at the second needle selection position B. The needles 3 which were selected for tuck level at the first needle selection position A are then selected for welt position at the second needle selection position B and the remaining needles are raised to tuck level, as shown in FIG. 8B. The needles 3 which are not selected remain at the welt level, as shown in FIG. 8A, with the first pile yarn 8 and the ground yarn 7 retained in the closed needle hook 3a. Meanwhile, the sinker 5, immediately after being advanced slightly inwardly, as shown in FIG. 7B, is moved outwardly. With further movement, the needle 3 lowers the pile yarn 8 supported by the upper sinker nose face 5c, as shown in FIG. 9A, while the needle is lowered.
As shown in FIG. 10A, the needles 3 are then moved to the lowest knitting or stitch drawing position so that the old loops 7b, 8b are cleared or shed as stitch loops are drawn with the new pile yarn 8 and the new ground yarn 7 over the upper sinker nose face 5c. The required length of the ground loop yarn 7 and the pile loop yarn 8 is drawn by the sinkers 5. Following the slight raising of the needles 3, the ground needle loop 7b and the pile yarn needle loops are tightened by inward advance of the sinkers 5, as shown in FIGS. 11A and 11B.
The needles 3 are then moved to the first feeder X and all of the needles 3 are again raised and the ground needle loop 7b and the pile needle loop 8b are retained on the needle and slide downwardly below the latch 3b and onto the needle stem 3c, as shown in FIG. 12A. After the needles 3 arrive at the knitting position as the highest position, they are lowered to tuck level, as shown in FIG. 13A, so that a newly fed ground yarn 7 may be fed to the hook of the needle in the first feeder zone X.
On the other hand, the needle 3 which was selected for welt at the first needle selection position A is selected for tuck level at the second needle selection position B. The needle 3 selected for tuck position is raised slightly, as shown in FIG. 7B, from the position shown in FIG. 6B. The sinker 5 advances slightly inwardly positioning the upper sinker throat 5d at the central portion of the needle hook and turning the floating part of the pile yarn 8 to the inside of the needle. The sinker 5 is immediately returned outwardly and the needle 3, after being raised to the tuck position, catches the pile yarn 9 while descending as shown in FIG. 8B. With further descent of the needle 3, the pile yarn 9 supported by the upper sinker nose face 5c is lowered, as shown in FIG. 9B.
As the needle 3 is moved to the lowest position, as shown in FIG. 10B, the needle 3 is cleared of the old loops and the pile yarn 9 is supported by the upper sinker nose face 5c and the ground yarn 7 is supported by the lower knitting face 5a. Both of these yarns 7 and 9 are lowered together so that the required length of the ground needle loop 7b and the pile needle loop 9b are drawn over the respective faces of the sinker 5. With the slight raising of the needle 3, the sinker 5 advances inwardly, as shown in FIG. 11B to tighten the ground needle loop 7b and the pile needle loop 9b. All needles are again raised at the first yarn feeder X and the ground needle loop B and the pile needle loop 9b are down below the tip of the latch 3b and slide downwardly on the needle stem 3c, as shown in FIG. 12B. After arrival of the needles 3 at the knitting position or the highest shed level, the needle loops 7b, 9b on the needle stem 3c are moved upwardly below the tip of the latch 3b, as shown in FIGS. 13A and 13B, so that a newly fed ground yarn 7 may be fed into the hooks of the needles. This three-feeder knitting procedure is continued to form pile loops of the different pile loop yarns 8, 9 in four adjacent sinker wales. The different pile loop yarns 8 and 9 are continuously knitted in side-by-side relationship in each course formed of the ground yarn 7.
In the second embodiment, the jacquard pattern fabric is produced by a two-feeder procedure in the manner schematically illustrated in FIGS. 14 through 25B. In this second embodiment, both a ground yarn 107 and a first pile loop yarn 108 are fed at a first yarn feeder zone XY by means of a yarn feed finger 100 with the first pile loop yarn 108 being fed at a higher level than the ground yarn 107. A first needle selection mechanism Al is provided at the first yarn feeder zone XY. In FIG. 14, the one-dot chain lines 101, 102 indicate the lines of movement of the top of the hook of the needles 3. A continuous line 104 indicates the top of the knitting faces 5a of the sinkers 5 whereas the two-dot chain line 106 indicates the line of movement of the sinker throats 5b. A second pile yarn 109 is fed through a feed finger 112 at the second yarn feeder zone Z.
All of the needles 3 are raised to stitch loop clearing level at the first yarn feeder zone XY , as indicated in dotted lines in advance of the yarn feeder 100 in FIG. 14, and certain of the needles are selected to be lowered to the welt position so that they are fed with the ground yarn 107 only, extending outwardly at the bottom of the yarn carrier 100. With the descent of the selected needles, the ground yarn 107 is caught by the needle hook, as illustrated in FIG. 15A. As these selected needles 3 are lowered, the sinker 5 retreats or is moved outwardly further to the outermost position, as shown in FIG. 15A. The selected needles 3 then descend until they reach the welt position, as shown in FIG. 16A, so that the old ground needle loop 107a and the old pile needle loop 109a slide upwardly on the needle stem to raise the latch 3b, thereby closing the hook 3a, as shown in FIG. 16A. The old loops 107a, 109a are not cleared from the needle and are retained on the outside of the closed latch 3b, as shown in FIG. 16A. The needles 3 are then moved to the second feeder Z, remaining at the welt position. The sinkers 5, having retreated to the outermost position, advance inwardly, as shown in FIG. 17A.
The needles 3 having been selected for picking up the pile loop yarn 108 at the first needle selection position Al have been raised so that the old loops 107a, 109a are moved below the latch 3b, as shown in FIG. 16B. These needles are fed with both the ground yarn 107 and the first pile yarn 108 in the hook of the needle 3 while the needles are being lowered, as shown in FIGS. 15B and 16B. With further descent of the needles 3, the pile loop yarn 108 and the ground yarn 107 are both caught in the hook of the needles, as shown in FIG. 17B. At this time, the sinkers 5 having retreated to the outermost position, are advanced inwardly so that the pile yarn 108 is drawn over the upper sinker noses 5c. The needles 3 are further lowered to the level at which the top of the hook is slightly higher than the upper sinker nose 5c, as shown in FIG. 18B. The ground yarn 107 and the pile loop yarn 108 are then retained by the needle hook with the latch 3 b raised by the old loops 107a, 109a. Thus, the pile loop yarn 108 is supported by the upper sinker nose 5c and, staying in that manner, is shifted to the second yarn feeder zone Z.
The needle selection of tuck or welt is performed by the second needle selection mechanism Bl in the second yarn feeder zone Z. The needles 3 having been selected for welt at the first needle selection position Al are selected for tuck at the second needle selection mechanism Bl, as shown by the one-dot chain line 101. These needles are moved to the second needle selection position Bl keeping the old loops 107a, 109b retained on the closed latch and then begin raising upwardly from this position, as shown in FIG. 19A. At this time, the sinkers 5 advance slightly inwardly, moving the floating part of the pile loop yarn 108 inwardly inside of the needle hooks and positioning the upper sinker throat 5d in the central space of the needle hook. The needles 3, after being raised to the tuck position, catch the second pile yarn 109, as shown in FIG. 20A, while the needles are being lowered. The pile yarn 109 supported by the upper sinker nose face 5c is drawn downwardly, as shown in FIG. 21A. With further descent of the needles 3, the old loops are cleared or cast off with the needles 3 guided to the lowest position, as shown in FIG. 22A, so that the pile loop yarn 109 and the ground yarn 107, supported by the respective knitting faces 5c and 5a, are drawn downwardly to provide a ground needle loop 107b and pile needle loop 109b which include the required length of yarn.
As the needles 3 are slightly raised, the sinkers 5 advance inwardly, as shown in FIG. 23A, so that the ground needle loop 107b and the pile needle loop 109b are tightened on the needle 3. The needle 3 is again shifted to the first feeder XY and all needles are again raised (FIGS. 24A and 24B). With the raising of the needles 3, the ground needle loop 107b and the pile needle loop 109b in the needle hook are cast off of the lower tip of the latch 3b and slide down the needle stem 3c as they are moved to the first needle selection position Al.
The needles 3 which were selected for picking up the pile yarn 108 at the first feeder XY are then selected for being raised to the welt position at the second needle selection mechanism Bl to produce a state in which the ground yarn 107 and the pile yarn 108 are retained by the needle hook as the needle 3 is moved while maintaining this state, as shown in FIG. 19B and FIG. 20B. As shown in FIG. 21B, the needles 3 draw the pile yarn 108 downwardly, supported by the upper sinker nose face 5c. When the needles 3 are guided to the lowest position, as shown in FIG. 22B, the old pile loops 109a and the ground yarn loops 107a are cleared therefrom so that the pile yarn 108 is supported by the upper sinker nose face 5c, as well as the ground yarn 107 supported by the knitting face 5a, is drawn downwardly to draw the required length of ground needle loop 107b and pile needle loop 108b. With the slight raising of the needles 3, as shown in FIG. 23B, the inward advance of the sinkers 5 tightens the ground loop 107b and the pile needle loop 108b. The needles 3 are again moved to the first feeder XY and all needles are raised. The needles 3 having been raised and cleared of the ground needle loop 107b and the pile needle loop 108b, because of the casting off of these loops from the tip of the latch 3b and downwardly sliding thereon on the needle stem 3c, are moved to the first needle selection position Al. Again, needle selection of pile or welt is performed at the first needle selection position Al.
By this knitting procedure, loops of pile loop yarns 108 and loops of pile loop yarns 109 are formed to be continuous and in a side-by-side manner in each course, and as this pattern is repeated, the pile fabric is produced. The knitting procedures, as referred to in the first and second embodiments described above, can be carried out on various types of circular knitting machines, such as model FX-SDP, presently manufactured and sold by Precision Fukuhara Works Ltd. It is to be understood that the knitting methods described above can be varied. For example, in the first embodiment, an increased number of additional second yarn feeders Y may be provided in which tuck or welt needle selection is performed at the additional yarn feeders. Also, in the second embodiment, an increased number of second feeders Z in which tuck or welt needle selection is performed may be provided to enable knitting of a pile jacquard knit fabric having courses each being in three or four colors, rather than in two colors, so that a pile jacquard knit fabric of increased pattern possibilities can be obtained.
In each of the described embodiments, the sinkers may be arranged, as shown in FIG. 26, to produce four wale wide vertical stripes in a two-color pile jacquard pattern fabric. One group A of four sinkers is indicated in the area marked with cross hatched circles and the other group B of four sinkers is indicated in the areas marked with solid circles. In this manner, one pile yarn, illustrated by the striped yarn Pl, forms individual pile loops in the sinker wales B and an elongate float in the sinker wales A while the other pile yarn P2 forms individual pile loops in the sinker wales A while forming an elongate float above the pile loops in the sinker wales B. As will be noted in FIG. 27, both the individual pile loops and the elongated floats of both pile yarns Bl and P2 are formed in a single course with the ground yarn and in side-by-side relationship so that the number of pile loops in the coursewise direction is equal to the number of ground loops in each course. When both of the groups of pile loops and pile yarn floats are cut or sheared, as illustrated in FIG. 28, a velour type of jacquard pattern fabric of thicker density is obtained than can be obtained with the conventional prior art method, as illustrated in FIGS. 29-31.
In the drawings and specification there have been set forth the best modes presently contemplated for the practice of the present invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims. | The methods of knitting the pile jacquard fabric are carried out on a circular knitting machine including needles and sinkers, and a plurality of adjacent yarn feeders. The fabric includes successive courses of plain jersey stitch wales knit of a ground yarn with each successive course also including a first pile loop yarn knit with the ground yarn in selected groups of adjacent wales and forming an individual pile loop in each intervening sinker wale, and a second pile loop yarn knit with the ground yarn in other groups of adjacent needle wales and forming an individual pile loop in each intervening sinker wale. Both the individual pile loops of the first and second pile loop yarns are positioned in side-by-side relationship in adjacent groups in each successive continuous ground yarn course so that the density of the pile loops corresponds with the density of the ground yarn stitch loops. The upstanding individual pile loops are adapted to be cut in a shearing operation to form a patterned velour jacquard fabric. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Embodiments of the present invention relate to and claim priority to Japanese Patent Application No. 2000-398367, filed on Dec. 27, 2000, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electronic pad for use as an electronic percussion instrument, and in certain embodiments, for use as an electronic hi-hat cymbal.
[0004] 2. Description of the Related Art
[0005] In recent years, electronic musical instruments have secured a position not simply as an alternative to acoustic musical instruments but as musical instruments capable of generating tones of various timbers with various effects.
[0006] One such electronic musical instrument is an electronic percussion instrument that imitates an acoustic percussion instrument. One technique relating to electronic percussion instruments, and specifically, a technique for allowing an electronic percussion instrument to generate tones similar to those of an acoustic percussion instrument, is disclosed in Japanese Patent Application Laid-Open (JP-A) No. 5-143071, which is incorporated herein by reference.
[0007] According to the electronic percussion instrument disclosed in JP-A No. 5-143071, a phenomenon occurs such that the initial amplitudes of vibrations caused by percussive strikes against the instrument may vary depending on where the instrument was struck. Moreover, the initial amplitudes of such vibrations may vary even if different parts of the instrument are struck with an equal striking force.
[0008] Next, experimental data on the above-described phenomenon will be described.
[0009] [0009]FIG. 1 shows an electronic pad 7 similar to an embodiment of the electronic pad disclosed in JP-A No. 5-143071. The electronic pad 7 has a frame 2 that transmits a vibration of a strike, a striking sensor 1 that detects the vibration of a strike wherein the striking sensor 1 is arranged on the central portion of the lower surface of the frame 2 , and a cover 3 which is in contact with the frame 2 and that covers the upper surface of the frame 2 .
[0010] [0010]FIG. 2 is a top view of the electronic pad 7 shown in FIG. 1. For illustrative purposes, the striking sensor 1 , which would not normally be seen in a top view, is shown. The striking surface of this electronic pad 7 is the area inside a circle having the radius A (A being measured from the center of the electronic pad 7 ). As shown in FIG. 2 and for purposes of discussion herein, a point a distance ‘a’ away from the center of the electronic pad 7 will be referred to as a point “inside,” a point away therefrom by distance ‘b’ will be a point “middle,” and a point away therefrom by distance ‘c’ will be a point “outside.” The ratios of the distances ‘a’, ‘b’, and ‘c’ to the radius A are 10%, 50%, and 90%, respectively.
[0011] [0011]FIG. 3 is a waveform view showing waveforms of vibrations detected by the striking sensor 1 (shown in FIG. 2). The three waveforms correspond to when points “inside”, “middle,” and “outside” on an electronic pad are struck by a percussion member, such as a stick, with an equal striking force. The solid line indicates a waveform detected when the point “inside” is struck, the dashed line indicates the waveform when the point “middle” is struck, and the dotted line indicates the waveform when the point “outside” is struck. A comparison of the amplitudes of the waveforms shows that the initial amplitude of the waveform corresponding to when the point “inside” is struck is the highest. The initial amplitude of the waveform corresponding to when the point “outside” is struck is the lowest. The initial amplitude of the waveform corresponding to when the point “middle” is struck is in between the others.
[0012] In the case of an acoustic percussion instrument, the volume thereof does not depend on the striking position on the striking surface. Instead, a sound is generated with a volume closely related to the strength of the strike (the “striking strength”). A conventional electronic percussion instrument, by contrast, may not generate a sound with a volume related to the striking strength because of the above-described phenomenon. The initial amplitudes of the waveform vibrations may vary even though different positions may be struck with the same striking strength.
[0013] Accordingly, conventional electronic percussion instruments may need to detect a striking position as well as a striking strength. By accounting for a striking strength as well as a striking position, an electronic percussion instrument may correct the volume so that a sound may be generated with a volume according to the striking strength irrespective of the striking position.
[0014] Therefore, conventional electronic percussion instruments, to accurately correct the volume according to the striking strength, may also need to detect the striking position. Further, to generate a sound without creating a delay from the time of the strike, any volume corrections must be done very quickly. Accordingly, it is a disadvantage of conventional electronic pads that they may have to promptly detect striking position and correct the detected striking strength.
SUMMARY OF THE DISCLOSURE
[0015] In view of the above, it is an object of embodiments of the present invention to provide an electronic pad that may detect a striking force without having to detect or account for the striking position.
[0016] To obtain the above-described object, an electronic pad according to embodiments of the present invention may comprise:
[0017] a disk-shaped or bowl-shaped frame curved upward or downward;
[0018] a striking sensor in contact with the frame; and
[0019] a cover in contact with, and covering, an upper surface of the frame, and formed out of a softer material than the material of the frame.
[0020] The frame 2 of a conventional electronic pad may be constituted out of a flat plate as shown in FIG. 1. The electronic pad according to the present invention, by contrast, may have a disk-shaped or bowl-shaped frame curved upward or downward. Due to the shape of the frame, a strike against an outer peripheral portion of the electronic pad may be transmitted to the striking sensor without being greatly attenuated as compared to a strike against a position inside of the outer peripheral portion.
[0021] In some embodiments of the present invention, the frame of the electronic pad may be convex and curved upward. Also, the striking sensor may be situated such that it is in contact with a central portion of a lower surface of the frame.
[0022] In addition, in some embodiments of the present invention, the electronic pad may further comprise a chassis having a protrusion on one surface that forms a circle or a ring. In such embodiments, the cover may extend around to a lower surface of the outer edge portions of the frame, thereby holding the frame. In these embodiments, the chassis supports the outer peripheral edge portions of the frame, with a portion of the cover being interposed between the chassis and the frame. Further, in some embodiments of the invention, the outer edge of the frame may not be extended beyond the protrusion of the chassis.
[0023] Embodiments of the invention may also employ a sheet sensor for detecting an applied pressure on edge portions of the cover. The sheet sensor may be disposed at a position on an upper surface of the chassis outside of the chassis protrusion. In such embodiments, the cover may have a cover protrusion on its bottom surface that may press the sheet sensor in response to a strike against the upper surface of the cover. In this embodiment, the cover may also have a hollow portion outside of the protrusion.
[0024] In electronic pads according to embodiments of the present invention, a portion of the cover near the striking sensor may be formed thicker than other portions of the cover. If the portion of the cover under which the striking sensor is provided is formed to be thicker than the other portions of the cover, then a strike against the cover above the striking sensor may be attenuated so that such a strike is not detected more excessively than strikes against other portions of the cover.
[0025] In electronic pads according to further embodiments of the present invention, a surface treatment may be applied to the cover, such as a rubber primer. The cover may also have concentric concave and convex configurations on a surface of the cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 shows a cross-section view of a conventional electronic pad.
[0027] [0027]FIG. 2 shows a top view of a conventional electronic pad.
[0028] [0028]FIG. 3 is a waveform view showing waveforms of vibrations detected when points designated as “inside”, “middle” and “outside” in a conventional electronic pad are struck by a percussion stick with an equal striking force.
[0029] [0029]FIG. 4 shows a partially cut-away view of an electronic hi-hat cymbal according to an embodiment of the present invention.
[0030] [0030]FIG. 5 shows a cross-sectional view of an electronic hi-hat cymbal according to an embodiment of the present invention.
[0031] [0031]FIG. 6 shows a cross-sectional view of a part of a cover covering the upper surface of an electronic hi-hat cymbal according to an embodiment of the present invention.
[0032] [0032]FIG. 7 is a waveform view showing waveforms of vibrations detected when points designated as “inside,” “middle,” and “outside” of an electronic hi-hat cymbal, according to an embodiment of the present invention, are struck with an equal striking force.
[0033] [0033]FIG. 8 shows a cross-sectional view of an electronic hi-hat cymbal according to an embodiment of the present invention.
[0034] [0034]FIG. 9 is a waveform view showing waveforms of vibrations detected when points designated as “inside,” “middle,” and “outside” of an electronic hi-hat cymbal, according to an embodiment of the present invention, are struck with an equal striking force.
[0035] [0035]FIG. 10 shows a cross-sectional view of an electronic drum pad according to an embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] One embodiment of the present invention involves an electronic hi-hat cymbal. FIG. 4 illustrates an arrangement of sensors employed in an electronic hi-hat cymbal 8 according to an embodiment of the present invention. For illustrative purposes, portions of the frame 2 and of the cover 3 are not shown in this view.
[0037] As shown in FIG. 4, the upper surface of the frame 2 may be covered with the cover 3 . The outer peripheral edge portions of the frame 2 may be supported by a chassis protrusion 5 a of a chassis 5 . Portions of the cover 3 may be interposed between the chassis 5 and the frame 2 . A piezoelectric sensor 1 (which is an example of a striking sensor according to embodiments of the present invention) may be disposed to be in contact with the central portion of the lower surface of the frame 2 . The piezoelectric sensor 1 may detect a strike as a waveform of a vibration. In addition, a sheet sensor 4 may be disposed near the outer peripheral edge portions of the chassis 5 .
[0038] [0038]FIG. 5 is a cross-sectional view of the electronic hi-hat cymbal 8 shown in FIG. 4, according to an embodiment of the invention. In FIG. 5, the entire upper surface of the cover 3 may comprise a striking surface of the electronic hi-hat cymbal 8 . The outer edge of the cover 3 may also serve as a striking surface.
[0039] [0039]FIG. 5 shows a state in which points corresponding to the striking points designated as “inside,” “middle,” and “outside” (shown in FIG. 2), as well as the outer edge of the cover 3 , of the electronic hi-hat cymbal 8 , are struck by percussion sticks 11 .
[0040] With respect to the electronic hi-hat cymbal 8 shown in FIG. 5, the distance A (as shown in FIG. 2) is the radius of the frame. The ratios of the distances, from the center of the frame 2 to points “inside”, “middle”, and “outside”, to the radius A, are 10%, 50%, and 90%, respectively. These ratios are the same as those discussed with respect to FIG. 2. Other embodiments may employ other suitable ratios.
[0041] Embodiments of the electronic hi-hat cymbal 8 shown in FIG. 5 may have a generally bowl-shaped frame 2 made of a hard material and curved upward. The bowl-shape of frame 2 may be the shape of a portion of a sphere. Alternatively, other bowl-shaped curvatures may be employed for frame 2 . As a material for this frame 2 , a metal such as iron, a hard plastic material such as ABS or polycarbonate, or any like material, may be used. The outer peripheral edge portions of the frame 2 are supported by the chassis protrusion 5 a . A portion of the cover 3 may be interposed between the chassis 5 and the frame 2 . According to this configuration, if the upper surface of the electronic hi-hat cymbal 8 is struck, the frame 2 vibrates with the outer peripheral portions acting as fulcrums. The vibration of the frame 2 may be transmitted to the piezoelectric sensor 1 , which is in contact with the central portion of the lower surface of the frame 2 in this embodiment. Based on an electric signal generated in response to the vibration transmitted to this piezoelectric sensor 1 , a striking force and a striking position may be detected by various well-known detection methods.
[0042] Even if this embodiment of the electronic hi-hat cymbal 8 is continuously struck at short intervals (fast), a vibration generated by the strike may be attenuated relatively quickly because the cover 3 covers the frame 2 , and the cover 3 is interposed between the frame 2 and the protrusion 5 a of the chassis 5 . Therefore, even fast strikes may be accurately detected on an individual basis.
[0043] Moreover, embodiments of the electronic hi-hat cymbal 8 may be provided with the cover 3 covering the upper surface of the frame 2 and made of a softer material than that of the frame 2 . The cover 3 may be formed out of rubber, an elastomer, or any like material, which may have both elasticity and durability. The cover 3 provides a striking surface. Therefore, it may be desirable for the cover to be sufficiently hard so that the percussion stick has adequate rebound.
[0044] In embodiments of the invention, a surface treatment may be applied to the surface of the cover 3 in order to suppress the friction coefficient of the surface, to gloss the surface, and/or to improve the abrasion resistance of the surface. The surface treatment may make it easier to smoothly slide the percussion stick on the surface. The surface treatment may also help to protect the cover 3 , which may be struck by a percussion stick many times. For the surface treatment, a rubber primer or the like may be applied by means of, for example, dipping, brushing or spraying, or by other like means. Also, the cover 3 may be formed of a material having the same effect as that of the surface treatment. In any event, the cover should generally be softer than the frame 2 . The surface treatment may also be applied to the outer peripheral edge portions of the cover 3 and to a cover protrusion 3 a , which presses on the sheet sensor 4 , so as to prevent abrasion.
[0045] In embodiments of the invention, the surface of the cover 3 may be configured to have concentric concave and convex configurations as shown in FIG. 6. In one embodiment, the concave and convex configurations may be, for example, grooves with a width of 2 mm, a pitch of 4 mm (2 mm between the grooves), and a depth of 0.1 mm. Each convex portion may be subjected to embossing (a processing for lightly roughening a surface). As a result of the processing, a metallic gloss (light reflection) may be obtained. Accordingly, the appearance of the electronic hi-hat cymbal 8 may be akin to the appearance of an acoustic cymbal. Also, there may be an effect of reducing the abrasion of the cover 3 due to striking with a percussion stick.
[0046] An electronic hi-hat cymbal 8 according to further embodiments of the invention may include the chassis 5 constituting a lower portion of the electronic hi-hat cymbal 8 . As a material for this chassis 5 , hard plastic, such as ABS or polycarbonate, may be used as may any like material. A stand holder 6 may be assembled into the lower portion of the center of the chassis 5 . By fitting a stand (not shown) into the stand holder 6 , and fixing the stand to the stand holder 6 , the electronic hi-hat cymbal 8 may be supported by the stand.
[0047] Further, a sheet sensor 4 may be disposed between the fitted portions of the frame 2 and the chassis 5 . The sheet sensor 4 , which is ring-shaped, may detect a strike when the outer edge of the cover 3 of the electronic hi-hat cymbal 8 is struck.
[0048] To actuate the sheet sensor 4 , the cover protrusion 3 a may be provided on the outer peripheral edge portions of the cover 3 . The cover protrusion 3 a may be formed outside of the outer periphery of the protrusion 5 a . As a result, if the edge portion of the electronic hi-hat cymbal is struck, the outer peripheral edge portions of the cover 3 are deformed and the cover protrusion 3 a may actuate the sheet sensor 4 .
[0049] Further, the chassis 5 may support the frame 2 by the cover 3 using the protrusion 5 a as described above. In addition, the chassis 5 may be configured so that the edge of the frame 2 does not extend outside of the protrusion 5 a (i.e., the frame 2 is smaller in size than the outside diameter of the protrusion 5 a ).
[0050] Moreover, by providing a hollow portion outside of the cover protrusion 3 a (the portion that actuates the sheet sensor 4 ), the outer peripheral edges of the cover 3 may be deformed more easily when struck. This deformation may create a feel that is similar to striking the edge portion of an acoustic hi-hat cymbal. An acoustic hi-hat cymbal is constituted out of two cymbals, one of which faces and rests on the other. When the edge portion of an acoustic hi-hat cymbal is struck, the two cymbals are shifted to thereby convey a feeling as if the striking portion was deformed. The electronic hi-hat cymbal 8 in this embodiment may give a sense or feel of a strike that is similar to that of the acoustic hi-hat cymbal because the edge portion of the cover 3 may be deformed as described above.
[0051] Here, when the striking surface of the electronic hi-hat cymbal 8 or the outer edge of the cover 3 is struck by a percussion stick 11 , a generated vibration may be detected by the striking sensor 1 , as shown in FIG. 5. When only the outer edge of the cover 3 is struck, not only does the striking sensor 1 detect the vibration, but the sheet sensor 4 may also detect a strike. While the striking sensor 1 detects vibrations relative to all types of strikes against the striking surfaces, including strikes against the outer edge of the cover 3 , the sheet sensor 4 may only detect strikes against the outer edge of the cover 3 .
[0052] A cable, or the like, that could be attached to the electronic hi-hat cymbal 8 , is not shown in FIG. 5.
[0053] [0053]FIG. 7 is a waveform diagram showing waveforms of vibrations detected by the striking sensor 1 when points designated as “inside”, “middle”, and “outside” (shown in FIG. 2) are struck with an equal striking force, according to embodiments of the invention illustrated in FIGS. 4 and 5. In FIG. 7, a solid line indicates a waveform detected when the point “inside” is struck, a dashed line indicates a waveform detected when the point “middle” is struck, and a dotted line indicates a waveform detected when the point “outside” is struck.
[0054] Although distances from these striking points to the striking sensor 1 differ from one another, the initial amplitudes of waveforms of vibrations detected by the striking sensor 1 are almost equal.
[0055] That is to say, this embodiment of an electronic hi-hat cymbal 8 according to the invention may accurately detect striking strength without having to also detect striking position. Accordingly, a vibration having an amplitude according to a striking force may be accurately transmitted to the striking sensor no matter which point is struck by the percussion stick. Therefore, the waveform of a vibration obtained by the striking sensor may be used to generate a sound without having to first correct the waveform according to the striking position.
[0056] Next, another embodiment of the present invention will be described.
[0057] In the example embodiment described above, the central portion of the electronic hi-hat cymbal 8 (the portion of the cover 3 above where the piezoelectric sensor 1 is disposed) may be thicker than the rest of the cover 3 . Accordingly, the striking force, as described above, may be attenuated. Such a configuration prevents a strike against the central portion from being detected more excessively than strikes against the other portions. FIG. 8 shows an electronic hi-hat cymbal according to another embodiment of the invention wherein the central portion of the cover of the electronic hi-hat cymbal may be made equal in thickness to the other portions of the cover. In such an embodiment, a frame 2 may be bowl-shaped or disk-shaped, as is the frame in the embodiment described above. FIG. 8 is a cross-sectional view of an electronic hi-hat cymbal 9 according to this embodiment of the invention.
[0058] In this embodiment illustrated in FIG. 8, the points on this electronic hi-hat cymbal 9 corresponding to the striking points designated as “inside,” “middle,” and “outside” (shown in FIG. 2) may be superimposed on the electronic hi-hat cymbal 9 . Waveforms detected when these three striking points are struck are shown in the waveform view of FIG. 9.
[0059] As illustrated in FIG. 9, if the above-described three points on the electronic hi-hat cymbal 9 in FIG. 8 are struck with an equal striking force, the amplitudes of the waveforms of vibrations at the points “middle” and “outside,” as detected by the piezoelectric sensor 1 (i.e., the strengths of the vibrations), are almost equal. Accordingly, the electronic hi-hat cymbal 9 in FIG. 8 is improved from the conventional electronic pad in FIG. 1.
[0060] In other words, in the case of the electronic hi-hat cymbal 9 shown in FIG. 8, a striking sensor 1 may detect a waveform of a vibration according to a striking force irrespective of the distance of a striking point to the striking sensor 1 . This holds true for a large area outside of the point “middle.”
[0061] Next, another embodiment of the present invention will be described.
[0062] In the embodiments described above, the examples of the electronic hi-hat cymbals each had the frame 2 configured to be convex upward, bowl-shaped, or shaped as a portion of a sphere. In another embodiment illustrated in FIG. 10, an example of an electronic drum pad 10 has a frame 2 that is curved downward. This embodiment has a central portion of a cover that may be formed to be sufficiently thick so that a striking surface may be flat. By curving the frame and thickening the portion of the cover 3 above the piezoelectric sensor 1 , all striking strengths of equal strength may be detected by the striking sensor as equal in strength.
[0063] [0063]FIG. 10 is a cross-sectional view of an electronic drum pad 10 according to this embodiment of the invention. In FIG. 10, the frame 2 of the electronic drum pad 10 is curved downward. Even with the frame 2 curved downward, the sensitivity distribution from a point “middle” to a point “outside” on a striking surface becomes flat.
[0064] Further, since the portion of the cover 3 above the striking sensor 1 is formed to be sufficiently thick, the sensitivity distribution of the point “inside” may be flat, as well.
[0065] In the above-described embodiments, the sheet sensor 4 is disposed between the fitted portion of the cover 3 and the fitted portion of the chassis 5 . The sheet sensor 4 may be embedded within the outer edge portion of the cover 3 so long as the sheet sensor 4 can detect a strike against the outer edge of the cover 3 .
[0066] Moreover, the sheet sensor 4 is not limited to a sheet-like sensor, but it may also be any other kind of sensor capable of detecting a strike against the outer edge of the cover 3 . The sheet sensor 4 may be provided to detect a strike against the outer edge of the cover 3 . By detecting strikes against the outer edge, the electronic pad may imitate a sound generated when the peripheral edge of the striking surface of an acoustic percussion instrument, or the like, is struck. Therefore, other embodiments of the invention may not include a sheet sensor 4 at all if the detection of edge strikes is not desired.
[0067] As described above, embodiments of the electronic pad according to the present invention make it possible to obtain striking data having less dependence on a striking position than in conventional electronic pads.
[0068] While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that the invention is not limited to the particular embodiments shown and described and that changes and modifications may be made without departing from the spirit and scope of the appended claims. | An electronic pad generates a sound imitating a tone generated during a musical performance by an acoustic percussion instrument. In some examples, an electronic hi-hat cymbal imitates the sound created by an acoustic hi-hat cymbal without having to correct for uneven detection of striking sensitivity. The electronic pad includes a striking sensor, a striking surface, and a bowl-shaped frame that is curved such that the sensor detects vibration waveform data according to the striking force of a strike against the striking surface. | 6 |
FIELD OF THE INVENTION
[0001] The invention relates to reinforcement systems and methods for articulated overhead doors for reinforcing such doors against high wind and pressure loads, and more particularly relates to a vertical post reinforcement system that can be readily and easily adapted to overhead doors and installed in and removed from a doorway without tools.
BACKGROUND
[0002] Sectional overhead garage doors commonly are used to cover large entryways of residential garages and other structures. Such doors typically are constructed of a plurality of pivotally interconnected door panels with rollers that travel in guide tracks mounted on the sides and above the inside frame of an entryway. In order to facilitate ease of operation, such doors commonly include articulated door panels that are constructed of lightweight materials such as thin-gauge steel or other metal, plastic, fiberglass, and the like. Such panels typically include an integral frame structure that provides the panels with acceptable strength and rigidity under normal conditions.
[0003] During extreme weather conditions, however, high wind and pressure loads can cause substantial distortion, buckling, and damage to such lightweight door panels and doors. For example, such lightweight overhead sectional doors can become distorted and forced from their guide tracks in gusting hurricane-force winds and under sudden air pressure differentials created by strong storms. Accordingly, at least in areas that are subject to hurricanes or other periodic violent storms, there is a need for an apparatus and method that temporarily reinforces an overhead door of typical lightweight construction to increase the door's strength and rigidity such that the doors are capable of withstanding high wind and pressure loads with minimal damage and without dislodgement.
[0004] Various methods and devices are known for reinforcing sectional overhead doors of conventional lightweight construction. For example, horizontal reinforcement struts can be affixed to the inside surfaces of one or more door panels to increase the overall strength and stiffness of the door panel(s) and doors. Such struts typically have deep cross-sections that make the struts strong and stiff. Because these struts necessarily include relatively deep cross-sections, the struts can substantially increase the overall depth of the door panels to which they are connected. In addition, because the depth of horizontal reinforcement struts can vary, the overall depths of doors having reinforcement struts can vary significantly.
[0005] Others have developed vertical post reinforcement systems that include vertical posts or beams installed in an entryway behind a closed sectional door. Such systems typically include at least one rigid vertical post that has a lower end removably anchored to a floor, and an upper end that is removably attached to a header above an entryway. One or more of the door panels are connected to the installed vertical post by links, wire cables, or the like. These removable vertical posts are installed in an entryway when high wind and pressure loads are expected, thereby adding substantial strength and rigidity to the door system. Such vertical post reinforcement systems may be used alone, or in combination with horizontal reinforcement struts as described above.
[0006] When using a vertical post to reinforce a sectional overhead door against high wind and pressure loads, the system preferably secures the door in close proximity to the post to prevent the door from flexing and rattling under oscillating severe load conditions. Accordingly, where flexible cables are used to connect sectional door panels to a vertical post, the cables preferably tightly wrap around the post with little or no loose slack in the cables when the innermost edges of the door panels or struts attached thereto are snuggly against the post. One problem with known vertical post reinforcement systems is that such systems do not easily accommodate doors having varying overall depths. For example, when cables or links are used to connect the door panels to a vertical post, cables or links of different lengths may be required to tightly hold door panels of different overall depths against the vertical post.
[0007] Accordingly, there is a need for a vertical post reinforcement system that simply and adjustably accommodates sectional overhead door panels having various overall depths. For example, an adjustable vertical post reinforcement system is needed that can accommodate both door panels having horizontal reinforcement struts, and those without struts. In addition, there is a need for a vertical post reinforcement system that is relatively easy to install in an entryway, and also is relatively easy to remove from an entryway. In addition, there is a need for a vertical post reinforcement system that includes at least some components that can be permanently installed in an entryway, and that will not interfere with the entryway or operation of the overhead door when the vertical post is not installed.
SUMMARY
[0008] The invention includes an improved vertical post reinforcement system and method for reinforcing a conventional lightweight sectional overhead door against high wind and pressure loads. In one embodiment, the invention includes a reinforcement system for a sectional overhead door having a plurality of pivotally interconnected door panels. The system includes a post having an upper end with an aperture extending therethrough, and a lower end. The system further includes an anchor for removably connecting the lower end of the post to a floor, the anchor including a bracket having a vertical leg configured to be removably attached to the lower end of the post, and a horizontal leg. An eyebolt removably attaches the horizontal leg of the bracket to the floor, and includes an eye. An upper bracket removably connects the upper end of the post to a garage door header. A plurality of door brackets are configured for attachment to the door panels. Each door bracket includes a first wall having at least a pair of first openings therein, and an opposed second wall having at least a pair of second openings therein. A selectively positionable clevis pin removably extends through at least one set of opposed first and second openings. This embodiment of the invention further includes a plurality of cables, each cable having first and second ends configured to be removably engaged around the clevis pin of one of door brackets when the cable is wrapped around the vertical post.
[0009] The invention also includes a reinforcement apparatus for a sectional overhead door including a plurality of pivotally interconnected door panels having inner faces. The apparatus includes a vertical post. At least one door panel bracket is configured for attachment to a door panel of the overhead door, and includes a first plate having a plurality of spaced first openings therein, and a second plate in opposed spaced relation to the first plate and having a plurality of spaced second openings therein. A pin removably extends between the first and second plates, and is capable of extending through different pairs of the first and second openings. The pin of each door bracket is capable of being selectively positioned between the first and second plates such that the cross pin is positioned at a selected distance from the inner face of the door panel.
[0010] The invention further includes a method of adapting a vertical post reinforcement system to overhead sectional doors having door panels with inner faces and differing overall depths. In one embodiment, the method includes providing a plurality of elongated cables having opposed ends and fixed lengths. The method further includes providing adjustable cable connection means for connecting the cables to the door panels of the overhead sectional door. The adjustable cable connection means permits the ends of the cables to be connected to the door panels at a selected distance from the inner faces of the door panels.
[0011] These and other aspects of the invention will be understood from a reading of the following detailed description together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an environmental perspective view showing one embodiment of a vertical post reinforcement system according to the invention installed in an entryway inside a closed sectional overhead door.
[0013] FIG. 2 is a side elevation view showing the vertical post reinforcement system of FIG. 1 .
[0014] FIG. 3 is a perspective view of a portion of the vertical post reinforcement system of FIGS. 1 and 2 showing attachments between door panels and the vertical post.
[0015] FIG. 4 is a top cross-sectional view of the vertical post reinforcement system of FIGS. 1-3 taken along line 4 - 4 in FIG. 1 , showing the system used with a door panel having a deep strut.
[0016] FIG. 5 is a top cross-sectional view similar to FIG. 4 , showing the system used with a door panel having a more shallow strut.
[0017] FIG. 6 is a perspective view of a door panel cable bracket for use in the vertical post reinforcement system shown in FIGS. 1-5 .
[0018] FIG. 7 is an exploded perspective view of the bracket shown in FIG. 6 .
[0019] FIG. 8 is a perspective view of a bottom anchor portion of the vertical post reinforcement system of FIGS. 1 and 2 .
[0020] FIG. 9 is a side elevation view of the bottom anchor portion shown in FIG. 8 .
[0021] FIG. 10 is a perspective view of a top support portion of the vertical post reinforcement system of FIGS. 1 and 2 .
DETAILED DESCRIPTION
[0022] One embodiment of a vertical post reinforcement apparatus 10 according to the invention is shown in FIG. 1 . As shown in FIG. 1 , the system 10 is used to reinforce a sectional overhead door 100 of the type having a plurality of pivotally interconnected door panels 102 , 104 , 106 that are movably mounted in an entryway bounded by a floor 200 and a header 220 . The door panels 102 , 104 , 106 include a plurality of stiles 108 that are pivotally connected by a series of hinges 112 . The door 100 may include a plurality of horizontal reinforcement struts 120 , 122 mounted on the inside faces of the door panels 102 , 104 , 106 . Horizontal reinforcement struts 120 , 122 like those shown in FIG. 1 may be used to increase the strength and stiffness of the elongated lightweight door panels, and may be produced in various widths or depths, depending upon the degree of added strength and stiffness that is desired. For example, relatively deep struts 120 may be about three inches deep, and relatively shallow struts 122 may be about two inches deep. Generally, wide doors 100 having wide door panels 102 , 104 , 106 require deeper struts 120 to sufficiently stiffen the panels, whereas narrower doors 100 are sufficiently stiffened by struts 122 that are relatively shallow. As shown in FIG. 1 , the struts 120 , 122 inwardly extend from the inner faces 116 of the door panels 102 , 104 , 106 . Though the door 100 shown in the figures includes reinforcement struts 120 , 122 , a vertical post reinforcement system 10 according to the invention also may be used with a door without struts 120 , 122 .
[0023] As shown in FIGS. 1 and 2 , the vertical post reinforcement system 10 includes an elongated vertical post 20 having a lower end and an upper end. The post 20 extends from the floor 200 to the header 220 , and is positioned proximate to the innermost edges of the horizontal struts 120 , 122 . Alternatively, when used with an overhead door without struts 120 , 122 , the post 20 can be positioned proximate to inner faces 116 of the door panels 102 , 104 , 106 . When so positioned, the post 20 blocks the inward movement of the door panels 102 , 104 , 106 and the struts 120 , 122 attached thereto, thereby preventing the door 100 from being forced into or through the entryway by outside wind and pressure loads. In addition, a plurality of spaced cables 60 are attached to the door panels 102 , 104 , 106 by a series of door panel cable brackets 30 , and extend around the post 20 , thereby binding the door 100 to the post 20 . The wrapped cables 60 prevent the door panels 102 , 104 , 106 from moving outwardly when the air pressure on the inside face of the door 100 exceeds the pressure on the outside of the door 100 . The post 20 preferably has a cross-section that provides the post with substantial rigidity. In the embodiment 20 shown, the post 20 is constructed of a suitably strong metal such as steel), and has a hollow rectangular cross-section. For example, the post 20 may be about 7 feet 6 inches tall, about 1½ inches wide, and about 3 inches deep, and may have a wall thickness of about 0.1 inch. The post 20 may be constructed of ASTM A-500 Grade B rectangular structural steel tubing.
[0024] FIG. 3 shows a preferred arrangement for binding the door panels 102 , 104 , 106 to the post 20 to limit the outward movement of the panels 102 , 104 and 106 . In this arrangement, a series of door panel cable brackets 30 are affixed to the inside faces of the door panel stiles 108 . The brackets 30 may be removably attached to the stiles 108 by one or more threaded fasteners, or the like. In the arrangement shown, one bracket 30 is attached to a stile 108 on a first door panel 102 just above a first horizontal strut 120 , 122 , and another bracket 30 is attached to a stile 108 on a second door panel 104 just below a second horizontal strut 120 , 122 , such that the hinge 112 and joint between the door panels 102 , 104 is positioned between the upper and lower brackets 30 , as shown in FIGS. 1 and 2 , a single lowermost cable 60 may be connected to a lower portion of a lowermost door panel 106 by a cable bracket 30 positioned just above a lowermost strut 120 , 122 .
[0025] As shown in FIG. 4 , each cable 60 extends around the post 20 such that the associated bracket 30 and stile 108 of the door panel are bound to the post 20 . Accordingly, the cables 60 limit the outward movement of the door 100 and door panels 102 , 104 , 106 away from the post 20 . The adjacent horizontal strut 120 shown in FIG. 4 has a depth D 1 . For a deep strut 120 having this depth, a clevis pin 80 on the bracket 30 is positioned at an innermost position in the bracket 30 that is a distance d 1 from the inner face 116 of the door panel stile 108 , such that the cable is wrapped around the post 20 with little or no slack in the cable 60 , and such that the post 20 is closely proximate to the innermost edge of the strut 120 . The cable 60 preferably has looped ends 62 that receive the clevis pin 80 of the bracket 30 , thereby securing the cable 60 around the post 20 and to the bracket 30 . A middle portion of the cable 60 may be affixed to the post 20 by a retainer clip 68 as shown, thereby capturing the cable 60 on the post.
[0026] FIG. 5 shows a door 100 having a shallow strut 122 bound to the post 20 by a cable 60 . The shallow strut 122 has a depth D 2 that is smaller than the depth D 1 of the deep strut 120 shown in FIG. 4 . For a door 100 with a shallow strut 122 , the clevis pin 80 of the associated bracket 30 is positioned to the inner face 116 of the associated door panel stile 108 at a distance d 2 . By providing for selective adjustable positioning of the clevis pin 80 in the bracket 30 , identical brackets 30 and cables 60 can be used for closely binding door panels having either deep horizontal struts 120 , or shallow horizontal struts 122 , to the post 20 .
[0027] One embodiment of a door panel cable bracket 30 is shown in FIGS. 6 and 7 . In this embodiment, the bracket 30 includes a base plate 32 , and two inwardly-extending opposed side plates 34 , 36 . Holes 31 are provided in the base plate to receive threaded fasteners for attaching the bracket 30 to a stile. The side plates 34 and 36 include a first pair of aligned clevis pin holes 33 , and a second pair of aligned clevis pin holes 35 . The holes 33 , 35 are sized to recieve the clevis pin 80 . The clevis pin 80 may include a head 84 on a first end, and a cross hole 81 in a second end. Once the clevis pin 80 is inserted in one of the pairs of holes 33 or 35 , a retainer 82 is inserted through the hole 81 . The retainer 82 and head 84 cooperate to capture the clevis pin 80 between the opposed side plates 34 , 36 . The retainer 82 may be a split ring, a cotter pin, or any other suitable retaining device.
[0028] FIGS. 8 and 9 show a preferred arrangement for anchoring the lower end of the post 20 to a floor or foundation 200 inside an entryway. In this arrangement, an L-shaped bracket 22 is attached to a lower face of the post 20 such that one leg of the bracket 22 inwardly extends from the post 20 proximate to the lower end of the post 20 . A hole 56 in the bracket 20 is sized to receive the shank 54 of an eyebolt 50 . The threaded shank 54 of the eyebolt 50 engages a hole 202 in the floor 200 , thereby securing the bracket 22 and post 20 to the floor 200 . The eyebolt 50 includes an eye 52 that permits the eyebolt 50 to be easily gripped in a person's hand, and inserted into the hole 202 without tools. As shown in FIG. 8 , the eye 52 also permits the eyebolt 50 to be movably connected to the post 20 by a cable 60 and retainer clip 68 such that the eyebolt 50 will not be lost or misplaced. A finishing plate 40 may be provided on the floor 200 around the hole 202 to provide the floor 200 with a finished appearance.
[0029] FIG. 10 shows one arrangement for attaching the upper end of the post to the header 220 above the door 100 . In this arrangement, a header bracket 24 is affixed to the header 220 , such as by a plurality of threaded fasteners 27 . The bracket includes a central open-ended slot 25 sized to receive the shank of a carriage bolt 26 , such that the head (not shown) of the carriage bolt 26 is captured by the header bracket 24 . The threaded shank of the carriage bolt 26 extends through aligned openings in opposed walls of the hollow post 20 . As shown in FIGS. 2 and 9 , nuts 28 and washers 29 are engaged on the carriage bolt to secure the top end of the post 20 at a desired distance from the header 220 . The header bracket 24 and carriage bolt 26 combine to fix the upper end of the post 20 in the entryway.
[0030] The vertical post reinforcement system 10 can easily be removed from an entryway when there is no imminent threat of high wind or pressure loads. First, the cables 60 are freed from the cable brackets 30 by removing the clevis pins 80 from the brackets. The lower end of the post 20 is released by manually removing the eyebolt 50 without tools. Once the lower end of the post 20 is freed, the carriage bolt 26 can be easily disengaged from the header bracket 24 by lifting the post 20 , and slidably disengaging the carriage bolt 26 from the open-ended slot 25 in the header bracket 24 . Accordingly, the system 10 can be removed from an entryway without the use of tools, and can be conveniently reinstalled in an entryway without tools.
[0031] Because the cables 60 are captured on the post 20 by the cable clips 68 , and because the carriage bolt 26 and eyebolt 50 also are attached to the post 20 , the system 10 includes no small loose parts when disassembled from an entryway. In addition, the cable brackets 30 and clevis pins 80 are securely retained on the door panels 102 , 104 , 106 . Accordingly, there is substantially no risk of losing or misplacing essential small parts when the system 10 is not in use.
[0032] The above description of various embodiments of the invention is provided to describe various details and aspects of the invention, and is not intended to limit the invention thereto. A person of ordinary skill in the art will understand that various modifications may be made to the described embodiments without departing from the scope of the invention. All such modifications are intended to be within the scope of the appended claims. | A reinforcement system for a sectional overhead door includes a post having a lower end, and an anchor for removably connecting the lower end of the post to a floor. The anchor includes an L-bracket configured to be removably attached to the lower end of the post, and a horizontal leg. An eyebolt removably attaches the horizontal leg of the L-bracket to the floor, and is movably attached to the post. A plurality of door brackets configured for attachment to the door panels each include a selectively positionable clevis pin removably extending through portions of the bracket. A plurality of cables having first and second ends are configured to be removably engaged around the clevis pin of one of the door brackets when the cable is wrapped around the vertical post. The reinforcement system is configured to permit the system to be installed and removed without tools. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method and apparatus for transferring a lead strip of a paper web from a first traveling surface (e.g., of a press roll or of a press belt) of a paper-making machine to a following section (e.g., a further wet press or drying section) of that machine. In particular, the beginning of a still wet lead strip (or “tail”) is transferred according to the invention. This is to facilitate the threading of the paper web into the machine.
[0003] 2. Description of the Related Art
[0004] In a dewatering press section of a papermaking machine, as disclosed in FIG. 1 of U.S. Pat. No. 5,404,811, a still wet paper web 9 travels from a wire belt 8 of a forming section through three press nips 16 / 17 , 1 / 2 and 2 / 3 and thereafter via a paper roll 59 to a further dewatering press 60 ; then the still wet web is transferred to a drying section (not shown). When the machine is started up or after a web break, the web is threaded into the machine in a known manner:
[0005] Initially the web (having the full web width) is running behind the third press nip downwardly and is guided by a doctor 14 into a broke pulper (not shown, positioned below the machine). The web includes a small edge strip, namely the so-called lead strip or “tail”, severed from the web by a water jet positioned in the forming section. This tail is now transferred across paper roll 59 and via a bottom press felt through press 60 as well as through the following drying section. Then the width of the tail is increased up to the full width of the web.
[0006] During the threading operation, the web is already running with the full machine speed which may be more then 1000 m/min, in modem high speed machines up to about 2000 m/min. Therefore, the transfer of the tail from press roll 2 to the press felt of press 60 is a very difficult step of the threading operation. Sometimes this is done manually by means of an air jet being directed onto the surface of roll 2 , thusly severing the tail and forming a new beginning of the tail guided across paper roll 59 to the further press 60 .
[0007] A modem high speed paper-making machine normally comprises an apparatus for carrying out this difficult step. One known apparatus of this type is disclosed in FIG. 2 of U.S. Pat. No. 5,635,030. Here again, a paper web 1 is traveling downwardly across a press roll 5 from a press nip toward a doctor 7 . A blast nozzle 6 (or “separating blow pipe”) is provided to peel off the tail from press roll 5 and to transfer the tail to paper roll 2 . A further blast nozzle 3 is arranged between the two rolls 5 and 2 , which blast nozzle creates an air stream, the velocity of which is greater than the velocity of paper roll 2 . Due to the Coanda-Effect, the air stream adheres to the rotating shell of paper roll 2 and guides the tail up to a stationary guide plate 9 which deflects the air stream and the tail toward subsequent press unit 8 .
[0008] The method and the apparatus disclosed in the '030 patent have some disadvantages. Among others, two blast nozzles are needed, one being positioned between the press roll 5 and the paper roll 2 . Also, there is a large distance between the paper roll 2 and the infeed area of the press felt 17 of the following press 8 . As a result, the tail transfer to the following press may not always be successful in a reliable manner.
[0009] In another concept, only a short distance has been provided between the paper roll and the infeed area of the following press felt. In other words, a felt roll guiding the following press felt to the following press has been arranged relatively close to the paper roll (as shown in FIG. 1 of the '811 patent). Also, an air cushion has been created onto the infeed area by means of a series of blast nozzles. However, this design also does not always operate satisfactorily. Also, a so-called pony roll has been suggested to be arranged on the infeed area instead of an air cushion, however this is mechanically complicated and therefore not desirable.
SUMMARY OF THE INVENTION
[0010] The present invention significantly improves the transfer of a tail from a first traveling surface to a following machine section by use of a novel method and by use of an improved apparatus which operates more reliably than previous proposals.
[0011] The method requires little operator skill. Thus, inexperienced personnel are able to start the threading operation without a lot of practice.
[0012] The threading operation is easily started by a reliable transfer of the tail, even with different paper grades (e.g., different basis weight) and with different machine speeds, including extremely high speed (e.g., more than 2000 m/min).
[0013] A lead strip or ‘tail’ of a paper web is transferred from a first traveling surface of an element of a paper-making machine to an infeed area of a second traveling surface which guides the tail into a following machine section.
[0014] The first traveling surface is the surface of a rotatable shell of a press roll which directly contacts the still wet paper web and which is part of a web dewatering press. It may also be the surface of a press belt traveling through a press nip of a web dewatering press.
[0015] The second traveling surface is the web-carrying surface of a dewatering press felt which guides the web through a subsequent dewatering press. However, the second traveling surface may also be the surface of a subsequent press roll or of a subsequent press belt. In another embodiment of the invention, the second traveling surface is the surface of a dryer fabric which guides the web through a part of a dryer section following the press section of the paper-making machine.
[0016] The method of the present invention includes providing at least one air jet for peeling off of the tail from the first traveling surface and for transferring it across a rotating paper roll to the infeed area of the second traveling surface. More particularly, the air jet initially severs the tail running with the first traveling surface, thereby forming a new beginning of the tail which is now transferred to the second traveling surface.
[0017] An air cushion is provided on the infeed area of the second traveling surface. The air cushion is created by an air table having a plurality of tiny orifices delivering air from an air plenum to the air cushion. According to the invention, the air cushion a created by a large number of tiny orifices which connect the air plenum to the air cushion and which are distributed substantially equally on the air table. This results in a significant advantage, namely that the oncoming tail (including its new beginning) is forced to lay on the second traveling surface with only a small amount of air moving with the second traveling surface. Therefore, the tail, which is running at the high machine speed together with the second traveling surface, is reliably pressed onto the second traveling surface. In other words, the air does not bounce off the second traveling surface and the tail is not lifted with the air. Such an undesirable behavior would result from creating an air cushion by use of a series of blast nozzles which deliver too much air at a too high pressure.
[0018] Too much air is also not directed into the following machine section, e.g., into a further dewatering press. Therein the press nip (or a similar wedge-like gap) would cause the air to flow sideways and to take the tail with it. This could happen both before the beginning of the tail has arrived in the press nip and thereafter.
[0019] In summary, the method of the invention results in a very easy and reliable transfer of the tail so that the transfer does not need much operator skill. Also, the transfer works well with different paper grades and with different machine speeds including the high speed of modern paper machines.
[0020] The present invention also includes an apparatus for transferring the tail as described above. The apparatus includes a peeling jet device for providing the at least one air jet as mentioned above. The peeling jet device is arranged close to the first traveling surface (e.g., the surface of the press roll).
[0021] The apparatus further includes a conventional paper roll which guides the web between the first and second traveling surfaces. The most important element of the apparatus of the invention is a so-called air table having a large number of tiny holes which connect an air plenum with the infeed area of the second traveling surface, thereby creating an air cushion which is almost stationary on the second traveling surface. This results in the advantages described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0023] [0023]FIG. 1 is a schematic side view of two dewatering presses of a paper-making machine including an air table;
[0024] [0024]FIG. 2 is a schematic view along arrow II of FIG. 1; and
[0025] [0025]FIG. 3 is a side schematic view of a segmented air table.
[0026] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In FIG. 1, the normal path of a paper web to be dewatered in two presses 11 and 21 is shown as a broken line and designated 9 ′. Web 9 ′ is traveling through the nip of a top-felted press 11 including a bottom press roll 12 (which directly contacts the web) and a top press roll 13 positioned in the loop of an endless dewatering felt 14 . Bottom press roll 12 includes a (downwardly) “first traveling surface” 15 . Close to it, a peeling jet device 16 and a conventional doctor 17 are arranged.
[0028] A subsequent dewatering press 21 is bottom felted. It includes a top press roll 22 (which directly contacts the web) and a bottom felt 24 guided by felt rolls 28 and 29 , one ( 28 ) of which is positioned near the bottom press roll 12 of press 11 . The part of felt 24 traveling from felt roll 28 to the nip of press 21 forms a so-called “second traveling surface” 25 including a so-called “infeed area” (positioned on felt roll 28 ) wherein the web comes into contact with felt 24 . Web 9 ′ is guided by a paper roll 20 from the first ( 15 ) to the second ( 25 ) traveling surface. There is a short distance between surface 15 and roll 20 as well as between roll 20 and surface 25 .
[0029] Behind press 21 , web 9 ′ is traveling across a further paper roll 30 to a dryer fabric 34 running across a fabric toll 33 transferring the web to a first drying cylinder 32 of a drying section 31 .
[0030] Normally, at least one further press nip (not shown) may be arranged upstream of press 11 . Typically, press 11 forms a third press nip of a complete press section; then press 21 forms a fourth press nip.
[0031] Before the web 9 ′ is traveling along its normal path it runs across press roll 12 and doctor 17 downwardly into a broke pulper (not shown). For threading the web into the bottom felted press 21 (and further to dryer section 31 ) an edge strip on “tail 9 ” of the web is severed by peeling jet device 16 , peeled off from the first traveling surface 15 and transferred to the second traveling surface 25 . An air table 40 extends along the infeed area of the second traveling surface 25 of felt 24 . The air table also extends from paper roll 20 across the gap between paper roll 20 and felt 24 at felt roll 28 . The width of air table 40 is slightly larger than the width of the tail 9 (see FIG. 2).
[0032] The air table 40 includes a box 41 connected to an air pressure source 43 providing a relatively low air pressure, the box 41 thusly forming a so-called air plenum, wherein the air pressure is preferably between 5 and 20 psi.
[0033] Box 41 includes a convex wall 42 facing towards felt 24 , the convex wall having a plurality of tiny holes 44 or orifices. The diameter of each hole may be about 0.5 to 2 mm; the percentage of open area, i.e., the total of the cross-sectional areas of throughholes 44 as a percentage of the surface area of the perforated surface of the air table, is about 0.03% to 0.1%. Thereby a stable air cushion is created between air table 40 and the traveling surface 25 of felt 24 pressing the tail onto felt 24 without moving much air toward the nip of press 21 . As a further improvement, box 41 is arranged in such a way that the air cushion formed between box 41 and surface 25 is converging with respect to the web travel direction. Close to paper roll 20 , an air jet pipe 45 is mechanically connected to box 41 , the pipe 45 being connected to a high pressure source 46 . Peeling jet device 16 may also be connected (not shown) to high pressure source 46 .
[0034] Air jet pipe 45 may provide an air jet approximately tangential to the shell or outer surface of paper roll 20 contrary the travel direction of the shell. At most one further air jet or air curtain may be directed from pipe 45 or from an additional pipe 67 (FIG. 3) toward the infeed area, i.e., toward felt roll 28 . Peeling jet device 16 produces an air jet approximately perpendicular to the first traveling surface 15 . If needed, jet device 16 may additionally create an air jet toward paper roll 20 .
[0035] In order to further improve the reliable transfer of the tail to the second traveling surface 25 or 34 , it may he helpful to provide suction devices ( 70 - 73 ) in the area of the tail within roll 28 and/or within roll 33 and/or beneath felt 24 and/or fabric 34 .
[0036] [0036]FIG. 2 shows the peeling jet device 16 air the air table 40 in their operating position held during a threading operation. During the normal operation of the paper-making machine, the peeling jet device 16 is removed to the outside of the machine. For this purpose, a pneumatic cylinder (not shown) or a similar equipment is provided which moves the device 16 automatically into or out of its operating position, as indicated by a double arrow. If needed, the air table 40 may also be connected to a pneumatic cylinder.
[0037] In order to facilitate the transfer of tail 9 from press roll 22 via paper roll 30 to the drying fabric 34 , a further peeling jet device 26 is arranged close to the surface of press roll 22 . Also, a further air table 50 may be arranged below fabric roll 30 . In this case, press roll 22 forms the first traveling surface and the drying fabric 34 forms the second traveling surface.
[0038] [0038]FIG. 3 shows a further developed air table 60 . It is divided into various (e.g., three) segments 61 o 63 . Each segment is formed as a box similar to box 41 of FIGS. 1 and 2. One ( 61 ) of the boxes is mechanically connected to a supporting device 65 which supports the complete air table 60 and which may be connected (if needed) to a pneumatic cylinder (not shown) of the type explained above. The segments 61 and 62 as well as the segments 62 and 63 are mechanically connected one to the other by a pivot 64 . Also, the outer end of the third segment 63 is connected to support 65 by a spindle 66 (or threaded bolt). Therefore, the distance between the outer end of segment 63 and support 65 may be changed. In other words, the average radius R of the curvature of the complete air table 60 may be changed. This allows the user to change the form of the complete air table 60 in order to adapt the same to various operating conditions, e.g., to various paper grades or to various machine speeds. As an example, the form of the complete air table may be approximately flat. The segments 61 - 63 may be provided with equal air pressure or with different air pressures. Finally, it is possible to create air tables of different size by using a different number of segments (e.g., two or three or four, etc.).
[0039] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | An apparatus transfers a lead strip of a paper web, in particular the beginning of a still wet lead strip or tail, from a press roll of a paper-making machine to a following section of that machine. An air jet device peels off the beginning of the tail from the press roll and transfers it across a paper roll to an infeed area of a felt which guides the web into the following section. On an infeed area of the felt, an air cushion is created by an air table having a plurality of tiny holes delivering air from a low pressure plenum to the air cushion. | 3 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a device for the clamping connection of structural parts which are spaced from each other by means of a spacer disk arranged for rotation in said space and resting with its outer broad side against one structural part.
In the known devices of this type, the thickness of the spacer disk must correspond to the distance between the two structural parts. This is expensive, particularly with respect to mounting. It is attempted in practice to provisionally solve this problem by adding or removing spacer disks of different thickness.
SUMMARY OF THE INVENTION
The object of the present invention is to develop a device of the introductory-mentioned type in such a manner that the spacer disk can be brought into the bearing position merely by turning.
According to the invention the spacer disk (9, 34, 42, 82, 89, 95) includes means for axially displacing the spacer disc by rotation thereof to the open distance between the structural parts, said means comprising helical first pitched bearing surfaces (10, 11, 31, 44, 44', 83, 87), and form-fitting helical mating second pitched bearing surfaces (2, 3, 32, 46, 46', 80, 86) coordinated with the other structural part which are located cooperatively opposite said first pitched bearing surfaces.
As a result of this development, there is created a device of the introductory-mentioned type which, while being of simple structural shape, assures easy mounting regardless of the distance actually present between the two structural parts. If there is still a distance between the outer broad side of the spacer disk and the facing structural part after the insertion of the disk it is merely necessary to turn the spacer disk, which moves into such a position that the positioning resulting from the pitched bearing surfaces and mating pitched bearing surfaces results in a spacing which corresponds to the actual space between the structural parts. The structural parts can then be clamped together by means of rivets, dowels, hollow rivets or screws, the spacer disk representing the bridging of the space. It is also possible to fasten the spacer disk by spot welding, applied adhesive, etc., after it has been turned into its bearing position. However, the entrainment (carrying along) of the spacer disk by a rivet, dowel, hollow rivet or fastening screw is also permitted. These parts pass by insertion into frictional locking with the spacer disk so that the spacer disk can be turned into its bearing position. The clamping force of the fastening screw, etc, prevents the spacer disk from turning backward during subsequent use. Assurance with respect to this is favored by tooth steps on the pitched bearing surfaces and/or mating pitched bearing surfaces. The pitched bearing surfaces can be provided on the wide side of the spacer disk, on its outer wall surface or on the wall of its inner cavity. The direction of tightening of the fastening screw can be opposite to or in the same direction as the pitched bearing surfaces of the spacer disk, depending on the arrangement of the screw with respect to the spacer disk and the structural part. The corresponding frictional locking between the outer wall surface and the fastening screw makes any use of an additional special tool for the turning of the spacer disk superfluous. Obtaining the frictional locking with a corresponding plastic mount is of considerable advantage for dependable entrainment and also makes it possible to develop the spacer disk of hard material which withstands the clamping forces. It is furthermore possible to develop the spacer disk of a single material having the corresponding properties. For precise turning movements of adjustment it is also possible to develop the mating pitched bearing surfaces in the manner of an outer-wall thread of the structural part. The arrangement of a corresponding resilient tongue on a plastic covering which forms the frictional locking provides, in combination with a shoulder provided on the other structural part, the possibility of fastening the spacer disk initially as sort of a pre-mounting on the structural part. It can then not be lost and the structural part can be easily applied, even at places which are of difficult access. The frictional locking is then obtained upon the insertion of the fastening screw. Since the latter must be screwed into its mating thread by at least a few turns, the frictional-locking entrainment leads to a reliable carrying along of the spacer disk up into the turned position which bridges over the open space. A stop for limiting the turning movement of the spacer disk can, if needed be provided to advantage, limiting the maximum rotation to the peripheral length of one inclined surface.
Another embodiment is characterized by forming the mating pitched bearing surfaces on the front end of a collar pressed out of the structural part. It is also possible to provide the mating pitched bearing surfaces on a bushing which is non-rotatably secured by means of a pin protruding from the annular surface which faces the structural part and extends into a hole in the structural part. The connection can also be accomplished by screwing. Furthermore, the pin can be clipped in place. A form locking between pin and hole is also possible, in the manner that the pin is provided as a collar with protruding ribs which enter into corresponding noches in the hole. It is then possible to arrange the mating pitched bearing surfaces which are on the structural-part side on a bushing provided with a flange, the flange being fastened to the structural part by spot welding or by cementing (adhering in general). Another possible manner of obtaining the frictional locking is to coordinate a suitably aligned leaf spring with the spacer disk, which spring then frictional lockingly engages the clamping element upon the insertion of the latter. A particularly easy mounting is obtained in this case by inserting the leaf spring from the wide side into a secant-shaped channel. The entraining of the spacer disk can also be obtained by a form lock between the fastening screw and spacer disk. When the spacer disk has entered into its bearing position, the form lock is destroyed by turning the fastening screw further with respect to the stationary spacer disk.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the object of the invention are shown in the accompanying drawings, in which
FIG. 1 shows, on an enlarged scale, a bearing block as a structural part of a hinge, with spacer disks arranged in the space from the wall of attachment, one of said disks having already been brought into its bearing position, relating to the first embodiment,
FIG. 2 is a view as seen in the direction of the arrow II in FIG. 1,
FIG. 3 is a section along the line III--III in FIG. 2,
FIG. 4 is a view, on a larger scale, of the mating pitched bearing surfaces of the bearing block,
FIG. 5 is a section along the line V--V of FIG. 4,
FIG. 6 is a section along the line VI--VI of FIG. 4,
FIG. 7 is a view corresponding to FIG. 4 but with plastic mount placed on,
FIG. 8 is a section along the line VIII--VIII of FIG. 7,
FIG. 9 shows the parts to be connected, in considerably enlarged size, prior to the mounting,
FIG. 10 is a view similar to FIG. 9 but with the plastic mount placed on, shown in cross section,
FIG. 11 is a view corresponding to FIG. 7, but after the mounting,
FIG. 12 is a top view of FIG. 11,
FIG. 13 is a top view of the spacer disk shown on a greatly enlarged scale,
FIG. 14 is a section along the line XIV--XIV of FIG. 13,
FIG. 15 is a broken-away view in the direction of the arrow XV of FIG. 13, showing a tooth step,
FIG. 16 is a top view of the plastic mount on a greatly enlarged scale,
FIG. 17 is a side view of the plastic mount, partially broken away,
FIG. 18 is a section along the line XVIII--XVIII of FIG. 17,
FIG. 19 shows the second embodiment of the device, in an enlarged sectional view, before mounting,
FIG. 20 is a sectional view similar to FIG. 19 but with the spacer disk already applied,
FIG. 21 shows the parts to the be connected in accordance with FIG. 19, but after mounting,
FIG. 22 is a longitudinal section through the third embodiment before the screwing-in of the fastening screw,
FIG. 23 is a cross section through the spacer disk in the region of the leaf spring which produces the frictional lock,
FIG. 24 shows the device in clamping position, partially in section and partially in elevation,
FIG. 25 is a corresponding cross section through the device in the region of the leaf spring,
FIG. 26 is a longitudinal section through the device according to the fourth embodiment, before the insertion of the fastening screw,
FIG. 27 is a cross section along the line XXVII--XXVII of FIG. 26,
FIG. 28 shows the device according to the fifth embodiment in its clamping position,
FIG. 29 shows the device according to the sixth embodiment in its clamping position, the bushing which has the mating pitched bearing surfaces being secured against turning on the structural part by means of prongs,
FIG. 30 shows the seventh embodiment of the device, in which the securing of the bushing against turning is effected by means of a pin which protrudes from the annular-surface side,
FIG. 31 is a cross section through the device at the height of the pin,
FIG. 32 shows the eighth embodiment of the device seen in cross section, the anti-rotation lock between bushing and structural part being produced by a pin which protrudes from the annular surface and, in its turn, is clipped to the hole of the structural part,
FIG. 33 shows the ninth embodiment of the device in cross section, in which a collar provided with external thread extends from the annular surface of the bushing and is screwed into an internal thread in the structural part,
FIG. 34 shows the tenth embodiment of the device, the mating pitched bearing surfaces being provided on the front end of a collar pressed out of the structural part,
FIG. 35 is a longitudinal section through the eleventh embodiment of the device in which the mating pitched bearing surfaces are seated on a bushing which is inserted into the structural part and the flange of which is fixed on the structural part,
FIG. 36 shows the twelfth embodiment of the device in which the bushing is clipped to the structural part,
FIG. 37 shows the thirteenth embodiment of the device in longitudinal section, in clamping position,
FIG. 38 shows the fourteenth embodiment of the device, also in longitudinal section,
FIG. 39 shows the fifteenth embodiment of the device, in the clamping position,
FIG. 40 is a cross section through the device according to the sixteenth embodiment, in which the spacer disk is coupled in form-locked manner to the fastening screw,
FIG. 41 is a showing corresponding to FIG. 40, but with the form lock released;
FIG. 42 is a cross section through the device according to the seventeenth embodiment with a coupling piece between spacer disk and fastening screw, and
FIG. 43 is a view corresponding to FIG. 42, after the releasing of the form lock.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the first embodiment, shown in FIGS. 1 to 18, two integrally developed collars extend from the rear of a hinge-like structural part 1, each of the collars forming at its end in each case two helical left-hand mating pitched bearing surfaces 2, 3. The collars surround an internal thread of the structural part 1. The two mating pitched bearing surfaces 2 and 3 are limited by diametrically located steps 4 and 5. The mating pitched bearing surface 2 forms, by means of a semicircular recess, radial steps 6, 7 for limiting the turning of a spacer disk 9. Furthermore, a shoulder 8 is provided on it for engaging behind a spring tongue 24 of the spacer disk 9.
The spacer disk 9 also has two helical pitched bearing surfaces 10 and 11 which are limited by diametrically located steps 12 and 13. The pitched bearing surfaces 10 and 11 are located on the wide side B of the spacer disk 9 and are provided with radially protruding tooth steps 14. The flanks of different length of each tooth step 14 form an angle of about 90°. The spacer disk 9 furthermore has an inner opening 15 with two opposite bays 16 and 17 to receive the collar sections 20 and 21 of a plastic mount 19. On the outer periphery of the spacer disk 9 there is provided, between two tooth steps 14, a radial cutout 18 to receive a rotation stop 25 of the plastic mount 19. The latter is of cup shape and forms on its bottom the two inwardly directed collar sections 20 and 21. These collar sections 20 and 21 produce the frictional locking with the outer wall surface 26 of the fastening screw 27 which is introduced in the screwing-in direction x.
The plastic mount 19 surrounds a metal disk 28 of the spacer disk a and is secured against dropping out, after its insertion, on the mating pitched bearing surfaces 2, 3, by the tongue 24 which engages behind the shoulder 8. In addition, the plastic mount 19 has the rotation stop 25 which extends over the entire height of the cup. This rotation stop 25 enters into the radial cutout 18 of the metal disk 28 of the spacer disk 9 and connects these two parts in non-turnable manner to each other. The spacer disk 9 (or the plastic mount 19) is formed laterally of its inner opening 15 with inner diametric insertion slots 22, 23 for a tool for turning the spacer disk. The mounting is effected as follows: After the placing of the spacer disks 9 on the collars which form the mating pitched bearing surfaces 2, 3, the spacer disks 9 are in a position in which the radial steps 4, 5 of the mating pitched bearing surface 3, 2 and the radial steps 12, 13 of the spacer disk 9 come against each other. The mating pitched bearing surfaces 2, 3 and bearing surfaces 10, 11 then lie with their surfaces on each other over their entire length so that there is then still a space between the bottom wall of the plastic mount 19 and the fastening wall W for the structural part 1. This means that the spacer disk 9 lies in the space A between structural part 1 and fastening wall W.
The fastening screw 27 which has a right-hand thread, is now screwed in. As a result of frictional lock between its outer wall surface 26 and the collar sections 20, 21, it carries the spacer disk 9 along with it in the screwing-in direction x and, as a result of the oppositely directed pitched bearing surfaces 10, 11 of the spacer disk 9, the spacer disk 9 is pressed away from the collar until the bottom of the cup comes against the fastening wall W. The clamping can then be effected, the spacer disk taking up the clamping force of the screw.
In accordance with the second embodiment, shown in FIGS. 19 to 21, the mating pitched bearing surfaces are located on the head 30 of a dowel pin 29. Said surfaces are formed by a thread 32 (left-hand thread) on the wall side.
The spacer disk 34 has a metal disk 33. The latter has an inner opening 37 with two bays 39 and 40 opposite each other to receive the collar sections 35 and 36 of a plastic mount 38 which grips around the metal disk 33.
The metal disk 33 has the pitched bearing surfaces on the inner cavity in the form of an internal thread 31 (left-hand thread).
The plastic mount 38 is of cup shape and forms on its bottom two inward-directed collar sections 35 and 36. These collar sections 35 and 36 produce the frictional locking with the outer wall surface 26 of the fastening screw 27 introduced in the screwing-in direction x. The fastening screw 27 has a right-hand thread. It is screwed into the internal thread 41 of the dowel pin 29.
This screw connection is produced as follows: First of all, the dowel pin 29 is inserted into a corresponding hole 1b in a structural part 1a. The head 30 of the dowel pin 29 forms, with its wall side thread 32, the mating pitched bearing surfaces for the pitched bearing surfaces of the thread 31 of the spacer disk 34. The spacer disk 34 is screwed on up to the position shown in FIG. 20 so that a space remains between the cup bottom of the plastic mount 34 and the fastening wall W.
The fastening screw 27 is now passed through a hole in the fastening wall and screwed into the internal thread 41 of the dowel pin 29.
As a result of frictional locking between the wall surface 26 and collar sections 35, 36, the spacer disk 34 is carried along in the screwing-in direction x. The oppositely directed thread between the spacer disk 34 and the dowel head 30 causes the spacer disk 34 to be shifted in the direction towards the fastening wall W and to abut against same (FIG. 21).
The spacer disk thus represents the abutment which bridges over the space A, for the fastening wall W.
In accordance with the third embodiment, shown in FIGS. 22 to 25, the spacer disk 42 is provided on its broad side facing away from the structural part 43 with right-hand pitched bearing surfaces 44. The latter are limited by two diametrically opposite steps 45. Helical mating pitched bearing surfaces 46 lie in form-fitting manner opposite the pitched bearing surfaces 44. Said helical mating pitched bearing surfaces 46 are located on the facing wide side of a bushing 47. A concentric collar 48 on the opposite annular surface is connected, fixed against rotation, with the other structural part 49. The passage hole 50 of the bushing 47 is aligned with the inner opening 51 of the spacer disk 42.
In front of the broad side of the spacer disk 42 which faces the structural part 43 there extends a secant-shaped channel 52. A leaf spring 53 is inserted in it. The ends 53' of said spring are bent at an angle and rest against the outer wall surface of the spacer disk 42. The central section 53" of the leaf spring 53, on the other hand, extends arched in inward direction and is tangent to the inner opening 51 of the spacer disk 42. It thus lies in the region of passage of the fastening screw 27. Before the screwing-in of the latter, the parts of the device assume the position shown in FIG. 22. If the fastening screw 27 is now inserted, its wall surface comes into frictional locking with the leaf spring 53. Upon the screwing-in of the fastening screw, which has a right-hand thread, the spacer disk 42 is carried along positively in the same direction of rotation. As a result of the right-hand pitch of the pitched bearing surfaces 44 and mating pitched bearing surfaces 46 axial displacement of the spacer disk 42 is obtained from the rotation, the wide side of said spacer disk which faces the structural part 43 coming against the structural part 43; see FIG. 24. No further carrying along of the spacer disk 42 then takes place any longer and the fastening screw 27 can be screwed in fully, thus obtaining the clamping. In this embodiment also the corresponding pitch surfaces 44, 46 can be provided with a toothing.
In accordance with the fourth embodiment, shown in FIGS. 26 and 27, the mating pitched bearing surfaces 46' have a left-hand pitch. The pitched bearing surfaces 44' which come into engagement with them accordingly have the same pitch. In this case also the spacer disk 47 is provided with a leaf spring 53 which produces a friction locking. A pin 54 extends from the bushing 47. The pin is developed as a collar which extends concentrically to the longitudinal axis of the bushing. On its outer circumference the pin 54 has three protruding ribs 54' arranged at equal angle apart which engage in corresponding grooves 55' of the hole 55 in the structural part 56. In this way, a locking of the bushing 47 against rotation is obtained. If the fastening screw 27 is now inserted by passing it through a hole in the structural part 57 and turned in the direction indicated by the arrow, in view of its right-hand thread, the spacer disk 42 will be carried along thereby, and as a result of the left-hand pitch surfaces 44', 46' the spacer disk 42 will be displaced axially until it comes into position against the structural part part 57. A nut 58 can now be screwed onto the end of the fastening screw 27 which extends beyond the structural part 56 so as to clamp the structural parts 56, 57 together with the interposition of the spacer disk 42.
The fifth embodiment, shown in FIG. 28, is of a construction similar to the preceding one. The same structural parts therefore are provided with the same reference numbers. The fastening screw is a wood screw 59 with right-hand thread. Upon the screwing-in thereof the spacer disk 42 is displaced into the bearing position while the threaded shank engages into the structural part 56' which is of wood. The frictional lock is also produced by a leaf spring 53 which presses against the outer wall surface of the fastening screw 59.
The sixth embodiment, shown in FIG. 29, corresponds substantially to the embodiment shown in FIG. 28. The securing of the bushing 47 against turning is now effected via pins developed as prongs 60 which protrude from the annular surface of the brushing 47, are arranged at equal distances apart and engage into the structural part 56' of wood in order to effect the securing against rotation.
In the seventh embodiment, shown in FIGS. 30 and 31, a pin 61 extends from the annular surface of the bushing 47 and engages in form-fitting manner into a hole 62 in the structural part 63. If the fastening screw 27 is inserted from the side of the structural part 57 and turned, the spacer disk 42 is positively carried along in the corresponding direction, coming into its position of bearing. A nut (not shown) can then be screwed onto the end of the fastening screw 27 which protrudes beyond the structural part 63, clamping the two structural parts 57, 63 together.
In accordance with the eighth embodiment, shown in FIG. 32, a pin 64 extends from the annular surface of the busing 47 facing the structural part 63. The pin engages into a hole 65 in the structural part 63. In this case there is a clip connection between pin 64 and hole 65, for which purpose the detent pin 64 has insert-side run-on bevels 64'.
In accordance with FIG. 33, which shows the ninth embodiment, a concentric pin 66 developed as a collar extends from the bushing 47 on the annular surface facing the structural part 63. The outer thread 67 of said pin comes into engagement with the inner thread 68 of the hole 69 of the structural part 63.
In the tenth embodiment, shown in FIG. 34, the mating pitched bearing surfaces 46' are formed on the end of a collar 71 pressed out of the structural part 70. The collar cooperates with the spacer disk 42, shown in dot-dash line, which, in its turn, is carried along into its bearing position by a fastening screw 27. A nut (not shown) can then be screwed onto the end of the fastening screw which protrudes beyond the structural part 70 in order to effect the clamping to the other structural part 72.
In FIG. 35, which shows the eleventh embodiment, a bushing 47 which forms the mating pitched bearing surfaces 46' passes through a hole 73 in the structural part 74. On the side opposite the mating pitched end surfaces the bushing 47 forms a flange 75 which comes against the bottom of the structural part 74 and is held fast there, for instance by spot welding, cementing (adhering in general), etc.
The twelfth embodiment, shown in FIG. 36, has a bushing 47 which is clipped to the hole 73 of the structural part 74. For this purpose, clip projections 76 extend facing the flange 75 and, after the insertion of the bushing 47, come against the top of the structural part 74 and, together with the flange 75, produce the axial non-displaceability of the bushing 47. The mating pitched bearing surfaces 46 of the bushing 47 extend with right-hand pitch. They cooperate with the correspondingly extending pitched bearing surfaces 44 of the spacer disk 42. Since the fastening screw 27 has a right-hand thread, the spacer disk 42 is also turned when the screw is screwed in, hand in hand with an axial displacement of the spacer disk 42 in the manner that it comes into the space-bearing position with respect to the opposite structural part 77, which has a correspondingly shaped inner thread 78 to receive the fastening screw 27.
In the thirteenth embodiment, shown in FIG. 37, two structural parts 79 and 79' are to be clamped together at a distance from each other. The structural part 79 has a threaded borehole 80 with left-hand mating pitched bearing surfaces. A threaded borehole 81 of smaller thread diameter extends axially to said threaded borehole 80. The threaded borehole 81 is provided with a right-hand thread corresponding to the external thread of the fastening screw 27. The latter passes with friction locking through a spacer disk 82 which is provided on its outer wall with a left-hand external thread 83 which forms the pitched bearing surfaces. The length of the spacer disk 82 is greater than the inside spacing between the structural parts 79 and 79' so that a part of the length of the spacer disk 82 enters into the threaded borehole 80. If the fastening screw 27 is screwed in corresponding to the pitch of its thread, this results in the carrying along of the spacer disk 82. As a result of the left-hand thread, the spacer disk 82 is displaced until it abuts against the structural part 79'. The spacer disk 82 upon the further screwing-in motion then assumes the bearing function.
In accordance with FIG. 38, which shows the fourteenth embodiment, two structural parts 84 and 85 are also clamped together at a distance apart. The structural part 85 has a continuous threaded borehole 86 with right-hand thread which forms the mating pitched bearing surfaces. The external thread 87 of the spacer disk 82 engages into the threaded borehole 86. The external thread 87 accordingly also has a right-hand pitch. The fastening screw 27, which passes with friction locking through the spacer disk 82, carries the spacer disk 82 along with it in the screwing-in direction when it is screwed in so that said disk rests against the facing surface of the structural part 84. The fastening screw furthermore passes through a washer 88 against which the screw head of the fastening screw presses. In this embodiment also, the length of the spacer disk 82 is greater than the open space between the structural parts 84, 85. The structural part 84 forms a threaded borehole with right-hand inner thread to receive the fastening screw 27.
In the fifteenth embodiment, shown in FIG. 39, which corresponds extensively to the fourteenth embodiment, the same structural parts bear the same reference numbers. The head of the fastening screw 27 now rests directly against the end surface of the spacer disk 82. The screw clamping force is accordingly transmitted via the pitched bearing surfaces.
In FIGS. 40 and 41, which show the sixteenth embodiment, the spacer disk 89 is provided centrally with a square opening 90 into which a shaped piece 91 of plastic fits. Said shaped piece contains a passage borehole 92 for the fastening screw 27. Into the passage borehole 92 there extends a rib 93 which extends integrally from the shaped piece and which engages in form-fitting manner into a longitudinal groove 94 in the fastening screw 27. In this way, upon turning of the fastening screw 27, the spacer disk 89 is carried along into its bearing position. The spacer disk 89 remains stationary and the fastening screw 27 turns relative to it, the rib 93 being sheared off by the corresponding edge of the longitudinal groove; see FIG. 41.
The seventeenth embodiment, shown in FIGS. 42 and 43, has a spacer disk 95 whose passage opening 96 forms a radially directed groove 97. A coupling piece 98 engages by on edge into said groove. The opposite edge, an the other hand, extends into the longitudinal groove 94 of the fastening screw 27, producing a form-locked connection. If the spacer disk 95 is brought into the bearing position by turning the fastening screw then, upon further turning of the fastening screw 27, the coupling piece 98 is cut through, releasing the form lock; see FIG. 43.
Herein for the claims the spacer disk 9 can include elements of the plastic mount as claimed. | The invention concerns a device for the clamping connection of structural parts which are spaced apart from each other by means of a spacer disk arranged within said space and resting by its outer broad side against one structural part. For easier mounting the spacer disk, in order to obtain an axial displacement, derived from its rotation, to the free distance between the structural parts, is provided with helical pitched bearing surfaces opposite which there are form-fitting helical mating, pitched bearing surfaces which are coordinated to the other structural part. | 5 |
BACKGROUND OF THE INVENTION
The prostaglandins are a group of hormone-like substances which may be viewed as derivatives of prostanoic acid. Several prostaglandins are found widely distributed in mammalian tissue and have been isolated from this source. Those prostaglandins have been shown to possess a variety of biological properties such as bronchodilation and the ability to reduce gastric secretion.
The present invention concerns PGF 2 .sub.β derivatives in which the 15-position (using the prostanoic acid numbering system) contains an ethynyl group, in addition to the normally present hydroxyl group. The preparation of 15-methyl PGF 2 .sub.β and 15-ethyl-PGF 2 .sub.β has been reported (see for example U.S. Pat. NO. 3,728,382).
SUMMARY OF THE INVENTION
The invention sought to be patented resides in the concept of a chemical compound of the structure: ##SPC1##
Wherein R is hydrogen, alkyl of from 1 to 6 carbon atoms, an alkali metal cation, or a pharmacologically acceptable cation derived from ammonia or a basic amine.
The tangible embodiments of the compositions of the invention possess the inherent general physical properties of being clear to yellow oils, are substantially insoluble in water and are generally soluble in organic solvents such as ethyl acetate and ether. Examination of compounds produced according to the hereinafter described process reveals, upon infrared, nuclear magnetic resonance, and mass spectrographic analysis, spectral data supporting the molecular structures herein set forth. The aforementioned physical characteristics, taken together with the nature of the starting materials, and the mode of synthesis, confirm the structure of the compositions sought to be patented.
The tangible embodiments of the compositions of the invention possess the inherent applied use characteristic of exerting hypotensive and bronchodilating effects, upon administration to warm-blooded animals. These effects are evidenced by pharmacological evaluation according to standard test procedures.
The invention sought to be patented in a sub-generic composition aspect resides in the concept of a chemical compound of the structure: ##SPC2##
The tangible embodiment of the sub-generic composition aspect of the invention possesses the inherent general physical properties of being a clear to yellow oil, is substantially insoluble in water and is generally soluble in polar solvents such as ethyl acetate and ether. Examination of the compound produced according to the hereinafter described process reveals, upon infrared, nuclear magnetic resonance, and mass spectrographic analysis, spectral data supporting the molecular structure herein set forth. The aforementioned physical characteristics, taken together with the nature of the starting materials, and the mode of synthesis, confirm the structure of the composition sought to be patented.
The tangible embodiment of the sub-generic composition aspect of the invention possesses the inherent applied use characteristic of exerting hypotensive, and bronchodilating effects upon administration to warm-blooded animals. These effects are evidenced by pharmacological evaluation according to standard test procedures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to designate the stereochemistry of the substituents on the prostaglandin skeleton, different types of lines are utilized when representing the bonds of said substituents. Thus, with reference to the plane of the paper, when a dashed line (----) is used, the substituent will be understood to be in the α (down) configuration, and when a heavy line ( ) is used, the substituent will be understood to be in the β (up) configuration. For purposes of convenience, the prostaglandin molecules referred to in the following description are free carboxylic acids; however, it will be obvious to those skilled in the art that these free acids may readily be esterified as for example with diazomethane, or with an alkanol and the proper catalyst. These esters are considered to be full equivalents to the free acid for the purposes of the invention. Finally, the use of a specific embodiment in the following description to illustrate the invention is merely descriptive and is not intended to delimit the scope of the invention.
The starting material for the synthesis of the compounds of the invention is 15-oxo-PGF 2 .sub.β which may be prepared synthetically as described, for example, in U.S. Pat. No. 3,728,382. This compound, 15-oxo-PGF 2 .sub.β , is reacted with an ethynyl metallic reagent such as ethynyl magnesium bromide, or lithium acetylide producing a mixture of the two tertiary alcohols 15α-ethynyl-PGF 2 .sub.β and 15β-ethynyl-PGF 2 .sub.β. This mixture is next separated by, for example, silica gel chromatography into pure 15α-ethynyl-PGF 2 .sub.β and pure 15β-ethynyl-PGF 2 .sub.β.
The compound of the invention which bears a carboxyl group can be readily converted to an alkali metal salt or a salt of a pharmacologically acceptable cation derived from ammonia or a basic amine. All such salts are full equivalents of the subject matter particularly claimed.
In using the compounds of the invention to produce bronchodilating effects in warm-blooded animals, they may be administered in a variety of dosage forms: oral, injectable, and aerosol inhalation. Aerosol inhalation is a preferred method because of its rapid onset of action, great potency, and specificity of action. The particular dosage to obtain the bronchodilating effect will vary with the particular compound employed, the particular animal involved, and the degree of bronchodilation desired. In the guinea pig, by aerosol inhalation, the dose to produce bronchodilation is from about 0.015 micrograms to about 50 micrograms, and preferably from about 0.015 to about 25 micrograms. The bronchodilation produced upon aerosol inhalation can be observed by the method of Rosenthale et al., J. Pharmacol. Exp. Ther., 178, 541 (1971). Using this procedure the following result was obtained.
______________________________________ Percent Inhibition of the bronchoconstricting Dose effects of a standardCompound (μg) dose of acetylcholine______________________________________7-(2β-[(3S)-3-Ethynyl-3- 1.5 64hydroxy-trans-1-octenyl]-3α, 15 785β-dihydroxy-1α-cyclopentyl)-cis-5-heptenoic acid______________________________________
In the use of the compounds of the invention to produce hypotensive effects in warm-blooded animals, administration by the injectable route is preferred, preferably the intravenous route.
Thus in the anesthetized dog by the intravenous route the dose to produce hypotension is from about 1 μg/kg. to about 200 μg/kg. and preferably from about 10 μg/kg. to about 100 μg/kg. Using this procedure the following results were obtained.
______________________________________Compound Dose (μg/kg) Δb.p. (mm. Hg)______________________________________7-(2β-[(3S)-3-Ethynyl-3- 100 -16hydroxy-trans-1-octenyl]-3α,5β-dihydroxy-1α-cyclopentyl)-cis-5-heptenoic acid______________________________________
When used herein and in the appended claims, the term "alkali metal" includes, for example, sodium, potassium, lithium, and the like. A "pharmacologically acceptable cation derived from ammonia or a basic amine" contemplates the positively charged ammonium ion and analogous ions derived from organic nitrogenous bases strong enough to form such cations. Bases useful for the purpose of forming pharmacologically acceptable non-toxic addition salts of such compounds containing free carboxyl groups form a class whose limits are readily understood by those skilled in the art. Merely for illustration, they can be said to comprise, in cationic form, those of the formula: ##EQU1## wherein R 1 , R 2 , and R 3 , independently, are hydrogen, alkyl of from 1 to about 6 carbon atoms, cycloalkyl of from about 3 to about 6 carbon atoms, monocarbocyclicaryl of about 6 carbon atoms, monocarbocyclicarylalkyl of from about 7 to about 11 carbon atoms, hydroxyalkyl of from about 1 to about 3 carbon atoms, or monocarbocyclicarylhydroxyalkyl of from about 7 to about 15 carbon atoms or, when taken together with the nitrogen atom to which they are attached, any two of R 1 , R 2 , and R 3 form part of a 5 to 6-membered heterocyclic ring containing carbon, hydrogen, oxygen, nitrogen, said heterocyclic rings and said monocarbocyclicaryl groups being unsubstituted or mono- or dialkyl substituted, said alkyl groups containing from about 1 to about 6 carbon atoms. Illustrative therefore of R groups comprising pharmacologically-acceptable cations derived from ammonia or a basic amine are ammonium, mono-, di-, and tri-methylammonium, mono-, di-, and triethylammonium, mono-, di-, and tripropylammonium (iso and normal), ethyldimethylammonium, benzyldimethylammonium, cyclohexylammonium, benzylammonium, dibenzylammonium, piperidinium, morpholinium, pyrrolidinium, piperazinium, 1-methylpiperidinium, 4-ethylmorpholinium, 1-isopropylpyrrolidinium, 1,4-dimethylpiperazinium, 1-n-butylpiperidinium, 2-methylpiperidinium, 1-ethyl-2-methylpiperidinium, mono-, di- and triethanolammonium, ethyldiethanolammonium, n-butylmonoethanolammonium, tris-(hydroxymethyl)methylammonium, phenylmonoethanolammonium, and the like.
The following example further illustrates the best mode contemplated by the inventor for the practice of the invention.
EXAMPLE
7-(2β-[(3R)-3-Ethynyl-3-Hydroxy-Trans-1-Octenyl]-3α,6β-Dihydroxy-1α-Cyclopentyl)-Cis-5-Heptenoic Acid (15α-Ethynyl-PGF 2 .sub.β) and 7-(2β-[(3S)-3-Ethynyl-3-Hydroxy-Trans-1-Octenyl]-3α,5β-Dihydroxy-1α-cyclopentyl)-Cis-5-Heptenoic Acid (15β-Ethynyl-PGF 2 .sub.β)
Add a solution of 0.35 g. of 7-[3α,5β-dihydroxy-2β-(3-oxo-trans-1-octenyl)-1α-cyclopentyl]-cis-5-heptenoic acid in 15 ml. of tetrahydrofuran to a cooled solution of ethynyl magnesium bromide (prepared from 5.0 ml. of 3M methyl magnesium bromide and excess acetylene) in 50 ml. of tetrahydrofuran and stir for 1/2 hour. Dilute the reaction mixture with ammonium chloride solution, acidify with acetic acid and extract with ether. After washing and drying, evaporate the ether extract and chromatograph the residue on silica with 70% ethyl acetate in hexane to obtain 7-(2β-[(3R)-3-ethynyl-3-hydroxy-trans-1-octenyl]-3α,6β-dihydroxy-1α-cyclopentyl)-cis-5-heptenoic acid as an oil, λ max film 3.0, 3.4, 5.75, 9.6, 10.2 μ. NMR: δ 5.3-6.1 (m, 4, olefinic H), 4.72 (3, 4, OH), 4.1 (m, 2, C-9, 11-H), 2.68 (s, acetylenic H) ppm. Mass spectrum: M + at m/e 378.
Continue eluting the column with 90% ethyl acetate in hexane to obtain 7-(2β-[(3S)-3-ethynyl-3-hydroxy-trans-1-octenyl]-3α,5β-dihydroxy-1α-cyclopentyl)-cis-5-heptenoic acid as an oil, λ max film 3.0, 3.45, 5.8, 9.6, 10.25 μ. Mass spectrum: M + at m/e 378. | Derivatives of PGF 2 .sub.β are prepared. These new compounds not heretofore found in nature possess various pharmacological activities, one of which is bronchodilation. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the earlier filing date of U.S. Provisional Application No. 60/166,404, filed 19 Nov. 1999, which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
The present invention relates to an integrated pressure management system that manages pressure and detects leaks in a fuel system. The present invention also relates to an integrated pressure management system that performs a leak diagnostic for the headspace in a fuel tank, a canister that collects volatile fuel vapors from the headspace, a purge valve, and all associated hoses.
BACKGROUND OF INVENTION
In a conventional pressure management system for a vehicle, fuel vapor that escapes from a fuel tank is stored in a canister. If there is a leak in the fuel tank, canister or any other component of the vapor handling system, some fuel vapor could exit through the leak to escape into the atmosphere instead of being stored in the canister. Thus, it is desirable to detect leaks.
In such conventional pressure management systems, excess fuel vapor accumulates immediately after engine shutdown, thereby creating a positive pressure in the fuel vapor management system. Thus, it is desirable to vent, or “blow-off,” through the canister, this excess fuel vapor and to facilitate vacuum generation in the fuel vapor management system. Similarly, it is desirable to relieve positive pressure during tank refueling by allowing air to exit the tank at high flow rates. This is commonly referred to as onboard refueling vapor recovery (ORVR).
SUMMARY OF THE INVENTION
According to the present invention, a sensor or switch signals that a predetermined pressure exists. In particular, the sensor/switch signals that a predetermined vacuum exists. As it is used herein, “pressure” is measured relative to the ambient atmospheric pressure. Thus, positive pressure refers to pressure greater than the ambient atmospheric pressure and negative pressure, or “vacuum,” refers to pressure less than the ambient atmospheric pressure.
The present invention is achieved by providing a method of managing pressure in a fuel system. The method comprises providing an integrated assembly including a switch actuated in response to the pressure and a valve actuated to relieve the pressure; and signaling with the switch a negative pressure at a first pressure level.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the present invention, and, together with the general description given above and the detailed description given below, serve to explain features of the invention. Like reference numerals are used to identify similar features.
FIG. 1 is a schematic illustration showing the operation of an apparatus according to the present invention.
FIG. 2 is a cross-sectional view of a first embodiment of the apparatus according to the present invention
FIG. 3 is a cross-sectional view of a second embodiment of the apparatus according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , a fuel system 10 , e.g., for an engine (not shown), includes a fuel tank 12 , a vacuum source 14 such as an intake manifold of the engine, a purge valve 16 , a charcoal canister 18 , and an integrated pressure management system (IPMA) 20 .
The IPMA 20 performs a plurality of functions including signaling 22 that a first predetermined pressure (vacuum) level exists, relieving pressure 24 at a value below the first predetermined pressure level, relieving pressure 26 above a second pressure level, and controllably connecting 28 the charcoal canister 18 to the ambient atmospheric pressure A.
In the course of cooling that is experienced by the fuel system 10 , e.g., after the engine is turned off, a vacuum is created in the tank 12 and charcoal canister 18 . The existence of a vacuum at the first predetermined pressure level indicates that the integrity of the fuel system 10 is satisfactory. Thus, signaling 22 is used for indicating the integrity of the fuel system 10 , i.e., that there are no leaks. Subsequently relieving pressure 24 at a pressure level below the first predetermined pressure level protects the integrity of the fuel tank 12 , i.e., prevents it from collapsing due to vacuum in the fuel system 10 . Relieving pressure 24 also prevents “dirty” air from being drawn into the tank 12 .
Immediately after the engine is turned off, relieving pressure 26 allows excess pressure due to fuel vaporization to blow off, thereby facilitating the desired vacuum generation that occurs during cooling. During blow off, air within the fuel system 10 is released while fuel molecules are retained. Similarly, in the course of refueling the fuel tank 12 , relieving pressure 26 allows air to exit the fuel tank 12 at high flow.
While the engine is turned on, controllably connecting 28 the canister 18 to the ambient air A allows confirmation of the purge flow and allows confirmation of the signaling 22 performance. While the engine is turned off, controllably connecting 28 allows a computer for the engine to monitor the vacuum generated during cooling.
FIG. 2 , shows a first embodiment of the IPMA 20 mounted on the charcoal canister 18 . The IPMA 20 includes a housing 30 that can be mounted to the body of the charcoal canister 18 by a “bayonet” style attachment 32 . A seal 34 is interposed between the charcoal canister 18 and the IPMA 20 . This attachment 32 , in combination with a snap finger 33 , allows the IPMA 20 to be readily serviced in the field. Of course, different styles of attachments between the IPMA 20 and the body 18 can be substituted for the illustrated bayonet attachment 32 , e.g., a threaded attachment, an interlocking telescopic attachment, etc. Alternatively, the body 18 and the housing 30 can be integrally formed from a common homogenous material, can be permanently bonded together (e.g., using an adhesive), or the body 18 and the housing 30 can be interconnected via an intermediate member such as a pipe or a flexible hose.
The housing 30 can be an assembly of a main housing piece 30 a and housing piece covers 30 b and 30 c . Although two housing piece covers 30 b , 30 c have been illustrated, it is desirable to minimize the number of housing pieces to reduce the number of potential leak points, i.e., between housing pieces, which must be sealed. Minimizing the number of housing piece covers depends largely on the fluid flow path configuration through the main housing piece 30 a and the manufacturing efficiency of incorporating the necessary components of the IPMA 20 via the ports of the flow path. Additional features of the housing 30 and the incorporation of components therein will be further described below.
Signaling 22 occurs when vacuum at the first predetermined pressure level is present in the charcoal canister 18 . A pressure operable device 36 separates an interior chamber in the housing 30 . The pressure operable device 36 , which includes a diaphragm 38 that is operatively interconnected to a valve 40 , separates the interior chamber of the housing 30 into an upper portion 42 and a lower portion 44 . The upper portion 42 is in fluid communication with the ambient atmospheric pressure through a first port 46 . The lower portion 44 is in fluid communication with a second port 48 between housing 30 the charcoal canister 18 . The lower portion 44 is also in fluid communicating with a separate portion 44 a via first and second signal passageways 50 , 52 . Orienting the opening of the first signal passageway toward the charcoal canister 18 yields unexpected advantages in providing fluid communication between the portions 44 , 44 a . Sealing between the housing pieces 30 a , 30 b for the second signal passageway 52 can be provided by a protrusion 38 a of the diaphragm 38 that is penetrated by the second signal passageway 52 . A branch 52 a provides fluid communication, over the seal bead of the diaphragm 38 , with the separate portion 44 a . A rubber plug 50 a is installed after the housing portion 30 a is molded. The force created as a result of vacuum in the separate portion 44 a causes the diaphragm 38 to be displaced toward the housing part 30 b . This displacement is opposed by a resilient element 54 , e.g., a leaf spring. The bias of the resilient element 54 can be adjusted by a calibrating screw 56 such that a desired level of vacuum, e.g., one inch of water, will depress a switch 58 that can be mounted on a printed circuit board 60 . In turn, the printed circuit board is electrically connected via an intermediate lead frame 62 to an outlet terminal 64 supported by the housing part 30 c . An O-ring 66 seals the housing part 30 c with respect to the housing part 30 a . As vacuum is released, i.e., the pressure in the portions 44 , 44 a rises, the resilient element 54 pushes the diaphragm 38 away from the switch 58 , whereby the switch 58 resets.
Pressure relieving 24 occurs as vacuum in the portions 44 , 44 a increases, i.e., the pressure decreases below the calibration level for actuating the switch 58 . Vacuum in the charcoal canister 18 and the lower portion 44 will continually act on the valve 40 inasmuch as the upper portion 42 is always at or near the ambient atmospheric pressure A. At some value of vacuum below the first predetermined level, e.g., six inches of water, this vacuum will overcome the opposing force of a second resilient element 68 and displace the valve 40 away from a lip seal 70 . This displacement will open the valve 40 from its closed configuration, thus allowing ambient air to be drawn through the upper portion 42 into the lower the portion 44 . That is to say, in an open configuration of the valve 40 , the first and second ports 46 , 48 are in fluid communication. In this way, vacuum in the fuel system 10 can be regulated.
Controllably connecting 28 to similarly displace the valve 40 from its closed configuration to its open configuration can be provided by a solenoid 72 . At rest, the second resilient element 68 displaces the valve 40 to its closed configuration. A ferrous armature 74 , which can be fixed to the valve 40 , can have a tapered tip that creates higher flux densities and therefore higher pull-in forces. A coil 76 surrounds a solid ferrous core 78 that is isolated from the charcoal canister 18 by an O-ring 80 . The flux path is completed by a ferrous strap 82 that serves to focus the flux back towards the armature 74 . When the coil 76 is energized, the resultant flux pulls the valve 40 toward the core 78 . The armature 74 can be prevented from touching the core 78 by a tube 84 that sits inside the second resilient element 68 , thereby preventing magnetic lock-up. Since very little electrical power is required for the solenoid 72 to maintain the valve 40 in its open configuration, the power can be reduced to as little as 10% of the original power by pulse-width modulation. When electrical power is removed from the coil 76 , the second resilient element 68 pushes the armature 74 and the valve 40 to the normally closed configuration of the valve 40 .
Relieving pressure 26 is provided when there is a positive pressure in the lower portion 44 , e.g., when the tank 12 is being refueled. Specifically, the valve 40 is displaced to its open configuration to provide a very low restriction path for escaping air from the tank 12 . When the charcoal canister 18 , and hence the lower portions 44 , experience positive pressure above ambient atmospheric pressure, the first and second signal passageways 50 , 52 communicate this positive pressure to the separate portion 44 a . In turn, this positive pressure displaces the diaphragm 38 downward toward the valve 40 . A diaphragm pin 39 transfers the displacement of the diaphragm 38 to the valve 40 , thereby displacing the valve 40 to its open configuration with respect to the lip seal 70 . Thus, pressure in the charcoal canister 18 due to refueling is allowed to escape through the lower portion 44 , past the lip seal 70 , through the upper portion 42 , and through the second port 46 .
Relieving pressure 26 is also useful for regulating the pressure in fuel tank 12 during any situation in which the engine is turned off. By limiting the amount of positive pressure in the fuel tank 12 , the cool-down vacuum effect will take place sooner.
FIG. 3 shows a second embodiment of the present invention that is substantially similar to the first embodiment shown in FIG. 2 , except that the first and second signal passageways 50 , 52 have been eliminated, and the intermediate lead frame 62 penetrates a protrusion 38 b of the diaphragm 38 , similar to the penetration of protrusion 38 a by the second signal passageway 52 , as shown in FIG. 2 . The signal from the lower portion 44 is communicated to the separate portion 44 a via a path that extends through spaces between the solenoid 72 and the housing 30 , through spaces between the intermediate lead frame 62 and the housing 30 , and through the penetration in the protrusion 38 b.
The present invention has many advantages, including:
providing relief for positive pressure above a first predetermined pressure value, and providing relief for vacuum below a second predetermined pressure value. vacuum monitoring with the present invention in its open configuration during natural cooling, e.g., after the engine is turned off, provides a leak detection diagnostic. driving the present invention into its open configuration while the engine is on confirms purge flow and switch/sensor function. vacuum relief provides fail-safe operation of the purge flow system in the event that the solenoid fails with the valve in a closed configuration. integrally packaging the sensor/switch, the valve, and the solenoid in a single unit reduces the number of electrical connectors and improves system integrity since there are fewer leak points, i.e., possible openings in the system.
While the invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the invention, as defined in the appended claims and their equivalents thereof. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims. | An integrated pressure management system manages pressure and detects leaks in a fuel system. The integrated pressure management system also performs a leak diagnostic for the headspace in a fuel tank, a canister that collects volatile fuel vapors from the headspace, a purge valve, and all associated hoses and connections. | 5 |
RELATED APPLICATION DATA
[0001] This application claims priority under 35 U.S.C. §119 to U.S. Provisional application No. 60/520,651, filed on Nov. 18, 2003, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to engine control systems, and in particular to engine control systems for controlling the fueling system in a combustion engine.
[0004] 2. Description of the Related Art
[0005] Engine control systems for controlling fueling in combustion engines often utilize fuel maps, such as shown in FIG. 1 , which define the amount of fuel to be supplied for an engine operating condition. In FIG. 1 , the bold line 100 a represents the rated power (i.e., brake power) of the engine, and the contoured wave lines 100 b represent the amount of fuel metered per horsepower (lbs/hp/hr). The curves 100 a - 100 b are graphed against engine speed in revolutions per minute (RPS).
[0006] In a typical engine, the lowest fuel consumption occurs at point A. This is the optimum operation point for the engine under heavy engine load conditions. As can be seen, the contour lines below point A have increased fueling requirements. However, if engine load conditions are light, then the optimum operating point is point B. The difference between point A and point B can be upwards of an eight percent difference in fuel economy and is further illustrated by example below.
[0007] Until recently, software and hardware technology were not capable of adjusting fuel flow based upon actual operating conditions. Fixed point operation was necessary, either point A or point B or some other fixed point, with the inherent trade offs in performance under all other operating conditions. Engines offered in the industry are currently available optimized at either point A or point B. Point A configured engines perform best under heavy load, but poorly when lightly loaded. Point B configured engines perform best when lightly loaded, but have poor fuel consumptions when heavily loaded. Such, fuel maps are often optimized for different operating conditions.
[0008] Engine parameters (e.g., A/F ratio, amount of fuel, etc.) currently are set for average conditions under which they operate. In other words, the engine is optimized for the average conditions that are predicted for its service and not for actual usage. This leads to compromises in engine fuel efficiency. The tendency is to optimize the engine to work at or near full load, which is represented by the published engine horsepower and torque curves. See FIG. 2 .
[0009] Operation around the full load line represents operating conditions such as heavy acceleration, high payload or traversing steep grades. However, conditions exist where light engine loads are encountered, such as some vehicle operations under less than full cargo, at low cruising speeds, or flat or downhill road grades. Under these conditions, fuel is wasted because the best operating point in the engine is not at the conditions the vehicle is experiencing. For example, the Mack® E7 ASET engine is optimized for operation at close to 100% load. Other engines, available in the Heavy Duty industry, may be optimized for partial load operation, such as when the vehicle is pulling less than a truckload of freight.
[0010] An engine using a fuel map that is optimized for 100% load operation may deliver better fuel economy under demanding conditions, such a mountainous terrain, than an engine using a fuel map optimized for partial load operation. Conversely, using a fuel map optimized for partial load operation may deliver better fuel economy over flat terrain than one would using a fuel map optimized for 100% load operation. The probability that an engine developed for one set of operating conditions would be mis-applied to another set of operating conditions, however, is high.
[0011] Fuel economy tests were run for two similar trucks under mountainous and flat operating conditions that illustrate this point. The first truck was a Mack® CH outfitted with an E7 engine optimized for 100% load operation, and the second truck was a competitor outfitted with a competitor engine optimized for partial load operation. In a first test, the Mack® and the competitor were operational under identical operating conditions on a mountainous route from Richmond, Va. to Lexington, Ky. along U.S. Interstate 64. During this test, the Mack® achieved 6.5 miles per gallon (mpg) while the competitor achieved 6.27 mpg—3.5% lower fuel consumption than the Mack®.
[0012] In a second test, the Mack® and the competitor were operational under identical operating conditions on a flat route from Richmond, Va. to Atlanta Ga. along U.S. Interstate 95. The engines of each of the trucks were running at partial load during this test, outputting only approximately 150 horse power (hp) out of a maximum rated output of 350 hp. During this test, the Mack® achieved 6.95 miles per gallon (mpg) while the competitor achieved 7.32 mpg—5.3% higher fuel economy than the Mack®.
[0013] As can be clearly seen from the experiment, the first and second trucks respectively out performed each other in the first and second tests. Thus, there is a need for improved engine control that does not depend upon a single fuel map or is not optimized for a single set of operating conditions.
SUMMARY OF THE INVENTION
[0014] The present invention includes a control system and methods for continuously adapting engine control parameters to optimize and adjust engine fuel consumption based upon all detectable vehicle and engine operating conditions. Engine fuel flow can be adjusted based on limitless factors, such as how hard the engine is requested to work, sensed driver commands, gross vehicle weight, road grade and road speed demand.
[0015] In one embodiment, a large number of fuel maps, tailored for each conceived condition, can be utilized to optimize engine fuel consumption based upon rapidly changing conditions. For example, a CD changer could be implemented for storing and retrieving fuel maps. In another embodiment, a fuel map or fuel maps may be used as a basis for calculating amount of fuel to be injected into the cylinder. However, the amount of fuel is adjusted in real time based on a plurality of vehicle and engine operating conditions. Alternatively, fuel maps may be calculated interactively “on the fly.”
[0016] When the operating point moves, the fuel map also moves to maintain the operation within the “sweet spot”, the point of Fuel Economy optimization, and the corresponding topography of the fuel map changes.
[0017] According to an embodiment in the present invention, a fuel control system for a combustion engine in a motor vehicle is provided. The fuel control system includes a plurality of sensors that measure a plurality of vehicle and engine operating conditions. The fuel control system also includes an electronic control module (ECM) coupled with a plurality of sensors and with a fuel system. The ECM is configured to receive measurements from the plurality of sensors and to adjust fueling parameters of the fuel system to optimize the operation of the combustion engine based on the measurements.
[0018] According to another embodiment in the present invention, a method of controlling the fuel system of a combustion engine in a vehicle is provided. The method includes a step of measuring a plurality of engine and vehicle operating conditions. Fueling parameters of the fuel system are adjusted based upon the measurements made in order to optimize the output power of the engine for maximum fuel efficiency.
[0019] According to another embodiment in the present invention, a control system for a fueling system of a combustion engine is provided. The control system includes sensing means for measuring a plurality of engine and vehicle conditions in real time. The control system also includes a fuel map that defines engine fueling parameters corresponding to engine operating conditions. The control system also includes a control module means for controlling the fueling parameters of the fueling system by selecting fueling parameters from the fuel map based on current engine operating conditions and adjusting the selected fueling parameters based on the plurality of engine and vehicle conditions measured by the sensing means.
[0020] Further applications and advantages of various embodiments of the present invention are discussed below with reference to the drawing figures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] FIG. 1 is a fuel map for use with an embodiment of the invention;
[0022] FIG. 2 is a graph of torque, brake power, and specific fuel consumption versus engine speed for use with an embodiment of the invention;
[0023] FIG. 3 is a diagram of an engine control system for use with an embodiment of the invention; and
[0024] FIG. 4 is a block diagram of an engine control system according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] While the present invention may be embodied in many different forms, a number of illustrative embodiments are described herein with the understanding that the present disclosure is to be considered as providing examples of the principles of the invention and such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrated herein.
[0026] It is desirable that the performance of an engine be optimized for a variety of operating and load conditions under which it may operate. It is further desirable for the performance of an engine to be adaptable to a wide variety of road conditions under which it may operate. Finally, it is desirable for an engine to be optimizable to operate at maximum performance for all possible operating conditions. To that end, the present invention includes systems and methods for controlling a fuel system of a combustion engine, in real-time, based on engine and vehicle operating conditions.
[0027] FIG. 4 is a block diagram of an engine control system according to an embodiment of the present invention. System 400 includes an electronic control module (ECM) 102 coupled with a memory device 104 , with the various components of the combustion engine fueling system 402 , and a plurality of engine and vehicle sensors 404 - 412 . Any number of engine and vehicle sensors may be employed in the present invention. For example, sensors can include those that determine vehicle speed 404 , road grade 406 , vehicle load 408 , operator demand 410 and elevation 412 . Sensors could include accelerometers, temperature sensors, gyroscopes, etc. and are not limited to those described in this document. One skilled in the art will readily understand that most vehicles and engines already employ a number of sensors for measuring engine and vehicle conditions, such as oil temperature and pressure sensors, coolant temperature sensors, etc. Accordingly, the invention is not intended to be limited to the number and type of sensors as listed in FIG. 4 .
[0028] Further, operating conditions can be deduced from other measurements. For example, road grade could be deduced from a combination of throttle position and road speed. If at a constant throttle and engine speed, there begins a deceleration, it could be inferred that a hill is being traversed.
[0029] ECM 102 is configured to receive data (i.e., measurements) from the plurality of sensors 404 to 412 , access fueling data (e.g., fuel map data, brake power curve, etc.) stored on the memory unit 104 , and control the various components of the combustion engine fueling system 402 associated with engine performance in order to optimize the operation of the combustion engine in real time, based on real time measurements, continuously and systematically.
[0030] For example, referring to FIG. 3 , ECM 102 could be further coupled with the systems that control the turbo charger (i.e., air delivery) 302 , fuel injector (i.e., fuel delivery) 304 , crank shaft position (which indicates engine speed 308 , drive shaft speed 310 , and valve timing 312 . ECM 102 is configured to control turbo charger 302 , fuel injection 304 , and valve timing 312 , based on real time data to optimize the performance of the engine at any given moment.
[0031] For example, ECM 102 could instantly measure GVW, vehicle speed, engine speed, the drivers fuel pedal (demand) and road grade and determine that, based upon the engines known characteristics, that a particular combination of fuel and air will achieve optimization of the engine at that instant, and accordingly control the turbo charger 302 , fuel injection 304 and valve timing 312 . The ECM 102 could include an algorithm or program that calculates “point A” of the Fuel Consumption Map, the point of optimization, based on the measured condition. For example, given a vehicle with a heavy payload traversing a hill, the ECM 102 shall calculate an optimum operating point close to the power curve, or near point A. As the vehicle ranges over the hill and starts to descend, the ECM 102 will recognize the decent and will recalculate the optimum point to move toward point B. Base on conditions, the engine could be controlled to operate at a higher or lower RPM for the road speed, with a particular air and fuel injection, in order to operate at maximum fuel efficiency.
[0032] In the next instant, if driver demand, road grade, or another condition changed, the ECM 102 would detect the change in vehicle and engine operating conditions and modify fueling parameters to optimize the engines performance for the next instance.
[0033] One skilled in the art will recognize that from the engine performance curve, such as that shown in FIG. 2 , the power and torque can be correlated with an amount of specific fuel and air needed for combustion. Based on vehicle operating conditions, the present invention can determine how to meet the driver's demands while optimizing performance and fuel consumption. However, the ECM might calculate that a particular combustion state would be most efficient, such as lean burn states, but would be operating outside of EPA regulation for emissions. Therefore, the ECM can be bounded by current EPA regulations so that maximum fuel efficiency is met within emissions standards.
[0034] One skilled in the art will recognize that system 302 - 312 may also input measurements to the ECM 102 that can be used to control fueling.
[0035] ECM memory 104 can include the data necessary for creating fuel map “on the fly,” or alternatively, could include a large number of fuel maps, each of which are optimized for a certain condition. For example, based on instantaneous vehicle and engine conditions, the ECM 102 could select a fuel map from a plurality of fuel maps, each of which is optimized for the particular road and vehicle conditions. Fueling could then be performed based on the selected fuel map. In order to accommodate the amount required for a large number fuel maps, memory 104 could include a “juke box” or CD changer.
[0036] Alternatively, a single fuel map could be stored in the memory unit, ECM could be configured to obtain the fueling parameters from the fuel map and adjust the fueling parameters obtained from the fuel map based on the real time measurements from a plurality of sensors. For example, referring back to FIG. 1 , adjustments could be made between Point A and Point B in order to optimize the engine operation.
[0037] In one embodiment of the present invention, a memory unit 104 could comprise a CD changer. Multiple fuel maps could be loaded in the software like discs in a CD changer. For example, ninety-nine separate fuel maps may be stored. The ECM 102 may calculate what conditions or which application the engine is operating under, such as mountainous terrain, flat terrain, high gross vehicle weight (GVW), or low GVW based upon inputs like turbocharger speed 302 , injector delivery volume 304 , engine speed 308 , vehicle speed 310 , or variable valve timing 312 , as shown in FIG. 3 .
[0038] The ECM 102 then can select the appropriate “disc” or fuel map and load it to operate the engine. When application conditions change, a new disc could chosen by the changer and loaded. In practice, the various fuel maps may be stored in memory. If enough discs are available to drive efficient operation this approach will match fuel delivery to the engine operating conditions. It is recognized that this approach may be expensive because of the costs necessary to develop each of the fuel maps independently.
[0039] In another embodiment, the control system can adapt engine control parameters continuously and infinitely to adjust engine fuel consumption based upon the various operating conditions experienced by the vehicle. This embodiment is particularly applicable to a commercial vehicle.
[0040] The control system can continuously adjust the fuel flow based on limitless numbers of factors such as how hard the engine is required to work, driver commands or intent, the GVW of the vehicle, road grade, and road speed demanded.
[0041] In one embodiment, interactive real time adjustments of the fuel maps may be developed with the changes to “not to exceed limits” imposed by EPA. In this embodiment, software control may be improved because the fuel map may be calculated interactively or “on the fly”. This embodiment may require inputs from additional sensors and controls of other devices such as variable geometry turbochargers (which control engine airflow). In this embodiment, application optimization may be continuous and optimized under all conditions.
[0042] Thus, a number of preferred embodiments have been fully described above with reference to the drawing figures. Although the invention has been described based upon these preferred embodiments, it would be apparent to those of skilled in the art that certain modifications, variations, and alternative constructions would be apparent, while remaining within the spirit and scope of the invention. | A control system is provided for controlling the fueling system ( 402 ) of a combustion engine. The control system includes a sensing arrangement for measuring a plurality of engine and vehicle conditions ( 404, 406, 408, 410, 412 ) in real time. The control system also includes a fuel map that defines engine fueling parameters corresponding to engine operating conditions. The control system also includes a control module ( 102 ) for controlling the fueling parameters of the fueling system by selecting fueling parameters from the fuel map based on current engine operating conditions and adjusting the selected fueling parameters based on the plurality of engine and vehicle conditions measured by the sensing arrangement. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention.
[0002] The present invention relates to a hinge assembly for use in space constrained applications, such as cable arms in electrical equipment racks.
[0003] 2. Description of Related Art.
[0004] To remove a conventional swinging door or rotating arm, typically a hinge pin is removed by pulling it out vertically and the door or arm can then be removed from the stationary mounted section of the hinge assembly. However, if a hinge has to be placed in an application with insufficient overhead above the hinge, it may not be possible to remove the hinge pin without increasing the overhead space. For example, when thin, rack-optimized computer systems with cable management arms are removed from a rack, the cable management arm often has to be disconnected from the rack. These arms are often impossible to install or remove when another system is installed directly above the one being serviced because the hinge pin can not be inserted or removed due to the limited height available for the hinge pin.
[0005] It can be seen that there is a need to provide an improved hinge assembly for space constrained applications.
SUMMARY OF THE INVENTION
[0006] To overcome the limitations in the prior art described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention provides a low overhead hinge assembly comprising a stationary hinge plate and a rotating hinge plate. The stationary hinge plate having a stationary hinge plate body portion and a plurality of stationary hinge plate digits coupled to the stationary hinge plate body portion, each of the stationary hinge plate digits having an opening therein. The rotating hinge plate having a rotating hinge plate body portion and a plurality of pins coupled to the rotating hinge plate body portion, wherein the stationary hinge plate digits are configured to be engaged with the rotating hinge plate pins so that each of a plurality of the rotating hinge plate pins is inserted into an opening in one of the stationary hinge plate digits so as to pivotally couple the rotating hinge plate to the stationary hinge plate.
[0007] In a further embodiment the low overhead hinge assembly includes a shim having a shim body portion and a plurality of shim digits, wherein the shim is coupled to the rotating hinge plate and wherein each shim digit is configured to be inserted between one of the stationary hinge plate digits and an adjacent rotating hinge plate pin when the stationary hinge plate digits and rotating hinge plate pins are engaged.
[0008] In a further embodiment the stationary hinge plate digits have a notch in a side wall of the digits so as to allow the rotating hinge plate pins to be inserted into the cavity of the stationary hinge plate digits using a motion in a direction substantially perpendicular to an edge of the rotating hinge plate on which the rotating hinge plate pins are coupled.
[0009] These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and form a part hereof. However, for a better understanding of the invention and its advantages, reference should be made to the drawings which form a further part hereof, and to accompanying descriptive matter, in which there are illustrated and described specific examples of an apparatus in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
[0011] FIG. 1A illustrates a stationary hinge plate for a hinge assembly according to an embodiment of the present invention;
[0012] FIG. 1B illustrates a rotating hinge plate for a hinge assembly according to an embodiment of the present invention;
[0013] FIG. 1C illustrates a shim plate for a hinge assembly according to an embodiment of the present invention;
[0014] FIG. 2 illustrates a hinge assembly according to an embodiment of the present invention;
[0015] FIG. 3 illustrates the components of a no overhead hinge assembly according to an embodiment of the present invention;
[0016] FIG. 4 illustrates a no overhead hinge assembly according to an embodiment of the present invention; and
[0017] FIG. 5 illustrates a perspective view of a computer equipment rack assembly including a cable arm assembly according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] In the following description of preferred embodiments of the present invention, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized as structural changes may be made without departing from the scope of the present invention.
[0019] The present invention provides a hinge assembly for space constrained applications. The present invention allows the hinge assembly to be disassembled with very little or no overhead above the hinge.
[0020] FIG. 1A illustrates a stationary hinge plate 100 for a hinge assembly according to an embodiment of the present invention. Stationary hinge plate 100 is comprised of a body portion 102 and five protruding digits 104 a - 104 e. Stationary hinge plate digits 104 a - 104 e are each comprised of a hollow cylinder coupled to a member extending from body portion 102 . Stationary hinge plate digits 104 a - 104 e may either have a cylindrical hole through the entire digit or a cavity that only extends part of the length of the digit such that each digit has a solid bottom. FIG. 1B illustrates a rotating hinge plate 130 for a hinge assembly according to an embodiment of the present invention. Rotating hinge plate 130 is comprised of a body portion 132 and hinge pins 134 a - 134 e. Hinge pins 134 a - 134 e are relatively short to allow the pins to be removed from the stationary hinge plate hollow cylindrical digits with a small upward movement. Rotating hinge plate 130 further includes a spring mounting element 136 .
[0021] FIG. 1C illustrates a shim plate 160 for a hinge assembly according to an embodiment of the present invention. Shim plate 160 is comprised of four disc shaped digits 164 a - 164 d which extend from body portion 162 . Shim plate 160 further includes a clip 166 for attaching the shim plate to the rotating hinge plate 130 , as well as a spring mounting element 168 . Shim plate 160 provides additional stability and strength for the hinge assembly. Shim plate 160 slides horizontally along the rotating hinge plate to act as a wedge between the rotating and stationary sections of the hinge. Shim plate 160 is spring-loaded and can also be latched for extra security.
[0022] FIG. 2 illustrates a hinge assembly 200 according to an embodiment of the present invention. This hinge assembly is comprised of stationary hinge plate 100 , rotating hinge plate 130 and shim plate 160 (shown in FIGS. 1A-1C ). More specifically, FIG. 2 shows stationary hinge plate hollow cylindrical digits 204 a - 204 e and shim plate digits 264 a - 264 d engaged with the rotating plate hinge pins. A rotating plate spring mounting bracket 236 is coupled to the rotating plate body portion 232 . FIG. 2 further comprises a shim spring 270 mounted between the shim spring mounting bracket 268 and the rotating plate spring mounting bracket 236 . Shim spring 270 keeps the shim plate digits 264 a - 264 d engaged with hinge plate hollow cylindrical digits 204 a - 204 e and the rotating plate hinge pins.
[0023] To connect the components of the hinge assembly, first the shim plate and rotating hinge plate are coupled together using clip 166 , shown in FIG. 1C . Next shim plate 160 is slid backwards relative to stationary hinge plate 100 to allow access to stationary hinge plate hollow cylindrical digits 204 a - 204 e. Rotating hinge plate 232 is then lifted slightly above stationary hinge plate 100 , then slid horizontally and lowered such that rotating hinge plate pins 134 a - 134 e ( FIG. 1B ) are inserted into stationary hinge plate hollow cylindrical digits 204 a - 204 e. When rotating hinge plate pins 134 a - 134 e are engaged into the hollow cylindrical digits on the stationary hinge plate, then the shim plate is slid forward to close the hinge. Spring 270 keeps the components engaged or an optional latch can also be used to lock the hinge assembly together. The assembly is then complete and functional. In normal operation, connection and disconnection of the hinge assembly does not require the shim plate and the rotating hinge plate to be separated from each other, it just requires sliding of the shim plate relative to the rotating hinge plate.
[0024] To disconnect the hinge assembly the shim plate is slid backwards to open the hinge. If there are any latches keeping the shim plate in place, they are unlatched to allow the shim plate to be slid back. Once the shim plate is slid out of place, the rotating hinge plate can be removed from the stationary hinge plate of the hinge by lifting it slightly, pulling it horizontally to clear the hinge pins, and the hinge plate components are then separated.
[0025] This embodiment of the present invention provides a hinge assembly that requires very little overhead clearance to install or remove the stationary hinge plate or cable management arm from the rotating hinge plate. The shim plate provides additional strength to the overall hinge assembly. The present invention can generally be used with any type of rotating arm, cover or door and is particularly useful for applications where the area above the stationary hinge is limited such that there is not sufficient space to remove a conventional hinge pin.
[0026] FIG. 3 illustrates the components of a no overhead hinge assembly 300 according to an embodiment of the present invention. Stationary hinge plate 310 is comprised of a body portion and three protruding digits 304 a - 304 c. Stationary hinge plate digits 304 a - 304 c are each comprised of a hollow cylinder with a notch. Rotating hinge plate 330 is comprised of a body portion and three hinge pins 334 a - 334 c. Hinge pins 334 a - 334 c are relatively short to allow the pins to be inserted into the notches in the stationary hinge plate digits 304 a - 304 c. Shim plate 360 is comprised of a body portion and three disc shaped digits 364 a - 364 c with a side wall extending down from the top surface of each disc around part of the circumference of the disc. Shim plate 360 provides additional stability and strength for the hinge assembly. The shim plate slides horizontally along the stationary hinge plate to act as a wedge between the rotating and stationary sections of the hinge. The sidewalls on the shim plate digits 364 a - 364 c prevent the rotating plate hinge pins 334 a - 334 c from being disengaged from the stationary hinge plate notched digits 304 a - 304 c. This shim plate can be spring-loaded and or latched for extra security.
[0027] FIG. 4 illustrates a no overhead hinge assembly 400 according to an embodiment of the present invention. In FIG. 4 the stationary hinge plate notched hollow cylindrical digits and shim plate digits are engaged with the rotating plate hinge pins. No overhead hinge assembly 400 further comprises a shim spring 470 mounted between the shim 460 and rotating hinge plate 410 . Shim spring 470 keeps the shim plate digits 364 a - 364 c engaged with hinge plate notched hollow cylindrical digits 304 a - 304 c and rotating plate hinge pins 334 a - 334 c.
[0028] To connect the hinge assembly components shown in FIG. 3 , shim plate 360 ( FIG. 3 ) is slid back relative to the rotating hinge plate such that stationary hinge plate digits 304 a - 304 c are exposed. Rotating hinge plate 330 is then slid substantially horizontally into the stationary hinge plate such that the hinge pins slide through the stationary hinge plate digit notches to sit in the hollow cylindrical area of the stationary hinge plate digits. When the rotating hinge plate pins are engaged into the stationary hinge plate notched cylindrical digits, then the shim plate digits with side walls are slid forward to close the hinge. The shim digit side walls prevent the rotating hinge plate digits from slipping out of the stationary hinge plate notched cylindrical digits. Spring 470 keeps the components engaged or an optional latch can also be used to lock the hinge assembly together. The hinge assembly is then complete and ready for operation.
[0029] To disconnect the hinge assembly 400 , if there are any latches keeping the shim plate in place, they are unlatched to allow the shim plate to be slid away. Shim plate 460 is then slid backwards to open the hinge. Once the shim plate is slid out of place, the notches in the stationary hinge plate digits are now accessible. Rotating hinge plate 430 can then be removed from stationary hinge plate 410 by moving it horizontally away from the stationary hinge plate.
[0030] FIG. 5 illustrates a perspective view of a computer equipment rack assembly 500 including a cable arm assembly according to an embodiment of the present invention. Equipment rack 502 provides a housing for a plurality of individual equipment units 504 , which may be a file server, storage server, or other computing device. Each equipment unit 504 is slidably mounted in rack 502 using drawer slides 506 . Cable arm 512 is coupled to a low overhead hinge assembly 510 which in turn is coupled to rack 502 via stationary hinge plate 508 . Low overhead hinge assembly 510 allows the rotating hinge plate to be removed from the stationary hinge plate, thereby disconnecting the cable arm without requiring removal of a hinge assembly—cable arm above or below this cable arm.
[0031] While the present invention has been described in terms of preferred embodiments for achieving this invention's objectives, it will be appreciated by those skilled in the art that variations may be accomplished in view of these teachings without deviating from the spirit or scope of the present invention. | A low overhead hinge assembly comprising a stationary hinge plate and a rotating hinge plate. The stationary hinge plate having a stationary hinge plate body portion and a plurality of stationary hinge plate digits coupled to the stationary hinge plate body portion, each of the stationary hinge plate digits having an opening therein. The rotating hinge plate having a rotating hinge plate body portion and a plurality of pins coupled to the rotating hinge plate body portion, wherein the stationary hinge plate digits are configured to be engaged with the rotating hinge plate pins so that each of a plurality of the rotating hinge plate pins is inserted into an opening in one of the stationary hinge plate digits so as to pivotally couple the rotating hinge plate to the stationary hinge plate. | 4 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to a slag retaining device for use in tapping converters or hot metal ladles during the tapping of steel therefrom. The use of the device permits the tapping of steel free from slag.
2. Description of the Prior Art
Prior devices for blocking or minimizing slag carry over when tapping molten steel from a converter or ladle are known in the art and a typical disclosure of a device requiring manual placement is seen in Canadian Pat. No. 822,607. An example of a prior art floatable device may be seen in U.S. Pat. No. 4,462,574, W. M. Keenan, and U.S. Pat. No. 4,494,734, M. D. LaBate,
It is an object of the present invention to overcome the disadvantages of the above-mentioned prior art and to provide an improved automatically placed floatable device for minimizing slag carry over during tapping of molten metal from a converter or ladle and to provide a manually insertable device forming a closure having guide means and movable into the tap hole of the converter or ladle at a desired time to prevent molten slag from flowing therethrough. The device in its preferred form is combined with a cylindrical refractory sleeve positioned in the tap hole of the converter or ladle and forms circular valve seat for engagement with the slag retaining device and avoids the erosion of the material heretofore used in defining the tap hole which frequently resulted in an irregularly shaped tap hole and inability of a slag retaining device to properly seat therein.
SUMMARY OF THE INVENTION
The slag retaining device of the present invention is disclosed herein in two forms. The first of these is a manually insertable stopper body, commonly called a dart, which incorporates a depending guide member engageable in the tap hole and insures the accurate placement of the stopper body in closing relation to the tap hole. Alternate configurations of the stopper body increase the efficiency of the same with respect to its placement in and engagement with the tap hole particularly when the tap hole is defined by a cylindrical refractory member preformed and positioned in the refractory lining of the converter or ladle in registry with the tap hole therein.
A variation of the form of the slag retaining device has a specific gravity lower than that of the steel, but higher than that of the slag therein in the converter or ladle and is automatically partially positioned in the tap hole where its configuration causes the swirling of the metal and the slag which may be visually observed and indicates that the slag is about to reach the tap hole whereupon the tapping of the converter or ladle may be terminated.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical section through the manually insertable form of the slag retaining device;
FIG. 2 is a top plan view of the slag retaining device;
FIG. 3 is a side elevation with parts broken away showing the slag retaining device with annular grooves formed in its exterior surface;
FIG. 4 is a perspective view of an alternate form of the device seen in FIGS. 1 and 2 wherein the guide rod is eliminated;
FIG. 5 is a perspective view of a further alternate form of the slag retaining device of FIG. 4;
FIG. 6 is a cross sectional view of a portion of a converter showing a cylindrical refractory sleeve defining the tap hole therein with molten steel above the tap hole and molten slag thereon and the slag retaining device of FIG. 1 positioned in the tap hole; and
FIG. 7 is a cross sectional view of a portion of a ladle showing the tap hole therein and a cylindrical sleeve therein defining said tap hole with molten steel above the tap hole and molten slag thereon and the slag retaining device of FIG. 4 engaged in the tap hole.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the form of the invention seen in FIGS. 1, 2 and 6 of the drawings, an upright, oval shaped body, which is cross sectionally circular, is preferably formed of upper and lower modified cone-shaped members 10 and 11 arranged in oppositely disposed relation to one another has its area of largest diameter 12 at its center, said area of largest diameter 12 being substantially greater than that of a tap hole in a converter or ladle in which it is to be placed.
The slag retaining device is shown assembled on a steel rod 13 with a portion of the rod 13 below the lower member 11 enclosed in sleeves 14 of fireproof material such as a suitable refractory and including a cap 15 surrounding a fastener on the lower end of the rod 13. The rod 13 extends vertically through the members 10 and 11 and upwardly and outwardly thereof and provides a portion of the slag retaining device that may be detachably engaged by a mechanical device used to position the slag retaining device in the tap hole.
In FIG. 6 of the drawings, the slag retaining device is shown in the tap hole of a converter 16 in which a pool of molten metal M topped by a layer of molten slag S are illustrated. The tap hole in the converter 16 is defined by a refractory sleeve 17 which extends through the layer of insulating refractory 18 which lines the converter 16.
Those skilled in the art will observe that the slag retaining device with its smooth, modified, global shape is inserted into the converter or ladle before a vortex forms as the final portion of metal starts to drain out of the tap hole. The time may be calculated from the estimated tonage of metal contained in the converter or ladle and the size and the shape of the tap hole in relation to the contents. It is desirable that the slag retaining device be introduced into the converter or ladle within a calculated time of between one to two minutes before the end of the tap when all of the metal is drained from the furnace.
The preferred density of the slag retaining device for use in steel making is preferably between 0.12 to 0.22 lbs. per square inch. The material of the upper and lower members 10 and 11 is preferably substantially indissoluble in the molten metal and the slag and its density is such that it floats at or near the surface of the molten steel M and at the junction of the molten metal and the slag where its contoured modified global shape permits the molten steel to flow around the same and cause a bobbing action before finally seating in the tap hole where it stops the slag from flowing through the tap hole.
It will also be seen that the modified global shape of the slag retaining device when placed in the vortex formed by the molten metal above the tap hole will rotate several times before seating itself firmly. The rotation insures the desirable positioning of the slag retaining device in the tap hole which may be uneven or erroded which would otherwise tend to tilt the slag retaining device and permit an undesired amount of slag to flow out of the tap hole.
In order to form the modified global-shaped body of the slag retaining device comprising the upper and lower body members 10 and 11, a suitable mix may comprise refractory cement 8 lbs., fine iron ore concentrate 16 lbs., steel shot 30 lbs., stainless steel fibers 2 lbs., and water from 3 lbs. to 5 lbs. This formula will produce a body having a density of from 0.15 to 0.17 lbs./inch 3 although any density between that of the slag 0.10 lbs./inch 3 and that of molten steel, about 0.25 lbs./inch 3 is suitable.
It will occur to those skilled in the art that the shape of the exterior of the slag retaining device of FIGS. 1, 2, 4 and 6 of the drawings may be changed to increase its efficiency and one such modification is illustrated in FIG. 3 of the drawings wherein the modified, global-shaped body of the slag retaining device is formed of upper and lower members 20 and 21 respectively, assembled on a steel rod 22, the members 20 and 21 provided with several annular grooves 23 spaced with respect to the area of widest diameter 24 of the device. A broken away section of the device is illustrated in FIG. 3 of the drawings and the material of the device may be the same in the upper and lower members 20 and 21 or it may differ as to density so as to desirably control the floating relation of the device with respect to the molten metal and slag as hereinbefore described. The annular grooves 23 assist in the final closing of the tap hole when the same moves in a bobbing action and/or rotates as it nears the same in the vortex of the metal flowing through the tap hole as defined by a refractory sleeve 17 which is illustrated in FIG. 6 of the drawings and hereinbefore described. A further modification of the invention may be seen in FIGS. 5 and 7 of the drawings and in FIG. 5 upper and lower portions 26 and 27 respectively of a slag retaining device having a modified global shape with flat upper and lower ends 28 and 29 respectively is provided with circumferentially spaced substantially vertically positioned arcuate ribs 30 and grooves 31, the ribs 30 and grooves 31 being alternately arranged. The modified slag retaining device of FIG. 5 may be used as illustrated, like that of FIG. 4, by being positioned in the vortex of the metal flowing out of the tap hole in a converer or ladle where it will move in a bobbing and/or rotating motion as the level of the metal nears the tap hole so that it will seat in the tap hole and allow some metal to flow therethrough creating a substantially increased swirling vortex in the metal and slag which will visually indicate to an operator the proximity of the slag layer to the tap hole and enable the operator to move the converter or close the tap hole in a ladle to prevent the slag from entering the same. The modified forms of the invention are formed of the same material hereinbefore described and of the same or comparable densities to control their desired floating relation with respect to the metal and the slag thereon being controlled with respect to preventing the entry of the slag into the tap hole.
One of the problems heretofore existing in tapping converters, hot metal ladles, and the like, is the irregular shape of the tap hole through which the hot metal flows. The refractory shape normally forming the tap hole in the prior art has been formed by placing a thin metal tube in the tap hole, the tube being of a slightly smaller diameter than the tap hole in the vessel and subsequently forming refractory clay in a putty-like consistency around the tube in the well which surrounds the tap hole as a result of the building up of the refractory lining in the vessel from refractory bricks and the like.
In the present disclosure, the tap hole in the refractory lining in the vessel is formed by a preshaped, prefired, cylindrical sleeve resembling a sewer tile which is positioned in the vessel in registry with the tap hole therein and the refractory lining of the vessel formed directly thereabout. The preshaped, prefired, refractory sleeve is considerably more efficient in resisting erosion of hot metal flowing therethrough than the above described structures of the prior art and they are particularly useful in maintaining a circular configuration in which the slag retaining devices of the present invention may be seated manually or mechanically or floated thereinto all as hereinbefore described.
In FIG. 6 of the drawings the refractory sleeve is illustrated by the numeral 17 and the insulating refractory liner 18 which is usually refractory prefired bricks is shown directly abutting the refractory sleeve 17. Some refractory cement may be used in sealing the refractory bricks to one another and to the refractory sleeve 17 as will occur to those skilled in the art.
In FIG. 7 of the drawings, the refractory sleeve is indicated by the reference numeral 32 and the insulating refractory lining 33 of the ladle 34 is usually formed of prefired refractory bricks which are laid up in abuttment with the refractory sleeve 32. In FIG. 7 of the drawings, the ladle 34 has a slide valve 35 positioned below the refractory sleeve 32 which can be used to control the flow of hot metal from the ladle as for example when the hot metal is being transferred into a tundish or like receptacle in communication with a continuous caster.
It will thus be seen that the substantially improved slag retaining device as illustrated and described herein in combination with the refractory sleeve defining the tap hole, substantially improves the function of the slag retaining device and in effect automatically shuts off the flow of molten steel through the tap hole before the slag layer reaches the same thus assuring that only clean steel free of slag (non-metallic inclusions) is delivered from the vessel.
Although but four embodiments of the present invention have been illustrated and described, it will occur to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention and having thus described my invention what I claim is: | A device for the separation of slag and its retention in a converter, ladle, or the like, consists of a closure commonly called a dart, adapted to be placed either manually or automatically in the tap hole of the converter or ladle during tapping of molten metal therefrom. The device may have smooth exterior surfaces or may include configurations enabling it to substantially close the tap hole and impart a swirling motion to the molten metal and slag therein. The device may be formed of material having a specific gravity lower than that of the metal in the converter or ladle, but higher than that of the slag thereon or alternately having a specific gravity higher than that of the metal to facilitate manual placement of the device in the tap hole. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to a drive circuit for an injector arrangement. It relates particularly, although not exclusively, to a drive circuit for an injector arrangement for an internal combustion engine, the injector arrangement including at least one injector of the type having a piezoelectric actuator for controlling injector valve needle movement.
BACKGROUND ART
[0002] Automotive vehicle engines are generally equipped with fuel injectors for injecting fuel (e.g., gasoline or diesel fuel) into the individual cylinders or intake manifold of the engine. The engine fuel injectors are coupled to a fuel rail which contains high pressure fuel that is delivered by way of a fuel delivery system. In diesel engines, conventional fuel injectors typically employ a valve that is actuated to open and close to control the amount of fluid fuel metered from the fuel rail and injected into the corresponding engine cylinder or intake manifold.
[0003] One type of fuel injector that offers precise metering of fuel is the piezoelectric fuel injector. Piezoelectric fuel injectors employ piezoelectric actuators made of a stack of piezoelectric elements arranged mechanically in series for opening and closing an injection valve to meter fuel injected into the engine. Examples of piezoelectric fuel injectors are disclosed in U.S. Pat. Nos. 4,101,076 and 4,635,849. Piezoelectric fuel injectors are well-known for use in automotive engines.
[0004] The metering of fuel with a piezoelectric fuel injector is generally achieved by controlling the electrical voltage potential applied to the piezoelectric elements to thereby vary the amount of expansion and contraction of the piezoelectric elements. The amount of expansion and contraction of the piezoelectric elements varies the travel distance of a valve piston and, thus, the amount of fuel that is passed through the fuel injector. Piezoelectric fuel injectors offer the ability to precisely meter a small amount of fuel. However, piezoelectric fuel injectors also generally require relatively high voltages (typically in the hundreds of volts) and high currents (tens of amps) in order to function properly.
[0005] Known conventional drive circuitry for controlling a piezoelectric fuel injector is generally complicated and requires extensive energy. This energy is usually provided by a dedicated power supply such as a transformer which steps-up the voltage generated by the vehicle battery (e.g., 12 volts) to a higher voltage (e.g., 230 volts). The step-up voltage is then applied to large reservoir capacitors for powering the charging and discharging of one or more fuel injectors for each injection event. This dedicated power supply generates enough energy to maintain the reservoir capacitor voltage over the full operating load and speed range of the engine. However, a disadvantage of providing a dedicated power supply of this size is increased cost. Thus, a further disadvantage is that the controller required to control the drive circuit must be of large size.
[0006] German patent application no. DE 102 45 135 A1 (Nippon Soken, Inc. et al) describes a drive circuit for controlling a plurality of piezoelectric fuel injectors. The drive circuit comprises a DC/DC voltage converter 21 for stepping up the voltage produced by a vehicle battery. The stepped-up voltage is applied to capacitors in the circuit which are then used for charging the fuel injector piezoelectric elements. The drive circuit comprises a single voltage supply rail and operates in a purely unidirectional manner (i.e., it does not provide negative voltages), and therefore cannot be used to drive bi-directional fuel injectors which require both negative and positive voltages.
[0007] It has been suggested that vehicle manufacturers are planning to replace 12 volt vehicle batteries with a 42 volt charging system This change has been prompted by the move to replace mechanical and hydraulic systems with electronics (i.e. “drive-by-wire”), and will provide a way to improve fuel economy and reduce emissions. Another problem with current drive circuits is that it is difficult to control dynamically the voltage across the large reservoir capacitors should the higher 42 voltage supply (or a lower voltage supply) be required.
[0008] An object of the invention is therefore to provide a drive circuit which requires less components than existing drive circuits for injector arrangements, and which is therefore cheaper and more controllable than such drive circuits. Another object of the invention is to provide a drive circuit which is suitable for use with voltage supplies having different capabilities.
SUMMARY OF THE INVENTION
[0009] According to a first aspect of the present invention there is provided a drive circuit for an injector arrangement having at least one injector, the drive circuit comprising:
first charge storage means for operative connection with one of the at least one injectors during a discharging phase so as to permit a discharge current to flow therethrough, thereby to initiate an injection event; second charge storage means for operative connection with the at least one injector during a charging phase so as to cause a charge current to flow therethrough, thereby to terminate the injection event; switch means for controlling whether the first charge storage means is operably connected to the at least one injector or whether the second charge storage means is operably connected to the at least one injector, a first voltage rail at a first voltage level; a second voltage rail at a second voltage level higher than the first voltage level; a voltage supply means; and regeneration switch means operable at the end of the charging phase to transfer charge from the voltage supply means to at least the second charge storage means via an energy storage device, prior to a subsequent discharging phase.
[0017] Preferably the first charge storage means is connected across the first voltage rail and ground, and the second charge storage means is connected across the first and second voltage rails.
[0018] In a first embodiment of the present invention, the regeneration switch means is preferably operable at the end of the charging phase to transfer charge from the voltage supply means to the first charge storage means, and then to the second charge storage means from the first charge storage means via the energy storage device. Most preferably, the regeneration switch means is used to transfer charge from the voltage supply means to both the first and second voltage rails such that the voltage across the first and second charge storage means is increased. In this embodiment, the voltage supply means advantageously comprises a vehicle battery and a transformer to step-up the voltage generated by the vehicle battery to a higher voltage suitable for applying to the first charge storage means. An advantage of this embodiment of the present invention is that the voltage supply means is only used to increase the charge on the first charge storage means, and therefore a smaller and cheaper voltage supply means may be used than in known drive circuits. A further advantage of this embodiment of the present invention is that if the voltage supply means provides a 42 Volt charging system, and the injectors are operable at a similar voltage, then a transformer may not be required, thereby leading to a further reduction in the size and cost of the voltage supply means.
[0019] In a second embodiment of the present invention, the regeneration switch means is preferably operable at the end of the charging phase to transfer charge from the voltage supply means to the first charge storage means and also to the second charge storage means prior to the subsequent discharging phase. Most preferably, the regeneration switch means is used to transfer charge from the voltage supply means to the second voltage rail such that the voltage across the second charge storage means is increased (the first voltage rail being supplied by the voltage supply means). Preferably the voltage supply means comprises a vehicle battery, and advantageously no transformer is required to step up the voltage generated by the vehicle battery. The advantage of this embodiment is that there is no need to provide a dedicated power supply (such as a transformer) which leads to a cheaper and more controllable drive circuit than those known in the prior art
[0020] If injectors which are operable at approximately −12 Volts are utilised in the drive circuit, then the ratio of the capacitance of the first charge storage means to the second charge storage means is preferably selectable to achieve the required injector negative operating voltage.
[0021] In both embodiments of the present invention, the drive circuit may further comprise a switch means including a first switch (such as a “charge” switch) operable to close to activate the charging phase, and a second switch (such as a “discharge” switch) operable to close to activate the discharging phase. Thus, in the first embodiment, the regeneration switch means is preferably arranged to transfer charge from the voltage supply means to the second charge storage means in response to the operation of the second switch, as charge is supplied to the first charge storage means by the voltage supply means. However, in the second embodiment, the regeneration switch means is preferably arranged to transfer charge from the voltage supply means to the first and second charge storage means in response to the operation of the second switch.
[0022] The regeneration switch means need not be operable between all injection events, but may be selectively operable between only some injection events.
[0023] Preferably the first and second charge storage means comprise capacitors, and the energy storage device is an inductor.
[0024] Preferably the drive circuit includes first and second injectors which are arranged in parallel and operatively connected to the switch means, the regeneration switch means, and a further switch means for controlling independent selection of the first or second injector to permit a discharging current to be supplied to the selected injector during a discharge phase so as to initiate an injection event
[0025] The drive circuit is preferably configured as a half H-bridge circuit having a middle circuit branch, with the first and second injectors being arranged in parallel in the middle circuit branch.
[0026] The drive circuit may also include voltage sensing means for sensing the voltage across the selected injector (and also the unselected injector, if desired), and control means for receiving a signal indicative of the sensed voltage and providing a termination control signal to the further switch means to terminate the charging phase of the selected injector once a predetermined charge threshold voltage is sensed. The control means may also be arranged to provide an initiate signal to the switch means to initiate the charging phase of the selected injector. The control means may also be arranged to provide an initiate control signal to the switch means to initiate the discharge mode of the selected injector, and to provide a terminate control signal to the switch means to terminate the discharge phase once a predetermined threshold discharge voltage is sensed.
[0027] The drive circuit may also include sensing means for sensing the voltage on the first and second capacitors. The control means may also be arranged to provide an initiate signal to initiate the regeneration phase of the circuit, and to provide a terminate signal to terminate the regeneration phase.
[0028] The control means may further be arranged to provide a pulse width modulated signal to alternately enable and disable the discharge switch (i.e. to pulse the discharge switch on and off) during the regeneration phase.
[0029] By “enabling” the discharge switch, it is meant that the discharge switch is put in a state so that it may be activated (i.e. closed), whether under the direct control of the microprocessor via a pulse width modulated signal, by the regeneration current falling below a predetermined current level, or via any other suitable method. Similarly, by “disabling” the discharge switch, it is meant that the discharge switch is put in a state so that it cannot be activated without first being enabled.
[0030] The drive circuit of the present invention is appropriate for controlling a bank of at least two injectors, with each injector being arranged to inject fuel to an associated combustion space or engine cylinder. The bank may include any number of injectors, and an engine may have more than one injector bank, depending on the number of engine cylinders. The drive circuit is equally applicable, however, to controlling just a single injector. Due to the drive circuit of the present invention having first and second voltage rails, the drive circuit operates in a bi-directional manner and is therefore suitable for driving bi-polar fuel injectors which require both positive and negative voltages for their operation.
[0031] According to a second aspect of the present invention there is provided a control method for an injector arrangement having at least one injector, the method comprising: operably connecting a first charge storage means to one of the at least one injectors during a discharging phase so as to cause a discharge current to flow therethrough, thereby to initiate an injection event; operably connecting a second charge storage means with the at least one injector during a charging phase so as to cause a charge current to flow therethrough, thereby to terminate the injection event; activating a regeneration switch means at the end of the charging phase to initiate a regeneration phase wherein charge is transferred from a voltage supply means to an energy storage device, and transferred from the energy storage device to at least the second charge storage means prior to the subsequent discharging phase; and deactivating the regeneration switch means to terminate the regeneration phase.
[0032] In one embodiment of the present invention, during the activating step charge is transferred from the voltage supply means to the energy storage device, and subsequently transferred from the energy storage device to the first and second charge storage means. In another embodiment of this aspect of the invention, during the activating step charge is transferred from the voltage supply means to the first charge storage means, and subsequently transferred from the first charge storage means to the energy storage device for transfer to the second charge storage means.
[0033] Preferably the steps of transferring charge to and from the energy storage device are carried out periodically, most preferably under the control of a pulse-width modulated (PWM signal.
[0034] The efficiency of the fuel injectors determines how much energy is removed from the first and second charge storage means, and also determines a peak current in the energy storage device over a period of time to regenerate the charge stored on the first and second charge storage means. In other words, the more efficient the injector, the less current in the energy storage device, and the shorter regeneration time required. It is therefore a preferable feature of the present invention that the regeneration time is controllable.
[0035] Preferably the method includes the further step of varying the characteristics (such as duty-cycle and modulating frequency) of the PWM signal. The duty-cycle required may depend upon the voltage of the voltage supply means. For example, if the voltage of the voltage supply means is low, then longer PWM ON times are required and, conversely, if the voltage of the voltage supply means is high, then shorter PWM ON times are necessary. The duty-cycle and/or modulating frequency of the PWM signal are optionally varied by the microprocessor, for example to directly actuate the regeneration switch means. Preferably, the characteristics of the PWM signal may be controlled by allowing the drive circuit to detect the current in the energy storage device by starting a normal discharge event, but selecting the regeneration switch means rather than an injector.
[0036] The method may include the further step of controlling whether the first or second charge storage means is operably connected to the injector.
[0037] The method may also include the steps of providing a regeneration initiate signal to activate the regeneration switch means and hence begin the regeneration phase, and providing a regeneration terminate signal to deactivate the regeneration switch means and thus terminate the regeneration phase.
[0038] Preferably the regeneration initiate signal may be provided after each injection event. Alternatively, the regeneration initiate signal may be provided after a predetermined number of injection events. That is, the regeneration phase may be carried out between injection events. Advantageously, the regeneration phase is carried out for a period necessary to maintain a constant charge on the first and second charge storage means.
[0039] It will be appreciated that although the present invention is particularly applicable to an injector system in which the injectors have piezoelectric actuators, it is equally applicable to any system in which the injectors have capacitive-like properties, for example motor-driven injectors.
BRIEF DESCRIPTION OF DRAWINGS
[0040] Preferred embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0041] FIG. 1 is a block diagram illustrating a drive circuit according to preferred embodiments of the present invention for controlling a piezoelectric fuel injector in an engine;
[0042] FIG. 2 a is a circuit diagram illustrating the piezoelectric drive circuit of FIG. 1 , according to a first embodiment of the present invention;
[0043] FIG. 2 b shows the circuit diagram of FIG. 2 a indicating the current flow path during a regeneration phase of operation of the circuit;
[0044] FIG. 3 a is a graph to illustrate the energy levels in a first capacitor in the drive circuit of FIG. 2 during operation of the drive circuit;
[0045] FIG. 3 b is a graph illustrating the energy levels in a second capacitor in the drive circuit of FIG. 2 during operation of the drive circuit;
[0046] FIG. 3 c is a graph showing the current in an inductor, the pulsing of a discharge switch, and the activation of a regeneration switch in the drive circuit of FIG. 2 during operation of the drive circuit;
[0047] FIG. 3 d is a graph to illustrate a drive pulse applied to a fuel injector to initiate and terminate an injection event;
[0048] FIG. 3 e illustrates the enabling/disabling and activation/deactivation of a switch during operation of the drive circuit of FIG. 2 ;
[0049] FIG. 4 is a circuit diagram illustrating the piezoelectric drive circuit of FIG. 1 , and the current flow path through the circuit during the regeneration phase of operation of the circuit, according to a second embodiment of the present invention;
[0050] FIG. 5 a is a graph illustrating the energy levels in the first capacitor in the drive circuit of FIG. 4 during operation of the drive circuit;
[0051] FIG. 5 b is a graph illustrating the energy levels in the second capacitor in the drive circuit of FIG. 4 during operation of the drive circuit; and
[0052] FIG. 5 c is a graph illustrating the current in the inductor, and the drive pulse applied to a fuel injector to initiate and terminate an injection event.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0053] Referring to FIG. 1 , an engine 10 , such as an automotive vehicle engine, is generally shown having a first and second piezoelectric fuel injectors 12 a and 12 b for metering and injecting fuel into individual cylinders or an intake manifold of the engine 10 . The piezoelectric fuel injectors 12 a and 12 b control the amount of fluid (e.g., liquid) fuel injected from a fuel rail of a fuel delivery system into an engine during each fuel injection stroke of the engine 10 . The piezoelectric fuel injectors 12 a and 12 b may be employed in a diesel engine to inject diesel fuel into the engine, or may be employed in a spark ignited internal combustion engine to inject combustible gasoline into the engine. While two piezoelectric fuel injectors 12 a and 12 b are shown and described in the embodiment of FIG. 1 , it should be appreciated that the engine 10 may include more piezoelectric fuel injectors, all of which could be controlled by a common drive circuit.
[0054] The engine 10 is generally controlled by an engine control module (ECM) 14 . The ECM 14 generally includes a microprocessor and memory 16 for performing various control routines for controlling the operation of the engine 10 , including control of the fuel injection. The ECM 14 may monitor engine speed and load and control the amount of fuel and injection timing for injecting fuel into the engine cylinder. Also included in the microprocessor and memory 16 is a pulse-width modulated signal generator 24 for generating pulse-width modulated (PWM signals 26 , the purpose of which will be described in detail later.
[0055] According to the present invention, a piezoelectric half H-bridge drive circuit 20 a , 20 b is shown integrated into the engine control module 14 . The drive circuit 20 a , 20 b is arranged to monitor and control the injector high side voltages INJ 1 HI, INJ 2 HI and injector low side voltages INJ 1 LO, INJ 2 LO to control actuation of the piezoelectric fuel injectors 12 a and 12 b to open and close the injectors. The piezoelectric drive circuit 20 a , 20 b may be integrated in the engine control module 14 as shown, or may be provided separate therefrom. The microprocessor and memory 16 provide various control signals 18 , 26 to the drive circuit 20 a , 20 b .
[0056] The piezoelectric drive circuit 20 a , 20 b as shown and described herein operates in a discharge phase which discharges an injector 12 a , 12 b to open the injector valve to inject fuel, and further operates in a charge phase which charges an injector 12 a , 12 b to close the injector valve to prevent injection of fuel. In this case, the injectors are of the negative-charge displacement type. However, the drive circuit 20 a , 20 b and injectors 12 a and 12 b could be otherwise configured to open during a charge phase and close during a discharge phase, wherein the injectors are of the positive-charge displacement type.
[0057] The piezoelectric drive circuit 20 a , according to a first embodiment of the present invention, is illustrated in detail in the block/circuit diagram of FIG. 2 a The drive circuit 20 a includes first and second voltage supply rails V 0 and V 1 , and is generally configured as a half H-bridge having a middle circuit current path 32 which serves as a bi directional current path. The middle circuit branch 32 includes an inductor L 1 coupled in series with a parallel connection of the injectors 12 a and 12 b and associated switching circuitry. Each injector 12 a and 12 b has the electrical characteristics of a capacitor, with its piezoelectric actuator stack being chargeable to hold a voltage which is the potential difference between the charge (+) and discharge (−) terminals of the injector 12 a and 12 b . Charging and discharging of each injector 12 a , 12 b is achieved by controlling the flow of current through the bidirectional current path 32 by means of the microprocessor 16 .
[0058] The drive circuit 20 a further includes first and second switches Q 1 and Q 2 for controlling the charge and discharge operations of the injector 12 a and/or 12 b . The switches Q 1 and Q 2 may each include an n-channel insulated gate bi-polar transistor (IGBT) having a gate controlling current flow from the collector to the emitter. Each of switches Q 1 and Q 2 allows for unidirectional current flow from the collector to the emitter when turned on, and prevents current flow when turned off. Each switch Q 1 ,Q 2 has a respective recirculation diode D 1 ,D 2 connected across it to allow a recirculation current to return to energy storage capacitors C 1 ,C 2 during an energy recovery or recirculation phase of operation of the circuit, and also a regeneration phase, as described in detail below. The first energy storage capacitor C 1 is connected across the first and second voltage supply rails V 0 and V 1 , whereas the second energy storage capacitor C 2 is connected across the first voltage supply rail V 0 and ground.
[0059] The drive circuit 20 a also includes a voltage source 22 such as a vehicle battery. However, unlike known drive circuits for injector arrangements, the drive circuit 20 a of the first embodiment of the present invention does not include a dedicated power supply for supplying energy to the first C 1 and second C 2 energy storage capacitors, such as that indicated by the dashed lines 85 in FIG. 2 a.
[0060] Each of the injectors 12 a , 12 b is connected in series with an associated selector switch Q 3 ,Q 4 . Each selector switch Q 3 ,Q 4 typically takes the form of an IGBT having a gate coupled to a gate drive which is powered at a bias supply input When the selector switch Q 3 associated with the first injector 12 a , for example, is activated (i.e. switched on), current flow (I DISCHARGE ) is permitted in a discharge direction through the selected injector. A diode D 3 is connected in parallel with the selector switch Q 3 to allow current (I CHARGE ) to flow in the charge direction during the charging phase of operation of the circuit. Similarly, a diode D 4 is connected in parallel with the selector switch Q 4 for the second injector 12 b.
[0061] A regeneration switch Q 5 is included in the circuit 20 between the inductor L 1 and the vehicle battery 22 , for connecting (and disconnecting) the battery to the first C 1 and second C 2 capacitors. The regeneration switch Q 5 typically takes the form of an IGBT having a gate coupled to a gate drive which is powered at a bias supply input. A diode D 5 is connected in series with the regeneration switch Q 5 for preventing current from flowing therethrough during the charge phase.
[0062] The middle circuit path 32 further includes a current sensing and control means 34 arranged to sense the current in the path 32 , to compare the sensed current with predetermined current thresholds I P and I R , and to generate output signals, where I P is the peak current threshold, and I R is the recirculation current threshold. Predetermined values for I P and I R are stored in the microprocessor and memory 16 , along with a charge voltage threshold (V CHARGE ), and a discharge voltage threshold (V DISCHARGE ). Predetermined voltage levels V gc1 and V gc2 across capacitors C 1 and C 2 , for determining when the regeneration phase is to be terminated, may also be stored in the microprocessor and memory 16 . If required, the current thresholds I P and I R , the voltage thresholds, V CHARGE and V DISCHARGE , and the voltage levels, V gc1 and V gc2 , may be adjustable.
[0063] A voltage sensing means (not shown) is also provided to sense the voltage, V SENCE , across the injector 12 a , 12 b that is selected for injection. The voltage sensing means may also be used to sense the voltages V C1 and V C2 across the first C 1 and second C 2 capacitors, and the vehicle battery 22 voltage. The microprocessor and memory 16 further provides a charge/discharge signal C/D (which may be used to enable and disable a switch), an injector selector for selecting one of the injectors during the discharge operation, and a control signal for activating the regeneration switch Q 5 .
[0064] The drive circuit 20 a also includes control logic 30 for receiving the output of the current sensing and control means 34 , the sensed voltage, V SENCE , from the positive terminal (+) of the injectors 12 a andl 2 b , and the various output signals from the microprocessor and memory 16 . The control logic 30 may include software executed by the microprocessor and memory 16 for processing the various inputs so as to generate control signals for each of the charge/discharge switches Q 1 , Q 2 , the selector switches Q 3 , Q 4 , and the regeneration switch Q 5 .
[0065] During operation of the drive circuit 20 a , a drive pulse (or voltage waveform) is applied to the piezoelectric actuator of the fuel injectors 12 a and 12 b . The drive pulse varies between the charging voltage, V CHARGE , and the discharging voltage, V DISCHARGE . When the injector 12 a is in a non-injecting state, prior to injection, the drive pulse is at V CHARGE so that a relatively high voltage is applied to the piezoelectric actuator. Typically, V CHARGE is around 200 to 300 V. When it is required to initiate an injection event, the drive pulse is reduced to V DISCHARGE , which is typically around −100 V. To terminate injection, the voltage of the drive pulse is increased to its charging voltage level, V CHARGE once again.
[0066] The drive circuit 20 a generally operates in three phases: (1) a discharge phase to open a selected one of the fuel injectors 12 a , 12 b ; (2) a charge phase to close the fuel injectors 12 a andl 2 b ; and (3) a regeneration phase for re-energising the energy storage devices C 1 and C 2 in the circuit 20 a such that a dedicated power supply is not required. Each of these phases will now be described in detail.
[0067] During the discharge phase, the discharge switch Q 2 is activated (i.e. closed) and one of the selector switches Q 3 and Q 4 is activated to select one of injectors 12 a and 12 b for injection. So, for example, if it is required to inject with the first injector 12 a , the selector switch Q 3 is closed. The other selector switch Q 4 for the second injector 12 b remains deactivated as the second injector 12 b is not required to inject.
[0068] Assuming that it is desired to inject using the first injector 12 a , upon activation of the discharge switch Q 2 , current is allowed to flow directly from the voltage supply 22 across the capacitor C 2 , through the current sensing and control means 34 , through the selector switch Q 3 , and into the corresponding negative side of the selected injector 12 a . A discharge current I DISCHARGE flows from the injector load for injector 12 a , through the inductor L 1 , through the closed discharge switch Q 2 , and back to the negative terminal of the capacitor C 2 . As the selector switch Q 4 remains open, and due to the presence of the diode D 4 , substantially no current is able to flow through the second injector 12 b into the negative side of the injector 12 b.
[0069] The current sensing and control means 34 monitors the current flow through the bi-directional current path 32 as it builds up and, as soon as the peak current threshold I P is reached, an output signal is generated to initiate de-activation (i.e. opening) of the discharge switch Q 2 . At this point, the current that is built-up in the inductor L 1 recirculates through the diode D 1 associated with the charge switch Q 1 . As a consequence, the direction of current flow through the inductor L 1 and the selected one of the injectors 12 a and 12 b does not change. This is known as the “recirculation phase” of the discharging phase of operation of the drive circuit 20 a.
[0070] During the recirculation phase, current flows directly from the negative side of the capacitor C 1 , through the current sensing and control means 34 , through the selected switch Q 3 , through the selected injector 12 a , through the inductor L 1 , and finally through the diode D 1 and into the positive side of capacitor C 1 . During this recirculation phase, energy from the inductor L 1 and the selected one of the piezoelectric injectors 12 a or 12 b is transferred to the capacitor C 1 for energy storage therein.
[0071] The current sensing and control means 34 monitors the recirculation current, and when the recirculation current has fallen below the recirculation current threshold IR, a signal is generated to reactivate the discharge switch Q 2 , thereby continuing the discharge operation. The voltage V inj1 or V inj2 across the selected injector 12 a or 12 b is also monitored by the voltage sensing means (not shown), and the cycle of current buildup and recirculation continues until the appropriate discharge voltage level (threshold V DISCHARGE ) has been achieved.
[0072] In this discharge cycle, the capacitor C 2 provides energy, while the capacitor C 1 receives energy for storage. Once the appropriate discharge voltage threshold V DISCHARGE is achieved, the half H-bridge drive circuit 20 a is deactivated until a charge cycle is initiated.
[0073] In order to charge (i.e. close) the first injector 12 a , the charge switch Q 1 is activated, thus allowing a charge current I CHARGE to flow through the current path 32 and to the first injector 12 a . This is known as the charging phase of operation of the drive circuit 20 a During the charging phase, the majority of the charge current I CHARGE will flow through the previously discharged injector (i.e. the first injector 12 a ). The second injector 12 b that was not previously discharged will receive current if the corresponding voltage V inj2 across it has dropped below the charge voltage threshold V CHARGE .
[0074] The current sensing and control means 34 monitors the current buildup, and as soon as the peak current threshold I P is reached, the control logic 30 generates a control signal to open the charge switch Q 1 . At this point, the current that is built up in inductor L 1 recirculates through the diode D 2 associated with the (open) discharge switch Q 2 . This is the recirculation phase of the charging phase of operation of the drive circuit 26 . Thus, the direction of current flow through the inductor L 1 and injectors 12 a and 12 b does not change.
[0075] During the recirculation phase, current flows from the negative side of the second capacitor C 2 , through the diode D 2 associated with the discharge switch Q 2 , through the inductor L 1 and the injectors 12 a and 12 b , through the diodes D 3 and D 4 , and the current sensing and control means 34 , and into the positive side of energy storage capacitor C 2 . During this recirculation phase, energy from the inductor L 1 and piezoelectric injectors 12 a and 12 b is transferred to the energy storage capacitor C 2 . The current sensing and control means 34 monitors the recirculation current, and when the recirculation current has fallen below the recirculation current threshold I R , a signal is generated to reactivate the charge switch Q 1 to continue the charge process. The voltage across the selected injector 12 a is monitored, and the cycle of current buildup and recirculation continues until the appropriate charge voltage level (threshold V CHARGE ) has been achieved. In this charging phase, the energy storage capacitor C 1 provides energy, and the energy storage capacitor C 2 receives energy for storage. Once the appropriate charge voltage threshold V CHARGE is achieved, the half H-bridge drive circuit 20 a is deactivated until a discharge cycle is initiated.
[0076] Following the charging phase, at the end of the injection event, the regeneration phase follows. During the regeneration phase, the regeneration switch Q 5 (which has remained deactivated during the charge and discharge phases) is activated, and the discharge switch Q 2 is opened and closed, under the control of the pulse-width modulated signal 26 , until the voltages across the first C 1 and second C 2 capacitors reach predetermined levels (i.e. V gc1 and V gc2 in FIGS. 3 a and 3 b , respectively).
[0077] Referring to FIG. 2 b , with the regeneration switch Q 5 activated, while the discharge switch Q 2 is switched on, current is drawn from the vehicle battery 22 and passes through the inductor L 1 and the discharge switch Q 2 , as illustrated by the dashed arrows 87 . When the discharge switch Q 2 is switched off, current flows from the vehicle battery 22 , through the inductor L 1 , through diode D 1 associated with charge switch Q 1 , and passes through capacitors C 1 and C 2 (from positive to negative) such that the voltage V C1 and V C2 across the capacitors C 1 and C 2 increases and the energy stored thereon increases. Thus, during the regeneration phase, the inductor L 1 elevates the battery voltage to increase the voltage on the first and second voltage supply rails V 0 and V 1 such that the voltage across the capacitors C 1 and C 2 also increases (i.e., the inductor L 1 acts as a power supply means). The path of the current during the regeneration phase is illustrated by the solid arrows 89 in FIG. 2 b.
[0078] Referring now to FIGS. 3 a and 3 b , the energy Ec 1 and Ec 2 stored on the capacitors C 1 and C 2 are shown during discharge, charge and regeneration phases.
[0079] The energy E C1 stored on the capacitor C 1 (given by line 40 A in FIG. 3 a ) is shown increasing via waveform 42 A having spikes 46 A during the discharge phase, and decreasing via waveform 44 A having spikes 48 A during the charge phase. Waveform 50 A shows the energy stored on the capacitor C 1 increasing during the regeneration phase while the discharge switch Q 2 is pulsed on and off. Spikes 52 A are also shown illustrating that energy is transferred to the first capacitor C 1 every time the discharge switch Q 2 is switched between activated (closed) and de-activated (open) states.
[0080] The energy Ec 2 stored on the capacitor C 2 (given by line 40 B in FIG. 3 b ) is shown decreasing via waveform 42 B having spikes 46 B during the discharge phase, and increasing via waveform 44 B having spikes 48 B during the charge phase. Waveform 50 B shows the energy stored on the capacitor C 2 increasing during the regeneration phase while the discharge switch Q 2 is pulsed on and off. Spikes 52 B are also shown illustrating that energy is transferred to the second capacitor C 2 every time the discharge switch Q 2 is switched between activated (closed) and deactivated (open) states.
[0081] FIG. 3 c shows the current I L1 through the inductor L 1 , the switching on and off of the discharge switch Q 2 , and the switching on and off of the regeneration switch Q 5 during charge, discharge and regeneration phases.
[0082] The inductor current I L1 (given by line 50 ) is shown ramping down to approximately minus twenty amps (−20 A) during current buildup and decaying back to about minus five amps (−5 A) during the recirculation phase of the discharge phase as shown by spikes 56 of waveform 52 . During the charge phase, the inductor current I L1 increases from about zero amps to approximately twenty amps (+20 A) during current buildup, and ramps back down to approximately five amps (+5 A) during the recirculation phase, as shown by spikes 58 of waveform 54 . The spikes 56 and 58 of current I L1 occur for as long as the voltage V C2 or V C1 is applied to discharge or charge the injector voltage V inj1 , as shown in FIG. 3 d . Waveform 70 illustrates the inductor current I L1 periodically decreasing from about zero amps to approximately minus 15 amps (−15 A) during the pulsing of the discharge switch Q 2 during the regeneration phase (i.e. when regeneration switch Q 5 is activated, as shown by the dashed line 78 ). The waveform 72 represents the control signal applied to the discharge switch Q 2 to activate and deactivate the switch. So, for example, the waveform 74 illustrates the pulsing of the discharge switch Q 2 during the recirculation phase of the discharge phase, while the waveform 76 represents the pulse-width modulated pulsing of the discharge switch Q 2 during the regeneration phase of the circuit operation.
[0083] FIG. 3 d shows the charge/discharge voltage V inj1 across the injector 12 a during charge, discharge and regeneration phases. The injector voltage V inj1 , shown by line 60 in FIG. 3 d , shows the voltage V inj1 of the first injector 12 a decreasing in waveform 62 during the discharge phase and increasing in waveform 64 during the charge phase. Line 66 shows the voltage V inj1 of the first injector 12 a remaining substantially constant during the regeneration phase of the circuit operation.
[0084] In summary, when it is required to inject with a selected injector (e.g. the first injector 12 a ), the discharge switch Q 2 and the selector switch Q 3 of the first injector are both closed. During the discharge and recirculation phases that follow, the discharge switch Q 2 is automatically opened and closed until the voltage across the selected injector 12 a is reduced to the appropriate voltage discharge level (i.e. V DISCHARGE , as shown in FIG. 3 d ) to initiate injection. After a predetermined time for which injection is required, closing of the injector 12 a is achieved by closing the charge switch Q 1 , causing a charging current to flow through the first and second injectors 12 a and 12 b . During the subsequent charging and recirculation phases, the charge switch Q 1 is continually opened and closed until the appropriate charge voltage level is achieved (i.e. V CHARGE , as shown in FIG. 3 d ). During the regeneration phase, the regeneration switch Q 5 is activated, and the discharge switch Q 2 is periodically opened and closed under the control of the pulse-width modulated signal 26 until the voltage across the first C 1 and second C 2 capacitors reaches a predetermined level (i.e. V gc1 and V gc2 in FIGS. 3 a and 3 b , respectively).
[0085] Although the operation of the circuit 20 a in the charge, discharge and regeneration phases has been explained with reference to the activation of the charge and discharge switches Q 1 and Q 2 , in practice charge, discharge and regeneration of the injectors 12 a and 12 b can be controlled in a number of ways. Firstly, operation of the circuit 20 a in these phases can be carried out by enabling the charge switch Q 1 or discharge switch Q 2 , and using the peak current and recirculation current thresholds I P and I R to control the activation and deactivation of the charge switch or discharge switch (mode 1 ). Or, both activation and deactivation of the charge Q 1 or discharge Q 2 switches can be carried out under the direct control of the microprocessor 16 by pulsing the charge/discharge signal C/D (mode 2 ). Alternatively, the enabling of the charge switch or discharge switch can be carried out under the direct control of the microprocessor 16 , and the deactivation of the charge switch or discharge switch can occur when the current flowing in the bidirectional path 32 falls below a reduced recirculation current threshold I R (mode 3 ).
[0086] The aforedescribed modes are illustrated in FIG. 3 e , where plot (a) firstly illustrates the current I INJ1 , flowing in the first injector 12 a during a discharge phase (although the plot is equally applicable to the charge phase of operation). It can be seen that the current in the bidirectional path 32 is oscillating between the peak current threshold I P and the recirculation current threshold I R . Plot (b) illustrates the C/D signal changing from low (disable) to high (enable) to enable the discharge switch Q 2 during the discharge phase. Plot (c) shows the discharge switch Q 2 switching on as the current reaches I P , and switching off when the current falls to below I R . Mode 2 is illustrated in plots (d) and (e) where the C/D signal (shown in plot (d)) is pulsed to enable and disable the discharge switch Q 2 (shown in plot (e)).
[0087] A drive circuit 20 b according to a second embodiment of the present invention is shown in FIG. 4 . The drive circuit 20 b is generally configured as the drive circuit 20 a of the first embodiment of the invention, with like components having identical reference numerals. As for the first drive circuit 20 a , the second drive circuit 20 b has first and second voltage supply rails V supply and V 1 , and is generally configured as a half H-bridge having a middle circuit path 32 which serves as a bidirectional current path. The drive circuit 20 b also includes an inductor L 1 coupled in series with a parallel connection of injectors 12 a and 12 b . The second drive circuit 20 b also includes a first (charging) switch Q 1 and a second (discharging) switch Q 2 at opposite corners of the half H-bridge arrangement, with each switch having a respective recirculation diode D 1 and D 2 connected across it to allow a recirculation current to return to the first C 1 and second C 2 energy storage capacitors during the recirculation phase, and a regeneration current I regen to flow to the energy storage capacitors during the regeneration phase.
[0088] The second drive circuit 20 b also includes a voltage source 22 , such as a vehicle battery, which may be connected to an optional power supply unit (PSU) 36 . The power supply unit 36 (if required) is connected between ground and the voltage rail, V supply , (which is a low voltage rail) and is arranged to supply energy to the second energy storage capacitor C 2 . The first energy storage capacitor C 1 is connected across the first and second voltage supply rails V supply and V 1 , whereas the second energy storage capacitor C 2 is connected across the first voltage supply rail V supply and ground.
[0089] Each of the injectors 12 a and 12 b is connected in series with an associated selector switch Q 3 and Q 4 , and each selector switch has an associated diode D 3 and D 4 . The function of the selector switches and associate diodes is as described for the first drive circuit 20 a.
[0090] A regeneration switch Q 5 is included in the circuit 20 b in parallel with the first 12 a and second 12 b injectors, for connecting the second energy storage capacitor C 2 to the inductor L 1 . The regeneration switch Q 5 typically takes the form of an IGBT having a gate coupled to a gate drive which is powered at a bias supply input. The regeneration switch Q 5 has an associated protection diode D 5 connected in parallel thereto. A further diode D 6 is connected in series with the regeneration switch Q 5 for preventing current flowing therethrough during the charge phase.
[0091] The middle circuit path 34 further includes a current sensing and control means 34 which has the same function as in the first circuit 20 a and will therefore not be described further. A voltage sensing means (not shown) is also provided, as previously described.
[0092] The operation of the second drive circuit 20 b is generally as described for the first drive circuit 20 a , but with some differences during the regeneration phase of operation of the circuit due to the presence of the voltage supply 22 (and optionally the PSU 36 ) being connected to the V supply rail of the circuit.
[0093] As for the first embodiment of the invention, the regeneration phase follows the charging phase, at the end of the injection event. During the regeneration phase, the regeneration switch Q 5 (which has remained in its deactivated state during the charge and discharge phases) is activated, and the discharge switch Q 2 is opened and closed, under the control of the pulse-width modulated signal 26 , until the energy on the first C 1 capacitor reaches a predetermined level (i.e. E C1 in FIG. 5 a ). As in the first embodiment of the invention, the discharge switch Q 2 may be enabled during the regeneration phase (and the charge/discharge phases) in the manner previously described.
[0094] Referring again to FIG. 4 , with the regeneration switch Q 5 activated, while the discharge switch Q 2 is on, current is drawn from the vehicle battery 22 (or the PSU 36 ) and passes through the regeneration switch Q 5 , the diode D 6 , the inductor L 1 , the discharge switch Q 2 , and through the second energy storage capacitor C 2 (as illustrated by the dashed arrows) such that the energy on the second capacitor C 2 decreases. When the discharge switch Q 2 is switched off, current flows from the first capacitor C 1 , through the regeneration switch Q 5 , the diode D 6 , the inductor L 1 , and the diode D 1 associated with the charge switch Q 1 , such that the energy on the first capacitor C 1 increases (shown by the bold arrows). Thus, during the regeneration phase in the second embodiment of the invention, the inductor L 1 transfers energy from the second energy storage capacitor C 2 to the first energy storage capacitor C 1 , and the vehicle battery 22 (or the PSU 36 ) maintains the voltage on C 2 . Thus, the regeneration phase is used to transfer battery voltage to the second voltage supply rail V 1 such that the voltage across the first energy storage capacitor C 1 increases.
[0095] Referring now to FIGS. 5 a and 5 b , the energy E C1 and E C2 stored on the first C 1 and second C 2 capacitors is shown during the discharge, charge and regeneration phases.
[0096] The energy E C1 stored on the first capacitor (given by line 40 A in FIG. 5 a ) is shown increasing via waveform 42 A having spikes 46 A during the discharge phase, and decreasing via waveform 44 A having spikes 48 A during the charge phase. Waveform 50 A shows the energy stored on the first capacitor C 1 increasing during the regeneration phase while the discharge switch Q 2 pulses on and off. Spikes 52 A are also shown, illustrating that energy is transferred to the first capacitor C 1 every time the discharge switch Q 2 switches between its activated (closed) and de-activated (open) states.
[0097] The energy E C2 stored on the second capacitor C 2 (given by line 40 B in FIG. 5 b ) is shown decreasing via waveform 42 B having spikes 46 B during the discharge phase, and increasing via waveform 44 B having spikes 48 B during the charge phase. Waveform 50 B shows the energy stored on the second capacitor decreasing during the regeneration phase while the discharge switch Q 2 is pulsed on and off. The spikes 52 B show that energy is transferred from the second capacitor C 2 (and onto the first capacitor C 1 ) every time the discharge switch Q 2 is switched between activated (closed) and deactivated (open) states.
[0098] FIG. 5 c shows the current I L1 , through the inductor L 1 , the charge/discharge voltage V inj1 across the injector 12 a during charge, discharge and regeneration phases. The inductor current I L1 , (given by line 50 ) is shown ramping down to approximately minus twenty five amps (−25 A) during current buildup, and decaying back to about minus five amps (−5 A) during the recirculation phase of the discharge phase, as shown by spikes of waveform 52 . During the charge phase, the inductor current I L1 increases from about zero amps to approximately twenty five amps (+25 A) during current buildup, and ramps back down to approximately five amps (+5 A) during the recirculation phase, as shown by the spikes of waveform 54 . The spikes of current I L1 , occur for as long as the voltage is applied to discharge or charge the injector voltage V inj1 . Waveform 70 illustrates the inductor current I L1 , periodically decreasing from about zero amps to approximately minus fifteen amps (−15 A) during the pulsing of the discharge switch Q 2 during the regeneration phase.
[0099] The injector voltage V inj1 (given by line 60 ) shows the voltage of the first injector 12 a decreasing in waveform 62 during the discharge phase, and increasing in waveform 64 during the charge phase. Line 66 shows the voltage V inj1 remaining substantially constant during the regeneration phase.
[0100] Having described preferred embodiments of the present invention, it is to be appreciated that the embodiments in question are exemplary only and that variations and modifications such as will occur to those possessed of the appropriate knowledge and skills may be made without departure from the scope of the invention as set forth in the appended claims.
[0101] For example, the piezoelectric injectors 12 a , and 12 b described herein operate in a discharge mode which discharges an injector to open the injector valve to inject fuel, and further operate in a charge mode which charges an injector to close the injector valve to prevent injection of fuel. In this case, the injectors are of the negative-charge displacement type. However, the drive circuits 20 a and 20 b described herein could be otherwise configured to open during a charge mode and close during a discharge mode for an injector of the positive-charge displacement type.
[0102] While two piezoelectric fuel injectors 12 a and 12 b are shown and described in connection with the drive circuits 20 a and 20 b of the present invention, it should be appreciated that the engine 10 may include one or more fuel injectors, all of which could be controlled by the drive circuits 20 a and 20 b.
[0103] The drive circuits 20 a and 20 b described herein maybe integrated in the engine control module 14 , or may be provided separate therefrom. | A drive circuit ( 20 a ,20 b ) for an injector arrangement having at least one piezeoelectric injector ( 12 a ,12 b ) is described. The drive circuit comprises: a first charge storage means (C 2 ) for operative connection with the injector ( 12 a ,12 b ) during a discharging phase so as to discharge current to flow therethrough, thereby to initiate an injection event; a second charge storage means (C 1 ) for operative connection with the injector ( 12 a ,12 b ) during a charging phase so as to cause a charging current to flow therethrough, thereby to terminate the injection event; a switch means (Q 1 ,Q 2 ) for controlling whether the first charge storage means (C 2 ) is operably connected to the injector or whether the second charge storage means (C 1 ) is operably connected to the injector; a first voltage supply rail at a first voltage level; a second voltage supply rail at a second voltage level higher than the first; a voltage supply means ( 22,36 ); and regeneration switch means (Q 5 ,Q 2 , L 1 ) operable at the end of the charging phase to transfer charge from the voltage supply means to at least the second charge storage means (C 1 ) via an energy storage device (L 1 ) prior to a subsequent discharging phase. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to the conversion of chemical energy to electrical energy, and more particularly, to an alkali metal electrochemical cell having a positive electrode comprising a cathode active admixture or formulation of a major portion of fluorinated carbon mixed with a minor portion of a metal-containing material. The metal-containing constituent is particularly useful as an end-of-service or end-of-life indicator for the cell.
2. Prior Art
It is known to provide composite cathodes comprising fluorinated carbon for the purpose of providing the cell with an end-of-service indicator. U.S. Pat. No. 5,180,642 to Weiss et al. discloses electrochemical cells having a cathode mixture comprised of manganese dioxide (MnO 2 ), carbon monofluoride (CF x ) or mixtures of the two and an end-of-service additive selected from the group consisting of vanadium oxide, silver vanadate, bismuth fluoride and titanium sulfide. U.S. Pat. No. 4,259,415 to Tamura et al. provides a positive active mixture as an end-of-service indicator comprising a main positive active material and a precursor. Suitable main positive active materials include molybdenum oxide (MoO 3 ), silver oxide (Ag 2 O) and graphite fluoride (CF) n while suitable precursor materials are oxyacid salts.
What is needed is a power source that is suitable for powering an implantable medical device wherein the battery includes a mixed cathode formulation of at least two active constituents which are characterized by two, discretely different operating voltages, the second of which may be used as an end-of-life indicator. Further, the provision of an end-of-life indicator must not be provided at the expense of safety especially under short circuit conditions. Compromise in this aspect can have fatal consequences.
SUMMARY OF THE INVENTION
The present invention is directed to the use of mixed cathode materials which are characterized by two, discretely different operating voltages, the second of which may be used as an end-of-life or end-of-service indicator. More particularly, the preferred mixed cathode material is a mixture of a major portion of fluorinated carbon and a minor portion of a second cathode active constituent selected from the group of a metal oxide, a mixed metal oxide, a metal halide, a metal sulfide and a metal chalcogenide, and mixture thereof. This mixed cathode material is preferably coupled with a lithium anode and activated with a nonaqueous electrolyte.
One active material which is particularly useful with the present invention is CuS. Copper sulfide mixed with fluorinated carbon provides a characteristic stepped discharge curve which is a useful end-of-service indicator. Also, short circuit testing of this combination cathode system in an alkali metal cell does not result in any increased safety risks. In addition, test results indicate that an alkali metal cell having a CF x /CuS cathode active admixture has higher rate capability than either of the active constituents, which is an unanticipated advantage of this combination cathode system.
These and other aspects of the present invention will become more apparent to those skilled in the art by reference to the following description and to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph constructed from the average discharge of two Li/CF x cells having a CuS cathode additive and discharged under a 1 kohm load with periodic open circuit storage.
FIG. 2 is a graph constructed from the average discharge of two Li/CF x cells devoid of a metal-containing additive and discharged under a 1 kohm load with periodic open circuit storage.
FIG. 3 is a graph constructed from the average discharge of two Li/CF x cells having a CuS cathode additive and discharged under a 5.1 kohm load with periodic open circuit storage.
FIG. 4 is a graph constructed from the average discharge of two Li/CF x cells devoid of a metal-containing additive and discharged under a 5.1 kohm load with periodic open circuit storage.
FIG. 5 is a graph constructed from the discharge of a Li/CF x cell having a Ag 2 O cathode additive and discharged under a 2 kohm load with periodic open circuit storage.
DETAILED DESCRIPTION OF THE INVENTION
The electrochemical cell of the present invention comprises an anode of a metal selected from Group IA of the Periodic Table of the Elements, including lithium, sodium, potassium, etc., and their alloys and intermetallic compounds including, for example, Li--Si, Li--Al, Li--Mg, Li--Al--Mg, Li--B and Li--Si--B alloys and intermetallic compounds. The form of the anode may vary, but typically, it is made as a thin sheet or foil of the anode metal, and a current collector having an extended tab or lead affixed to the anode sheet or foil.
The electrochemical cell of the present invention further comprises a cathode of electronically conductive composite material which serves as the other electrode of the cell. The electrochemical reaction at the cathode involves conversion of ions which migrate from the anode to the cathode into atomic or molecular forms. The composite cathode material of the present invention comprises at least a first cathode active constituent which preferably is a carbonaceous active material. The carbonaceous material preferably is prepared from carbon and fluorine, and includes graphitic and nongraphitic forms of carbon such as coke, charcoal or activated carbon. The fluorinated carbon is represented by the formula (CF x ) n wherein x varies between about 0.1 to 1.9 and preferably between about 0.5 and 1.2, and (C 2 F) n wherein the n refers to the number of monomer units which can vary widely. The preferred cathode active mixture comprises CF x combined with a discharge promoter component such as acetylene black, carbon black and/or graphite. Metallic powders such as nickel, aluminum, titanium and stainless steel in powder form are also useful as conductive diluents when mixed with the cathode active mixture of the present invention. If required, a binder material can also be used. Preferred binders comprise fluoro-resins in powdered form such as powdered polytetrafluoroethylene (PTFE) or powdered polyvinylidene fluoride (PVDF).
Active materials which are suitable as the second active constituent mixed with fluorinated carbon are generally selected from metal oxides, mixed metal oxides, metal sulfides, metal halides and metal chalcogenides. More particularly, the second cathode active constituent is selected from the group consisting of bismuth dioxide (Bi 2 O 3 ), bismuth lead oxide (Bi 2 Pb 2 O 5 ), copper sulfide (CuS), copper chloride (CuCl 2 ), copper oxide (CuO), iron sulfide (FeS), iron disulfide (FeS 2 ), molybdenum oxide (MoO 3 ), nickel sulfide (Ni 3 S 2 ), silver oxide (Ag 2 O), silver chloride (AgCl), copper vanadium oxide (CuV 2 O 5 ), silver vanadium oxide (AgV 2 O 5 .5), mercury oxide (HgO) and lead dioxide (PbO 2 ) and copper silver vanadium oxide (Cu x Ag y V 2 O z ). The latter active compound is described in U.S. Pat. No. 5,472,810 to Takeuchi et al., which is assigned to the assignee of the present invention and incorporated by reference. In some cases, mixtures of two or more of these active materials can be used as the second active constituent.
What is important is that the second active constituent is selected such that when mixed with the fluorinated carbon and incorporated into the electrochemical cell, should a short circuit occur, the cell will not experience a run-away electrochemical reaction that could eventually result in an explosive condition. Such an occurrence can be fatal, especially when the battery is used to power an implantable medical device.
A preferred cathode active admixture according to the present invention comprises from between about 60% to 85%, by weight, of the first cathode active constituent comprising fluorinated carbon, and from between about 15% to 40%, by weight, of the second cathode active constituent comprising the metal-containing material. A preferred admixture comprises, by weight, about 67% of the fluorinated carbon, about 26% of the second cathode active constituent, about 3% binder material and about 4% conductive diluents.
The blended cathode active admixture may be formed into a free-standing sheet prior to being contacted to a current collector to form the present cathode electrode. One preferred method of preparing a cathode material into a free standing sheet is thoroughly described in U.S. Pat. No. 5,435,874 to Takeuchi et al., which is assigned to the assignee of the present invention and incorporated herein by reference. Further, cathode components for incorporation into a cell according to the present invention may be prepared by rolling, spreading or pressing the cathode active formulations including one or more of the above listed metal-containing cathode active materials mixed with the fluorinated carbon constituent onto a current collector with the aid of a binder material. Suitable current collectors are comprised of a conductive metal including metals such as titanium, nickel, aluminum and stainless steel. Cathodes prepared as described above may be in the form of one or more plates operatively associated with at least one or more plates of anode material, or in the form of a strip wound with a corresponding strip of anode material in a structure similar to a "jellyroll".
In order to prevent internal short circuit conditions, the cathode is separated from the Group IA anode material by a suitable separator material. The separator is of electrically insulative material and the separator material also is chemically unreactive with the anode and cathode active materials and both chemically unreactive with and insoluble in the electrolyte. In addition, the separator material has a degree of porosity sufficient to allow flow therethrough of the electrolyte during the electrochemical reaction of the cell. Illustrative separator materials include fabrics woven from fluoropolymeric fibers including polyvinylidine fluoride, tetrafluoroethylene-ethylene copolymer (PETFE), and chlorotrifluoroethylene-ethylene copolymer. Fabrics woven from these fluoropolymeric fibers can be used either alone or laminated with a fluoropolymeric microporous film. Other suitable separator materials include non-woven glass polypropylene, polyethylene, glass fiber materials, ceramics, polytetrafluoroethylene membrane commercially available under the designation ZITEX (Chemplast Inc.), polypropylene membrane commercially available under the designation CELGARD (Celanese Plastic Company, Inc.) and a membrane commercially available under the designation DEXIGLAS (C. H. Dexter, Div., Dexter Corp.).
The electrochemical cell of the present invention further includes a nonaqueous, ionically conductive electrolyte which serves as a medium for migration of ions between the anode and the cathode electrodes during the electrochemical reactions of the cell. The electrochemical reaction at the electrodes involves conversions of ions in atomic or molecular forms which migrate from the anode to the cathode. Thus, nonaqueous electrolytes suitable for the present invention are substantially inert to the anode and cathode materials, and they exhibit those physical properties necessary for ionic transport, namely, low viscosity, low surface tension and wettability.
A suitable electrolyte has an inorganic, ionically conductive salt dissolved in a nonaqueous solvent, and more preferably, the electrolyte includes an ionizable alkali metal salt dissolved in an aprotic organic solvent or a mixture of solvents comprising a low viscosity solvent and a high permittivity solvent. The inorganic, ionically conductive salt serves as the vehicle for migration of the anode ions to intercalate into the cathode active material. Preferably the ion-forming alkali metal salt is similar to the alkali metal comprising the anode.
In a solid cathode/electrolyte system, the ionically conductive salt preferably has the general formula MM'F 6 or MM'F 4 wherein M is an alkali metal similar to the alkali metal comprising the anode and M' is an element selected from the group consisting of phosphorous, arsenic, antimony and boron. Examples of salts yielding M'F 6 are: hexafluorophosphate (PF 6 ), hexafluoroarsenate (AsF 6 ) and hexafluoroantimonate (SbF 6 ), while tetrafluoroborate (BF 4 ) is exemplary of salts yielding M'F 4 . Alternatively, the corresponding sodium or potassium salts may be used. Thus, for a lithium anode, the alkali metal salt of the electrolyte is selected from LiPF 6 , LiAsF 6 , LiSbF 6 and LiBF 4 . Other salts that are useful with a lithium anode include LiClO 4 , LiAlCl 4 , LiGaCl 4 , LiC(SO 2 CF 3 ) 3 , LIN(SO 2 CF 3 ) 2 and LiCF 3 SO 3 , and mixtures thereof.
Low viscosity solvents include tetrahydrofuran (THF), methyl acetate (MA), diglyme, trigylme, tetragylme, dimethyl carbonate (DMC), 1,2-dimethoxyethane (DE), diethyl carbonate and mixtures thereof, and high permittivity solvents include cyclic carbonates, cyclic esters and cyclic amides such as propylene carbonate (PC), ethylene carbonate (EC), acetonitrile, dimethyl sulfoxide, dimethyl formamide, dimethyl acetamide, γ-butyrolactone (GBL) and N-methyl-pyrrolidinone (NMP) and mixtures thereof. In the present invention, the preferred anode is lithium metal and the preferred electrolyte is 1.0M to 1.4M LiBF 4 in γ-butyrolactone (GBL).
The preferred form of the electrochemical cell is a case-negative design wherein the anode/cathode couple is inserted into a conductive metal casing such that the casing is connected to the anode current collector in a case-negative configuration, as is well known to those skilled in the art. A preferred material for the casing is titanium although stainless steel, nickel and aluminum are also suitable. The casing header comprises a metallic lid having a sufficient number of openings to accommodate the glass-to-metal seal/terminal pin feed through for the cathode electrode. The anode electrode is preferably connected to the case or the lid. An additional opening is provided for electrolyte filling. The casing header comprises elements having compatibility with the other components of the electrochemical cell and is resistant to corrosion. The cell is thereafter filled with the electrolyte solution described hereinabove and hermetically sealed such as by close-welded a stainless steel plug over the fill hole, but not limited thereto. The cell of the present invention can also be constructed in a case-positive design.
The following examples describe the manner and process of manufacturing an electrochemical cell according to the present invention, and they set forth the best mode contemplated by the inventors of carrying out the invention, but they are not to be construed as limiting.
EXAMPLE I
Prismatic, 8.6 mm Li/CF x cells of a central cathode design were used as the test vehicles. In particular, a group of control cells and a group of test cells was constructed to deliver a theoretical capacity of 2.47 Ah, with a 16% lithium excess based on theoretical capacity. Titanium screen served as the cathodic current collector, while the anode comprised lithium foil (0.75±0.01 g) pressed to a nickel screen.
Specifically, a group of test cells was built, designated as Cell Nos. 90360, 90362, 90364 and 90366 in Table 1, each having a cathode comprising a combination of CF x , CuS, PTFE binder and carbon black in the approximate amounts of 67%, 26%, 3%, and 4%, by weight, respectively. The control cells were built having cathodes comprised of CF x , PTFE binder, and carbon black in the approximate amounts of 91%, 4%, and 5%, by weight, respectively. The control cells are designated as Cell Nos. 90367, 90369, 90370 and 90373 in Table 1. The cathodes in both the test cells and the control cells were pressed to a titanium screen and then heat-sealed into a non-woven polypropylene separator envelope. One molar lithium tetrafluoroborate in gamma-butyrolactone served as the electrolyte (3.80±0.15 g).
Both the test cells and the control cells were preconditioned at 37° C. by discharge under a 1.5 kohm load for 18 hours. After a one week open circuit storage period at 37° C., a 20 mA acceptance pulse train, comprised of four pulses, each of a ten second duration immediately followed by a fifteen second rest period, was applied to each cell. The control cells and the test cells were then discharged under either a 1 kohm or a 5.1 kohm load. Closed circuit voltage (CCV) and 1 kHz impedance readings were recorded throughout discharge. AC impedance spectra were also recorded periodically throughout discharge. Specifically, test Cell Nos. 90360 and 90364 were discharged under a 1 kohm load, test Cell Nos. 90362 and 90365 were discharged under a 5.1 kohm load, control Cell Nos. 90369 and 90370 were discharged under a 1 kohm load and control cell Nos. 90367 and 90373 were discharged under a 5.1 kohm load.
It is known that the theoretical open circuit voltage (OCV) of a Li/CF x cell is approximately 3.3 V. Li/CuS cells discharge initially at 2.15 V as the first reduction of Cu(II) to Cu(I) occurs, and then at 1.85 V for the reduction of Cu(I) to Cu(0). As listed in Table 1, the last CCV recorded during cell conditioning is slightly higher on average for the test cells having the cathodes comprising the major portion of fluorinated carbon admixed with a minor amount of one of the enumerated metal-containing materials useful with the present invention, for example, CuS, than for the control cells devoid of the metal-containing additive. In addition, higher pulse 1 and pulse 4 voltage minima were achieved by the mixed cathode formulation test cells as recorded during the application of the acceptance pulse train. These results indicate that the mixed cathode formulation cells may have higher rate capability, which is an unanticipated advantage of the CF x /CuS combination cathode system.
TABLE 1______________________________________ Pulse 1 Pulse 4 Cathode Last CCV, minimum minimumS/N material Additive mV voltage, mV voltage, mV______________________________________90360 CFx none 2738 2865 253390362 2741 2875 253590364 2743 2900 255590365 2747 2930 2585avg. 2742 ± 4 2893 ± 29 2552 ± 2490367 CFx CuS 2752 2915 263890369 2748 2900 263390370 2747 2910 263090373 2747 2895 2605avg. 2749 ± 2 2905 ± 9 2627 ± 15______________________________________
FIGS. 1 to 4 show the average discharge profiles of the control and test cells used in this example, discharged under either a 1 kohm or a 5.1 kohm load. In FIG. 1, curve 10 was constructed from the average discharge of the first group of cells having the CF x cathode including the CuS additive and discharged under a 1 kohm load, and curve 12 was constructed from the average impedance of this group of cells. In FIG. 2, curve 20 was constructed from the average discharge of the second group of cells having the CF x cathode devoid of a metal-containing additive and discharged under a 1 kohm load, and curve 22 was constructed from the average impedance of this group of cells. In FIG. 3, curve 30 was constructed from the average discharge of the third group of cells having the CF x cathode including the CuS additive and discharged under a 5.1 kohm load, and curve 32 was constructed from the average impedance of the cell group. Finally, in FIG. 4, curve 40 was constructed from the average impedance of the fourth group of cells having the CF x cathode devoid of a metal-containing additive and discharged under a 5.1 kohm load.
The discharge profiles of the cells with the CuS additive clearly show a second plateau occurring at about 1.8 V and also exhibit a greater rise in impedance than the control cells under each discharge load. The characteristics of a second voltage plateau and an increased impedance rise can each be used to signal end-of-service or end-of-life of the discharged cell.
Furthermore the use of CuS as an end-of-life cathode additive does not result in any increased safety risks, as the short circuit temperature of the cell remains less than 50° C. The peak temperature of 48° C. for a lithium anode, CF x /CuS test cell built according to this example was reached 17 minutes and 24 seconds after application of the short, while the peak temperature of 43° C. for a Li/CF x control cell was reached 29 minutes after application of the short. A peak current of 0.28 A was reached by the test cell with the combination cathode, while a peak current of 0.13 A was attained by the control cells under the short circuit test. After the short circuit testing was completed, there was no physical change noted in the condition of either the test or control cells. In addition, there was no change in the OCV of either the test or control cells as a result of shock testing. (Shock testing procedure: 10 shocks applied for 0.5 milliseconds in each of 3 mutually perpendicular test axes for a total of 30 shocks. Cell OCV is measured and recorded prior to and after each axis is tested. The cells were visually examined after shock testing.)
EXAMPLE II
Ag 2 O was also tested and found to function as an effective end-of-service indicator for the Li/CF x system. A cathode comprised of 2.0 grams of CF x mixed with 2.4 grams of Ag 2 O was used in combination with a lithium anode and activated with an organic electrolyte comprising 1M LiB 4 dissolved in propylene carbonate. This cell was preconditioned under a 1.5 kohm load, stored for one week and then pulse discharged under a similar protocol as that used to discharge the test cells and the control cells in Example I. Following pulse discharge, this cell was discharged under a 2 kohm load with closed circuit voltage and 1 kHz impedance readings recorded throughout discharge. During discharge, this cell showed an initial potential of 2.7 V under the 2 kohm load before the discharge potential decreased to approximately 2.3 V prior to end-of-life, as indicated by curve 50 in FIG. 5. Curve 52 was constructed from the impedance of this cell.
It is appreciated that various modifications to the inventive concepts described herein may be apparent to those skilled in the art without departing from the spirit and the scope of the present invention defined by the hereinafter appended claims. | Battery-powered implantable medical devices require a suitable method for indicating end-of-service of the power source so that there is ample time for elective replacement of the device and/or power source. The present invention utilizes mixed cathode materials preferably comprising a major portion of a fluorinated carbon and a minor portion of a metal-containing material. This mixed cathode formulation is characterized by two, discretely different operating voltages, the second of which may be used as an end-of-life indicator. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/EP2016/051342 filed Jan. 22, 2016, which designated the United States, and claims the benefit under 35 USC §119(a)-(d) of German Application No. 10 2015 101 063.1 filed Jan. 26, 2015, the entireties of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a chisel, in particular, a round-shank chisel, having a chisel head and having a chisel shank, wherein the chisel head is formed at least from a base part and from a cutting element which is connected to the base part and which is composed of a hard material, in particular of hard metal, wherein the base part has, adjacent to the cutting element, a wear-resistant layer on its outer face, which wear-resistant layer covers at least one section, facing toward the cutting element, of the outer face of the base part, and wherein a front face, facing toward the cutting element, of the wear-resistant layer is covered by the cutting element.
[0003] The present invention furthermore relates to a chisel, in particular, a round-shank chisel, having a chisel head and having a chisel shank, wherein the chisel head is formed at least from a base part and from a cutting element which is connected to the base part and which is composed of a hard material, in particular of hard metal, wherein the cutting element lies indirectly or directly with a bearing face at least regionally on the base part, and wherein the base part has, adjacent to the cutting element, a wear-resistant layer on its outer face, which wear-resistant layer covers at least one section, facing toward the cutting element, of the outer face of the base part.
[0004] The present invention also relates to a method for coating at least a section of an outer face of a chisel head of a chisel, in particular of a round-shank chisel, having a wear-resistant layer, wherein, in a second method step, a cutting element is brazed onto a face, facing toward the cutting element, of the wear-resistant layer and a front counterpart face of a base part of the chisel head.
[0005] The present invention furthermore relates to a method for producing a chisel head of a chisel, in particular of a round-shank chisel, wherein the chisel head has a base part with a cutting element attached to the front end of the base part, wherein a wear-resistant layer is applied, so as to join the cutting element, to an outer face of the base part, and wherein a front face, facing toward the cutting element, of the wear-resistant layer is at least regionally covered by the cutting element.
BACKGROUND OF THE INVENTION
[0006] A chisel of this type is known from DE 90 16 655 U1. The chisel described in the document has a main body with a hard metal tip. On an outer face, adjacent to the tip, of the main body, there is arranged a wear-resistant layer composed of a hard material (hard metal or ceramic). The outer face of the tip transitions without a step into the surface of the wear-resistant layer. For this purpose, the main body has an encircling depression into which the hard material is applied. The hard material may, for example, be injection-molded onto the chisel. The main body is of frustoconical form at its front end. The tip has a corresponding frustoconical axial recess in which the frustoconical end of the main body is received and, in this way, the tip is positioned and laterally guided. In practical use, the axial recess leads to disadvantages, because the wall thickness of the tip is reduced in the region of the axial recess. At the termination of the axial recess, a relatively sharp edge is formed between the conical face and the bottom face of the recess. High stress peaks form in the region, in particular, under mechanical load acting laterally on the tip. The stress peaks increasingly lead, in the case of the relatively small wall thickness of the tip in the region, to fracture of the tip, which is produced from a brittle hard material, and thus to failure of the chisel. A further disadvantage arises from the possible production method for such an arrangement. To prevent damage to or destruction of the tip, in particular, during a required thermal treatment during the application of the wear-resistant layer, the tip is fastened, preferably brazed, to the main body only after the wear-resistant layer has been applied to the main body. The tip is then seated on a face, which is arranged in encircling fashion around the frustoconical end, of the main body. For manufacturing reasons, the front face of the wear-resistant layer does not terminate uniformly with the encircling face on which the tip lies, but is rather arranged so as to be recessed or so as to protrude in relation to the face within the range of manufacturing tolerances. Thus, no uniform brazing gap forms between the bearing face tip, the encircling face of the main body and the front face of the wear-resistant layer, as is also illustrated in the exemplary embodiment shown in DE 90 16 655 U1. The non-uniform brazing gap leads to an inadequate brazed connection, which can detach during use and lead to loss of the tip.
SUMMARY OF THE INVENTION
[0007] It is, therefore, an object of the present invention to provide a chisel of the type mentioned in the introduction which exhibits an improved mechanical load capacity. It is a further object of the present invention to provide a method for coating a chisel head and a further method for producing a chisel head of this type.
[0008] The object of the present invention relating to the chisel is achieved in that the base part has an axially oriented recess for receiving a fastening section of the cutting element, in that the base part has, encircling the recess, a counterpart face which faces toward the cutting element, and in that the counterpart face and the front face of the wear-resistant layer form a continuous planar face, or in that the front face of the wear-resistant layer extends to the counterpart face. Since the fastening section of the cutting element is held in the recess of the base part, thin-walled sections of the cutting element, which are subjected to intense action of external forces, are avoided. The risk of breakage of the tip is, thus, considerably reduced. The planar face formed by the counterpart face and the front face makes it possible for a uniform brazing gap to be formed between the planar face and the cutting element. It is thus possible to realize an optimized brazed connection between the cutting element and the base part of the chisel, which connection is not severed even under intense mechanical load. By virtue of the fact that the base part has a recess rather than a projection for the connection to the cutting element, the continuous planar face between the counterpart face and the front face of the wear-resistant layer can be produced easily in terms of manufacturing.
[0009] The wear-resistant layer preferably extends with its front side to the counterpart side, such that the transition region is protected against washout in an effective manner. For example, the wear-resistant layer may extend to the counterpart face so as to leave a gap of less than 1 mm.
[0010] For the connection to a chisel holder, the chisel head is preferably integrally connected to a chisel shank. The chisel shank may in this case be in the form of a round shank.
[0011] The wear-resistant layer is preferably received in a depression of the base part. Here, the depression is provided in encircling fashion around the counterpart face on the outer face of the base part. It may advantageously be provided that the wear-resistant layer that is introduced terminates radially on one side with the cutting element and on the opposite side with the outer face of the base part adjacent to the depression.
[0012] The wear-resistant layer may be formed by a coating which is layered onto the base part. The wear-resistant layer may also be formed by a separate hard material element which is, for example, cohesively connected to the base part. It is conceivable here to use a brazed-on hard metal ring or individual hard-metal segments which are correspondingly adapted to the base part and which are arranged in a regular or irregular arrangement.
[0013] In accordance with a particularly preferred design variant of the present invention, it may be provided that the counterpart face and the front face are in the form of parting faces created in one working step, in particular, are in the form of cut faces or in the form of ground faces or in the form of milled faces, or that the front face is in the form of an impression face, formed during an application process, in particular during a welding process, of the wear-resistant layer, of a base of an auxiliary tool, which base lies on the counterpart face and protrudes radially beyond the counterpart face. In both cases, a continuous planar face is formed between the counterpart face and the front face. In this way, a uniform brazing gap and thus an optimized, durable brazed connection between the face formed by counterpart face and front face and the cutting element is realized.
[0014] The flow behavior of the braze can be improved by virtue of the counterpart face and/or the front face being formed as smooth faces or as faces with a predefined roughness in a range from Rz=4 μm to Rz=280 μm or as faces with channels formed therein, which channels have a channel depth in a range from 2 μm to 500 μm. The roughness or the channels may in this case be produced, for example, during the parting process during the creation of the parting faces or as an impression of the base in accordance with desired specifications.
[0015] The cutting element is subjected to high mechanical loads during use. To realize a secure connection between the cutting element and the base part, it may be provided that the cutting element forms, in encircling fashion around its fastening section, a bearing face, that the bearing face at least regionally covers the counterpart face and the front face, and that a first brazed joint is formed between the bearing face and the continuous face formed by the counterpart face and the front face, and/or that a second brazed joint is formed between an outer face of the fastening section and an inner face of the recess and/or that a third brazed joint is formed between an end face of the fastening section and a bottom face of the recess. Here, the brazed joints preferably merge into one another, such that a continuous brazed connection is provided over the entire interface between the cutting element and the base part and between the cutting element and the front face of the wear-resistant layer.
[0016] The abrasive load acting on the base part is at its greatest adjacent to the cutting element and decreases toward that end of the chisel head which faces toward the chisel shank. At the same time, the cutting element is held with its fastening section in the recess on the front end of the base part. To protect the region of the holder of the cutting element and thus prevent the cutting element from being lost, it may be provided that the wear-resistant layer, in an axial orientation, surrounds at least that section of the chisel head in which the recess is formed.
[0017] In accordance with two alternative variants of the present invention, it may be provided that the wear-resistant layer has a uniform layer thickness, or that the wear-resistant layer has a varying layer thickness. A wear-resistant layer with a uniform layer thickness is easy and inexpensive to produce. By means of a varying layer thickness, the wear-resistant layer can be adapted to the actual loads in the different regions of the chisel head.
[0018] To adapt the layer thickness to the local loads, it may be provided that the layer thickness of the wear-resistant layer decreases, proceeding from its front face facing toward the cutting element, in the direction of its end facing toward the chisel shank, or that the layer thickness of the wear-resistant layer increases, proceeding from its front face facing toward the cutting element, in the direction of its end facing toward the chisel shank. By means of a layer thickness which increases in the direction of the chisel shank, it is possible, with a diameter of the base part which remains constant in the region of the coating, to realize a conical outer contour of the chisel head, by means of which excavated material is led away from a chisel holder in which the chisel is arranged. In the case of a layer thickness which decreases in the direction of the chisel shank, the greatest layer thickness is arranged in the region of the maximum abrasive load directly downstream of the cutting element. In this way, the layer thickness is adapted to the respectively prevailing abrasion, such that similar service lives are obtained from the different regions of the wear-resistant layer.
[0019] A further possibility for adapting the layer thickness of the wear-resistant layer to the local loads consists in that an outer surface of the wear-resistant layer is convexly curved along its longitudinal extent, or in that the outer surface is concavely curved along its longitudinal extent, or in that the outer surface has alternating concavely curved and convexly curved sections along its longitudinal extent. It is additionally possible by means of the shaping of the outer surface to influence the material flow of the excavated material. A convex surface of the wear-resistant layer thus guides the excavated material further outward directly downstream of the cutting element. With suitable adaptation of the outer contour of the cutting element and of the convex shape of the outer surface of the wear-resistant layer, it can be achieved that the excavated material is diverted by the cutting element and by the wear-resistant layer in approximately the same direction, and thus a uniform material flow is realized, in the case of which regions of the chisel head further remote from the cutting element are relieved of load. By means of convex shaping of the outer surface, the front coated region facing toward the cutting element poses less resistance to the excavated material, whereas the excavated material is diverted outward with greater intensity by the rear region. Uniform loading of the wear-resistant layer along the flow direction of the excavated material can be realized in this way. By means of alternating concave and convex regions, excavated material can collect in the concave regions. This leads to additional protection against wear, because the moving excavated material in these regions does not slide past directly on the wear-resistant layer.
[0020] It may furthermore be provided that an internal angle is formed between the surface of the cutting element and the outer surface of the wear-resistant layer at the transition thereof. A brazed joint which ends at said transition region is thus set back from the main flow of the excavated material sliding past, and is thus arranged in a protected manner. This protective action is enhanced in that excavated material can collect in the internal angle and can additionally shield the brazed joint from the abrasive action of the excavated material sliding past.
[0021] A further embodiment of the present invention may comprise a segmented coating or individual segments formed from one or more hard metals, wherein the arrangement is realized by means of fastening methods known from the prior art, such as for example brazing, adhesive bonding, build-up welding or the like.
[0022] The object of the present invention relating to the chisel is furthermore achieved in that the wear-resistant layer covers at least one surface section, adjacent to the bearing face, of the cutting element. The wear-resistant layer thus covers the mutually adjacent outer surfaces both of the base part and of the cutting element. In this way, both the cutting element and the base part are protected against abrasive wear in the particularly highly loaded transition region from the cutting element to the base part. In particular, the brazed joint formed between the bearing face of the cutting element and the base part is also arranged in protected fashion, such that no hard materials can ingress into the brazed joint from the outside and thereby separate the cutting element from the base part.
[0023] The strength of the connection between the cutting element and the base part can be further improved in that a brazed joint (fourth brazed joint) is formed between the wear-resistant layer and the surface section of the cutting element. The cutting element is thus, along its bearing face and along its surface section adjacent to the bearing face, connected by brazing to the base part.
[0024] It may advantageously be provided that the wear-resistant layer protrudes beyond the counterpart face in the direction of a central longitudinal axis of the chisel head, and/or that the wear-resistant layer and the counterpart face form a cup-shaped receptacle for the cutting element. It is preferable, for this purpose, for the wear-resistant layer to be applied to the base part and for the cutting element to subsequently be brazed on. By means of the protruding wear-resistant layer or the cup-shaped receptacle, the cutting element can be positioned easily and in an exactly aligned manner on the base part and brazed to the latter. Here, the cutting element remains held in its position during the brazing process by the wear-resistant layer, which surrounds the cutting element in its region facing toward the base part.
[0025] The object of the present invention relating to the method for coating a chisel head is achieved in that an auxiliary tool is fixed to the base part of the chisel head so as to lie with at least one section of an abutment face on the counterpart face, in that, in a first method step, the outer face is coated with the wear-resistant layer, and in that, subsequently, the auxiliary tool is removed. The wear-resistant layer is thus applied to the outer face of the base part of the chisel head, whereby said base part is protected against mechanical damage and abrasion during later use. The auxiliary tool prevents the counterpart face, onto which the cutting element is brazed in the second manufacturing process, from being jointly coated during the coating process. A defined face for the brazing-on of the cutting element is thus maintained. Furthermore, with the auxiliary tool, the external shape of the wear-resistant layer in its transition region to the cutting tool is predefined, such that a predetermined brazing face with respect to the cutting tool is produced here too.
[0026] In accordance with a preferred method variant, it may be provided that the wear-resistant layer is applied to the outer face of the chisel so as to bear with its front face against at least one section of the abutment face of the auxiliary tool and/or so as to bear against a surface region of the auxiliary tool, which surface region is adjacent to the abutment face and has a spatial orientation which deviates from the abutment face. Depending on the design of the auxiliary tool, it is, thus, possible to produce a different contour of that surface of the wear-resistant layer which is later adjacent to the cutting element. It is thus possible for the contour of that surface of the wear-resistant layer which faces toward the cutting element to be adapted to the contour of the cutting element. The contour of the auxiliary tool and thus the contour of the surface of the wear-resistant layer are predefined so as to follow the contour of the cutting element when the cutting element has been brazed on. It is thereby achieved that a uniform brazing gap is formed along the interface between the cutting element and the wear-resistant layer. If the auxiliary tool protrudes, for example, with its abutment face radially beyond the counterpart face of the base part, it is thus possible for the wear-resistant layer to extend to the abutment face. A front face of the wear-resistant layer is thus formed which is arranged radially with respect to the counterpart face of the base part and which forms a planar face with said counterpart face. In a subsequent manufacturing step, the cutting element can be placed with its bearing face onto the counterpart face and the front face and connected thereto by brazing. Alternatively or in addition to this, it may be provided that the wear-resistant layer is applied to a surface adjacent to the abutment face of the auxiliary tool. The adjacent surface is oriented so as to follow the contour of that surface of the cutting element which is adjacent to the bearing face. If, in a subsequent manufacturing step, the cutting element is placed with its bearing face onto the counterpart face of the base part, that surface of the cutting element which is adjacent to the bearing face is situated opposite the wear-resistant layer so as to be spaced apart by a brazing gap of defined width. The wear-resistant layer thus surrounds a part of the outer surface of the cutting element. The cutting element may be connected to the base part by brazing, wherein the brazing gap is formed along the interface between the cutting element on one side and the counterpart face and the wear-resistant layer on the other side.
[0027] The object of the present invention relating to the method for producing a chisel head is achieved in that the base part of the chisel head is produced in a size which, in relation to its final dimension, is lengthened in the direction of the cutting element, in that the wear-resistant layer is applied to the outer face of the lengthened base part, and in that the base part together with the wear-resistant layer is subsequently truncated along a parting line (T). The parting face thus formed constitutes a continuous, planar face between a formed counterpart face as front termination of the base part and the formed front face of the wear-resistant layer. The planar face promotes the formation of a uniform brazing gap with respect to the cutting element which covers the counterpart face and the front face, which cutting element is brazed onto the base part in a subsequent method step.
[0028] The wear-resistant layer may preferably be applied to the outer face of the chisel head by means of a welding process. The welding process permits the production of an inexpensive and durable wear-resistant layer. The disadvantage of the welding method, that an open face-side terminating face of the obtained coating can be defined only inaccurately in terms of its position and it is, therefore, not possible to produce a continuous, planar face with respect to an adjacent counterpart face, is eliminated by means of the described parting method.
[0029] A robust wear-resistant layer and thus a durable chisel can be obtained if a layer composed of a hard material, in particular of hard metal, and/or of an iron alloy and/or of a nickel alloy and/or of a cobalt alloy and/or of a titanium alloy and/or of tungsten carbide and/or of titanium carbide, is applied as a wear-resistant layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The present invention will be discussed in more detail below on the basis of an exemplary embodiment illustrated in the drawings, in which:
[0031] FIG. 1 shows, in a perspective side view, a chisel having a chisel shank and having a chisel head with a wear-resistant layer;
[0032] FIG. 2 shows the chisel shown in FIG. 1 in a lateral, partially sectional illustration;
[0033] FIG. 3 shows a detail of the chisel shown in FIG. 2 ;
[0034] FIGS. 4 a -4 i show, in lateral sectional illustrations, a detail of the chisel head with different embodiments of the wear-resistant layer;
[0035] FIG. 5 shows, in a further lateral sectional illustration, a detail of the chisel head with an auxiliary tool;
[0036] FIG. 6 shows, in a further lateral sectional illustration, a detail of a chisel head in a size lengthened in the direction of the cutting element in relation to its final dimension;
[0037] FIG. 7 shows, in a lateral sectional illustration, a detail of a wear-resistant layer which protrudes in an axial direction;
[0038] FIG. 8 shows, in a lateral sectional illustration, a detail of a chisel head in a further embodiment of a wear-resistant layer which protrudes in an axial direction; and
[0039] FIG. 9 shows, in a lateral sectional illustration, a detail of the chisel head with an auxiliary tool.
DETAILED DESCRIPTION OF THE INVENTION
[0040] FIG. 1 shows, in a perspective side view, a chisel 10 having a chisel shank 50 and having a chisel head 40 with a wear-resistant layer 30 . The chisel 10 is in the form of a round-shank chisel. The chisel head 40 is assigned a cutting element 20 composed of a hard material, for example, of hard metal. The cutting element 20 is connected, in the present exemplary embodiment by brazing, to a base part 41 , which tapers conically toward the cutting element 20 , of the chisel head 40 . In a region facing toward the cutting element 20 , the base part 41 is coated with the wear-resistant layer 30 in an encircling manner around the cutting element 20 . The wear-resistant layer 30 is composed of a hard material and is applied to the base part 41 by means of a welding process. In the exemplary embodiment shown, the wear-resistant layer 30 is formed from hard metal. It may also be produced from an iron alloy, from a nickel alloy, from a cobalt alloy, from a titanium alloy, from tungsten carbide or from titanium carbide.
[0041] Proceeding from the base part 41 , the chisel head 40 widens via a transition region 41 . 2 to a collar 41 . 3 with constant outer diameter. The collar 41 . 3 transitions into the chisel shank 50 . A fastening sleeve 51 is arranged around the chisel shank 50 . The fastening sleeve 51 is formed as a clamping sleeve which is formed from a resiliently elastic material, for example, steel sheet. As illustrated in FIG. 2 , fastening sleeve 51 has a longitudinal slot which is delimited by sleeve edges. Owing to the longitudinal slot, the fastening sleeve diameter can be varied, wherein the sleeve edges move toward one another (small diameter) or are spaced further apart from one another (large sleeve diameter). In this way, different clamping states can be realized. A supporting element 52 in the form of a wear prevention disk is pulled onto the fastening sleeve 51 . The supporting element 52 has a circular cross section and is extended through by a bore. Here, the bore is dimensioned such that the fastening sleeve 51 is, in relation to its relaxed state, held in a preloaded state with reduced outer diameter. The outer diameter thus generated is selected such that the fastening sleeve 51 can be pushed with little or no expenditure of force into a chisel receptacle of a chisel holder (not illustrated). The pushing-in movement is delimited by means of the supporting element 52 . During the further insertion of the chisel shank 50 into the bore, the supporting element 52 is moved into a region of the chisel shank 50 which is not surrounded by the fastening sleeve 51 . Then, the fastening sleeve 51 springs open radially and becomes clamped in the bore of the chisel holder. In this way, the chisel 10 is held captively in an axial direction but so as to be freely rotatable in a circumferential direction. As is also shown in FIG. 1 , the supporting element 52 , oriented toward the chisel head 40 , forms a supporting face 52 . 1 , which is surrounded by an edge 52 . 2 , for the support of the collar 41 . 3 of the chisel head 40 . The edge 52 . 2 is interrupted by edge recesses 52 . 3 .
[0042] Proceeding from a front cutting tip 21 , the cutting element 20 has a convexly shaped cutting edge face 22 which transitions into a pedestal 23 which terminates radially with the wear-resistant layer 30 .
[0043] For use, the chisel 10 is installed, so as to be mounted rotatably about its central longitudinal axis M shown in FIG. 2 , on a chisel holder on a rotating drum carrier. As a result of the rotation of the drum carrier, the cutting element 20 penetrates into the material to be removed, for example, asphalt or earth, and comminutes the material. The excavated material slides past the chisel head 40 and is guided outward by the base part 41 with the encircling wear-resistant layer 30 and the transition region 41 . 2 . A chisel carrier in which the chisel 10 is held is thus protected in the best possible manner against abrasion by the excavated material.
[0044] The mechanical load on the chisel head 40 is at its greatest in the region of the cutting element 20 . Therefore, the cutting element 20 is manufactured from a hard material, resulting in a long service life of the chisel 10 . In order, in particular, to increase the service life of the base part 41 in its mechanically highly loaded region adjacent to the cutting element 20 , the wear-resistant layer 30 is applied there.
[0045] FIG. 2 shows the chisel 10 shown in FIG. 1 in a lateral, partially sectional illustration. The section exposes a part of the base part 41 of the chisel head 40 . As can be seen there, a recess 44 is provided in the base part 41 at that end of the base part 41 which faces toward the cutting element 20 . The recess 44 has a cylindrical contour and is oriented axially along the central longitudinal axis M of the chisel 10 . The cutting element 20 forms, in relation to the cutting tip 21 , a likewise cylindrical fastening section 24 , which is held in the recess 44 of the base part. The cutting element 20 is brazed to the base part 41 and is thus connected securely and durably to the base part 41 .
[0046] The wear-resistant layer 30 surrounds the region of the recess 44 . A relatively thin-walled web 45 of the base part 41 which encloses the recess 44 is thereby protected against abrasive wear. In this way, the web 45 is prevented from being prematurely worn away by excavated material sliding past, which would lead to the loss of the cutting element 20 and thus to premature failure of the chisel 10 as a whole.
[0047] FIG. 3 shows a detail of the chisel 10 shown in FIG. 2 in the region of the cutting element 20 . As can be seen in the enlarged illustration, a depression 42 is provided in an encircling manner around the base part 41 in a region facing toward the cutting element 20 , into which depression the wear-resistant layer 30 is introduced. An outer surface 33 of the wear-resistant layer 30 thus terminates with the pedestal 23 and with that surface of the base part 41 which runs adjacent to the depression 42 . An inner surface 32 of the wear-resistant layer 30 forms a firm connection to an outer face 41 . 1 of the base part 41 onto which the wear-resistant layer 30 is applied. A front face 31 , facing toward the cutting element 20 , of the wear-resistant layer 30 is covered by a radially oriented bearing face 25 of the cutting element 20 , which bearing face 25 forms the termination of the pedestal 23 in the direction of the base part 41 . The web 45 of the base part 41 is terminated in the direction of the cutting element 20 by a counterpart face 43 . The counterpart face 43 and the front face 31 of the wear-resistant layer 30 form a continuous planar face. In the exemplary embodiment shown, the face is arranged radially and is covered by the bearing face 25 of the cutting element 20 .
[0048] The bearing face 25 of the cutting element 20 transitions via a connection region 28 of rounded form into the fastening section 24 . The rounding of the connection region 28 is situated opposite a rounding face 43 . 1 of the base part 41 , via which the counterpart face 43 transitions into an inner face 44 . 1 of the recess 44 . An outer face 26 of the fastening section 24 is arranged opposite the inner face 44 . 1 of the recess 44 . An end face 27 which terminates the fastening section 24 is situated so as to be spaced apart from a bottom face 44 . 2 of the recess 44 of the base part 41 .
[0049] A first brazed joint 11 . 1 is formed between the front face 31 of the wear-resistant layer 30 and the counterpart face 43 of the base part 41 , on one side, and the bearing face 25 of the cutting element 20 , on the opposite side. A second brazed joint 11 . 2 arranged between the inner face 44 . 1 of the recess 44 and the outer face 26 of the fastening section 24 of the cutting element 20 adjoins the first brazed joint 11 . 1 in a continuous fashion. A third brazed joint 11 . 3 is formed, so as to adjoin the second brazed joint 11 . 2 , between the bottom face 44 . 2 of the recess 44 and the end face 27 of the fastening section 24 .
[0050] The face formed by the front face 31 and the counterpart face 43 is continuous and planar. In this way, a first brazed joint 11 . 1 with a uniform thickness is realized between the face and the opposite bearing face 25 . A uniform thickness of the brazed joints 11 . 1 , 11 . 2 , 11 . 3 is a prerequisite for a stable and durable brazed connection. The planar face formed from the front face 31 and the counterpart face 43 may be produced by means of a parting or chip-removing manufacturing step or by means of a molding process during the application of the wear-resistant layer 30 , as discussed in more detail with regard to FIGS. 5 and 6 . It is advantageous here that the counterpart face 43 and the front face 31 form the front termination of the base part 41 , such that, for example, it is possible for chip-removing manufacturing processes to be performed over the full area of the front termination of the base part 41 after the application of the wear-resistant layer 30 and before the brazing-on of the cutting element.
[0051] By means of the brazed joints 11 . 1 , 11 . 2 , 11 . 3 that are formed, the cutting element 20 is held securely in the base part 41 of the chisel head 40 . By means of the design of the cutting element 20 with a fastening section 24 held in the recess 44 of the base part 41 , it is possible for thin-walled regions of the relatively brittle cutting element 20 to be avoided. Furthermore, by means of the rounded transition from the bearing face 25 to the outer face 26 of the fastening section 24 , stress peaks are avoided. Both measures considerably reduce the risk of breakage of the cutting tip 21 .
[0052] The wear-resistant layer 30 is introduced into the depression 42 . In this way, protruding edges at the transition of the wear-resistant layer 30 to the pedestal 23 and to the outer face 41 . 1 of the base part 41 outside the depression 42 are avoided, whereby both the abrasive wear of the chisel head 40 and the energy consumption during the use of the chisel 10 are reduced. The front face 31 of the wear-resistant layer 30 is covered by the cutting element 20 and by the braze-filled first brazed joint 11 . 1 . In this way, excavated material is prevented from passing between the outer face 41 . 1 of the base part 41 and the inner surface 32 of the wear-resistant layer 30 and breaking these apart.
[0053] An internal angle is formed between the pedestal 23 and the outer surface 33 of the wear-resistant layer 30 , at the apex of which internal angle the first brazed joint 11 . 1 ends. The first brazed joint 11 . 1 with the relatively soft braze material is thus arranged so as to be set back in relation to the main flow of excavated material sliding past, and is thereby additionally protected against wear.
[0054] FIGS. 4 a to 4 i show, in lateral, sectional illustrations, a detail of the chisel head 40 with different embodiments of the wear-resistant layer 30 .
[0055] In the embodiment as per FIG. 4 a , the outer face 41 . 1 of the base part 41 runs initially cylindrically in the region of the web 45 and then transitions into a conically widening region. The outer surface 33 of the wear-resistant layer 30 runs continuously conically. By means of this design, it is achieved that the web 45 has a uniform thickness with a continuously relatively large material thickness. In this way, high transverse forces acting via the cutting element 20 can be reliably accommodated. The wide counterpart face 43 that is formed yields secure seating of the cutting element 20 on the base part 41 and a large-area brazed connection between the bearing face 25 of the cutting element 20 and the counterpart face 43 .
[0056] In FIG. 4 b , the wear-resistant layer 30 has its greatest layer thickness in its region facing toward the cutting element 20 , which layer thickness decreases continuously toward the opposite end of wear-resistant layer 30 . The mechanical load on and thus the abrasive wear of the wear-resistant layer 30 is at its greatest directly adjacent to the cutting element 20 and decreases in the direction of the collar 41 . 3 of the chisel head 40 . By means of the illustrated distribution of the layer thickness, a uniform service life of the wear-resistant layer 30 over its entire extent is achieved. By means of the adaptation of the layer thickness in the direction of the collar 41 . 3 , the material consumption during the production of the wear-resistant layer 30 is optimized taking into consideration the expected mechanical load on the wear-resistant layer 30 in the different regions along the chisel head 40 .
[0057] Correspondingly to FIG. 4 c , the wear-resistant layer 30 has its smallest layer thickness in its region facing toward the cutting element 20 , which layer thickness increases continuously toward the opposite end of wear-resistant layer 30 . In this way, too, a web 45 with a uniform, relatively large material thickness is realized, with the advantages already mentioned with regard to FIG. 4 a . The outer face 41 . 1 of the base part 41 may, in the region of the depression 42 , be of cylindrical form with a uniform spacing to the central longitudinal axis M of the chisel 10 and thus be of easily producible design, while the conical outer contour of the chisel head 40 is maintained.
[0058] FIG. 4 d shows a design variant in which the outer surface 33 of the wear-resistant layer 30 is of convex shape. By means of this shaping, a transition without protruding edges, which lead to increased abrasion, is achieved in each case between the cutting element 20 and the wear-resistant layer 30 and between the wear-resistant layer 30 and the outer face 41 . 1 , adjacent to the depression 42 , of the base part 41 . At the same time, the wear-resistant layer 30 is provided with a large material thickness, whereby long service lives of the chisel head 40 and thus of the chisel 10 can be achieved. The outer surface 33 of the wear-resistant layer 30 , which is subject to wear, is oriented in approximately the same direction as the surface profile of the cutting edge face 22 of the cutting element 20 , resulting in a uniform material flow of the excavated material. The internal angle between the pedestal 23 and the cutting edge face 22 tapers to a relatively sharp point, such that the first brazed joint 11 . 1 is arranged so as to be considerably setback in relation to the main material flow of the excavated material and is thus protected. Likewise, an internal angle is formed at the transition of the outer surface 33 to the outer face 41 . 1 laterally with respect to the depression 42 , such that the connecting region between the material of the wear-resistant layer 30 and the material of the base part 41 is also setback in relation to the material flow of the excavated material and is thereby arranged in protected fashion.
[0059] FIG. 4 e shows an embodiment in which the outer surface 33 of the wear-resistant layer is designed to run conically. The outer face 41 . 1 of the base part 41 is of concave design in the region of the depression 42 , such that the inner surface 32 of the wear-resistant layer 30 is of convex form. In this way, a large layer thickness of the wear-resistant layer 30 , with a correspondingly long service life, is realized. The web 45 with the counterpart face 43 that is formed, is of correspondingly thick-walled or large-area design, with the associated advantages already described with regard to FIG. 1 . The conical outer surface 33 yields edge-free transitions at the edges of the wear-resistant layer 30 and thus the reduced abrasion and energy consumption as already described.
[0060] In FIG. 4 f , both the inner surface 32 and the outer surface 33 of the wear-resistant layer 30 are of convex form. In this way, the advantages of the design variant of a convex outer surface 33 as shown in FIG. 4 d can be combined with the advantages of a convex inner surface 32 as discussed with regard to FIG. 4 e.
[0061] In the design variant as per FIG. 4 g , the outer face 41 . 1 of the base part 41 is of cylindrical design in the region of the web 45 and is of conical design adjacent to the web 45 . The outer surface 33 of the wear-resistant layer 30 follows this shaping, wherein the conical region of the outer surface 33 runs more steeply than the conical region of the outer face 41 . 1 . The layer thickness of the wear-resistant layer 30 is selected to be at its greatest in the region of the web 45 and thus of the highest mechanical load on the base part 41 , and decreases within the conical regions. Owing to the outer surface 33 , which is of cylindrical design in the region of the web 45 , of the wear-resistant layer 30 , the wear-resistant layer 30 is setback in relation to the main flow direction of the excavated material predefined by the shaping of the cutting element 20 , such that the abrasion in the region is reduced in relation to a conical or concave design of the outer surface 33 . In this way, and as a result of the large layer thickness of the wear-resistant layer 30 , the relatively thin-walled web 45 is protected in the best possible manner against wear.
[0062] A similar effect is realized by the embodiment of the wear-resistant layer 30 shown in FIG. 4 h with a concave outer surface 33 and a conically running inner surface 32 . In this case, too, a large layer thickness is realized in the region of the web 45 and thus in the highly loaded direct vicinity of the cutting element 20 . The outer surface 33 runs, in the region of the web 45 , in the context of the deviation by means of the conical shaping, approximately in the direction of the surface of the pedestal 23 . As a result, the region of the web 45 provides only a small surface for the excavated material sliding past to act on, whereby the abrasion in the region of the relatively thin-walled web 45 is kept low. In the further concave profile of the outer surface 33 , the excavated material is guided outward away from the chisel 10 , and thus the non-coated region of the chisel head 40 is protected. As a result of the conical shaping of the coated outer face 41 . 1 of the base part 41 , the material thickness of the web 45 increases toward the base thereof, such that even high transverse forces introduced by the cutting element 20 can be accommodated without damage to the web 45 .
[0063] FIG. 4 i shows a detail of the chisel head 40 with a wear-resistant layer 30 , the outer surface 33 of which has alternating concave and convex regions. Excavated material can accumulate in the concave regions, such that the excavated material sliding past at the outside is, at least in the concave regions, not in direct contact with the outer surface 33 of the wear-resistant layer 30 . By means of this simple measure, the abrasion of the wear-resistant layer 30 can be considerably reduced.
[0064] FIG. 5 shows, in a further lateral sectional illustration, a detail of the chisel head 40 with an auxiliary tool 60 . The chisel head 40 is, in this case, present still in the form of a semifinished part without the brazed-on cutting element 20 . FIG. 5 shows one possibility for coating the base part 41 of the chisel head 40 with the wear-resistant layer 30 , such that a continuous planar face forms between the front face 31 of the wear-resistant layer 30 and the counterpart face 43 of the base part 41 .
[0065] FIG. 5 shows a chisel head 40 with a wear-resistant layer 30 which has a uniform layer thickness. The method may, however, also be applied to any other embodiment of the wear-resistant layer 30 as shown by way of example in FIGS. 4 a to 4 i.
[0066] The auxiliary tool 60 is formed from a base 61 , in the center of which there is arranged an axially oriented positioning peg 63 . The diameter of the base 61 is selected so as to protrude radially beyond the wear-resistant layer 30 . The positioning peg 63 is designed such that it can be inserted with little lateral play into the recess 44 of the chisel head 40 . The positioning peg 63 ends so as to be spaced apart from the closure of the recess 44 by a gap 44 . 3 . In the present exemplary embodiment of the present invention, the auxiliary tool 60 is produced from a metal, preferably from copper.
[0067] Before the application of the wear-resistant layer 30 , the auxiliary tool 60 is fixed with its positioning peg 63 in the recess 44 such that the auxiliary tool 60 lies with a shape-imparting abutment face 62 , which runs around the positioning peg 63 , on the counterpart face 43 of the base part 41 . Subsequently, the wear-resistant layer 30 is introduced into the depression 42 . For this purpose, the wear-resistant layer 30 is applied by means of a welding process so as to bear against the abutment face 62 of the base 61 . Thus, a front face 31 of the wear-resistant layer 30 is formed which transitions in planar and continuous fashion into the counterpart face 43 of the base part 41 . After the coating process, the auxiliary tool 60 is removed.
[0068] By means of a corresponding structuring of the shape-imparting abutment face 62 , the front face 31 of the wear-resistant layer 30 may be smooth or may be equipped with a predefined roughness or with some other structure, for example, with channels. Here, a roughness in a range from Rz=4 μm to 280 μm or channel depths in a range from 2 μm to 500 μm is/are advantageously provided. The surface structure of the front face 31 can thus be optimized for a good flow of the brazing agent.
[0069] FIG. 6 shows, in a further lateral sectional illustration, a detail of a chisel head 40 in a size lengthened in the direction of the cutting element 20 in relation to its final dimension. FIG. 6 also shows a semifinished part in which the cutting element 20 has not yet been applied. The subsequent final dimension of the base part 41 is marked by a parting line T. The base part 41 has been lengthened by the extent of an excess length 12 . The depression 42 of the base part 41 continues in the excess length 12 . The axial recess 44 is also formed in the base part 41 and in the excess length 12 . The excess length 12 ends at a radially oriented terminating face 13 .
[0070] FIG. 6 shows a chisel head 40 with a wear-resistant layer 30 which has a uniform layer thickness. The method can, however, be applied to any other embodiment of the wear-resistant layer 30 as shown by way of example in FIGS. 4 a to 4 i.
[0071] The wear-resistant layer 30 has been introduced into the depression 42 of the elongated chisel head 40 by means of a welding process. The illustration schematically shows the rough outer surface 33 , resulting from the welding process, of the wear-resistant layer 30 .
[0072] Likewise for manufacturing reasons, the wear-resistant layer 30 does not end flush with and in the same plane as the front terminating face 13 of the excess length 12 . In the exemplary embodiment shown, in relation to the terminating face 13 , the wear-resistant layer 30 forms a protruding bead 34 on one side of the excess length 12 and forms a recessed bead on the opposite side. Both are unsuitable for the formation of a durable brazed connection with a uniform brazed joint 11 . 1 , 11 . 2 , 11 . 3 with respect to a rectilinearly running surface such as is provided by the bearing face 25 of the cutting element 20 .
[0073] To form the demanded planar face between the counterpart face 43 of the base part 41 and the front face 31 of the wear-resistant layer 30 , the excess length 12 is separated from the base part 41 along the parting line T. This may be realized by means of a parting process, for example, by sawing, or by means of a chip-removing manufacturing process, such as, for example, milling. The parting face may also be machined further in a subsequent machining step. It is accordingly possible for a defined roughness of the parting face to be produced, or channels or other structures may be formed into the parting face, which improve the flow behavior of a braze used for the brazing-on of the cutting element 20 . The roughness may, for this purpose, be set in a range between Rz=4 μm and 280 μm, or channels may be formed in with a channel depth in a range between 2 μm and 500 μm.
[0074] After both the production methods described with regard to FIGS. 5 and 6 , a continuous and planar face formed from the counterpart face 43 and the front face 31 is obtained, opposite which the bearing face 25 of the cutting element 20 can be positioned and brazed. A uniform and thus durable first brazed joint 11 . 1 is formed, as shown in FIGS. 1 to 4 .
[0075] FIG. 7 shows, in a lateral sectional illustration, a detail of a wear-resistant layer 30 which protrudes in an axial direction.
[0076] The cutting element 20 is formed from the cutting tip 21 , from the cutting edge face 22 , which is of concave shape in the exemplary embodiment shown, and from the pedestal 23 . The pedestal 23 forms a continuous and planar bearing face 25 which is oriented toward the base part 41 of the chisel head 40 .
[0077] The wear-resistant layer 30 is introduced into the recess 44 which is arranged in encircling fashion around the base part 41 . Here, a radially inner part of the wear-resistant layer 30 terminates, in the direction of the cutting element 20 , with the counterpart face 43 of the base part 41 and forms the front face 31 there. The cutting element 20 lies with its support face 25 on the counterpart face 43 and the front face 31 via a brazed connection. Here, cutting element 20 covers a centering notch 43 . 2 which is formed into the counterpart face 43 along the central longitudinal axis M of the chisel head 40 .
[0078] Laterally with respect to the front face 31 , the wear-resistant layer 30 protrudes in an axial direction beyond the counterpart face 43 and the front face 31 . The wear-resistant layer 30 thus forms a centering collar 36 which surrounds the pedestal 23 of the cutting element 20 in its region facing toward the base part 41 . The wear-resistant layer 30 thus covers a surface section 29 , adjacent to the bearing face 25 , of the cutting element 20 . A fourth brazed joint 11 . 4 is formed between the surface section 29 and the centering collar 36 .
[0079] The wear-resistant layer 30 forms, together with the counterpart face 43 of the base part 41 , a cup-shaped receptacle 46 into which the cutting element 20 is brazed by way of its pedestal 23 . By means of the cup-shaped receptacle 46 , the cutting element 20 is correctly oriented and held in its position during the brazing process. A brazed connection is formed between the counterpart face 43 , the front face 31 and the centering collar 36 at one side and the cutting element 20 at the other side. The cutting element 20 is thus securely connected to the base part 41 of the chisel head 40 . That section of the brazed connection which is formed between the bearing face 25 and the counterpart face 43 or the front face 31 is arranged so as to be protected by the encircling centering collar 36 of the wear-resistant layer 30 . This yields a permanent connection, which is protected against wear, between the cutting element 20 and the base part 41 .
[0080] FIG. 8 shows, in a lateral sectional illustration, a detail of a chisel head 40 in a further embodiment of a wear-resistant layer 30 which protrudes in an axial direction.
[0081] The cutting element 20 substantially corresponds to the cutting element 20 illustrated in FIG. 7 , wherein a pedestal projection 23 . 1 is integrally formed on the pedestal 23 on the region facing toward the base part 41 of the chisel head 40 . The pedestal projection 23 . 1 has a cross section which narrows in conical form toward the base part 41 .
[0082] The centering collar 36 of the wear-resistant layer 30 follows the conically running surface section 29 of the pedestal 23 , which is arranged in the region of the pedestal projection 23 . 1 . The pedestal projection 23 . 1 , as that section of the cutting element 20 which faces toward the base part 41 , is thus covered by the wear-resistant layer 30 .
[0083] In this case, too, the pedestal projection 23 . 1 and the counterpart face 43 of the base part form a cup-shaped receptacle 46 into which the cutting element 20 is brazed. The brazed joint region formed between the bearing face 25 and the counterpart face is thus surrounded in encircling fashion, and thereby protected, by the wear-resistant layer 30 . By means of the fourth brazed joint 11 . 4 , the area of the brazed connection formed between the base part 41 and the cutting element 20 is enlarged, such that a firm connection is formed between the cutting element 20 and the base part 41 .
[0084] FIG. 9 shows, in a lateral sectional illustration, a detail of the chisel head 40 with an auxiliary tool 60 .
[0085] Here, the base part 41 and the wear-resistant layer 30 of the chisel head 40 have the same shape as already described with regard to FIG. 7 , with FIG. 7 , however, showing the inserted cutting element 20 .
[0086] The auxiliary tool 60 is formed from a base 61 on which a projection 64 is integrally formed. The auxiliary tool 60 is of rotationally symmetrical construction about the central longitudinal axis M. The projection 64 has a smaller diameter than the base 61 . The projection 64 lies with its abutment face 62 against the counterpart face 43 of the base part 41 and against the front face 31 of the wear-resistant layer 30 . In the center of the abutment face 62 , there is integrally formed a centering spike 64 . 1 which engages into the centering notch 43 . 2 of the base part 41 .
[0087] The auxiliary tool 60 is placed with its abutment face 62 onto the counterpart face 43 of the base part 41 before the wear-resistant layer 30 is applied. Here, the centering spike 64 . 1 engages into the centering notch 43 . 2 , such that the auxiliary tool 60 is oriented relative to the base part 41 . Subsequently, the wear-resistant layer 30 is applied, preferably by welding. The wear-resistant layer 30 is, in this case, applied so as to fill the recess 44 . On the side of the auxiliary tool 60 , the wear-resistant layer 30 is applied onto that face of the abutment face 62 of the auxiliary tool 60 which protrudes beyond the counterpart face 43 of the base part 41 and onto the outer surface of the projection 64 of the auxiliary tool 60 . The face surface 31 and the centering collar 36 are thus formed, which centering collar 36 protrudes axially beyond the counterpart face 43 and, in the present exemplary embodiment, beyond the front face 31 of the wear-resistant layer 30 . The centering collar 36 is delimited by the base 61 of the auxiliary tool 60 .
[0088] After the coating process, the auxiliary tool 60 is removed. The wear-resistant layer 30 of step form remains as an impression of the auxiliary tool 60 . The cutting element 20 can be brazed into the cup-shaped receptacle 46 thus formed, as shown in FIG. 7 .
[0089] The contour of the auxiliary tool 60 is configured so as to follow the contour of the cutting element 20 that is provided. To produce the chisel 10 illustrated in FIG. 8 , it is, for example, possible for an auxiliary tool 60 to be provided, the projection 64 of which narrows conically proceeding from the base 61 . In this way, a centering collar 36 corresponding to that shown in FIG. 8 is obtained, which follows the conical shape of the pedestal projection 23 . 1 of the cutting element 20 shown there.
[0090] The auxiliary tool shown in FIGS. 5 and 9 is preferably manufactured from a material which does not form a metallurgical connection with the wear-resistant layer. The auxiliary tool may be manufactured, for example, from copper.
[0091] To produce the cup-shaped receptacle 46 , it is also possible, in accordance with an alternative production method, for an elongated base part 41 to firstly be coated and subsequently truncated, as described with regard to FIG. 6 . The cup-shaped receptacle 46 may subsequently be formed into the base part 41 and the wear-resistant layer 30 by means of a subsequent machining step, in particular, by milling or drilling. | The invention relates to a pick, in particular a round-shank pick, comprising a pick head and a pick shank, wherein the pick head consists of at least a base part and a cutting element, which is connected to the base part and is composed of a hard material, in particular hard metal, wherein the base part has a wear-resistant layer on the outer surface thereof at the connection to the cutting element, which wear-resistant layer covers at least one segment of the outer surface of the base part facing the cutting element and wherein an end face of the wear-resistant layer facing the cutting element is covered by the cutting element. According to the invention, the base part has an axially oriented cut-out for receiving a fastening segment of the cutting element, the base part has a counter surface facing the cutting element and extending around the cut-out, and the counter surface and the end face of the wear-resistant layer form a continuous flat surface. The invention further relates to two methods for producing such a pick. The pick formed in such a way has low abrasive wear. | 4 |
This patent application is a continuation-in-part of U.S. application Ser. No. 09/826,127 filed on Apr. 4, 2001 now U.S. Pat. No. 6,881,709, and is a continuation-in-part of U.S. application Ser. No. 10/194,522 filed on Jul. 12, 2002 now U.S. Pat. No. 6,908,888.
TECHNICAL FIELD OF THE INVENTION
This invention relates to compositions and methods used in adjusting the rheological properties of viscoelastic surfactant (VES) fluids, especially for use in treatment of subterranean formations and oil and gas wells.
BACKGROUND OF THE INVENTION
Viscoelastic surfactant fluids are normally made by mixing in appropriate amounts suitable surfactants such as anionic, cationic, nonionic and zwitterionic surfactants in an aqueous medium. The rheology of viscoelastic surfactant fluids, in particular the increase in viscosity of the solution, is attributed to the three dimensional structure formed by the components in the fluids. When the surfactant concentration significantly exceeds a critical level, and eventually subject to the presence of an electrolyte, the surfactant molecules aggregate and form structures such as micelles that can interact to form a network exhibiting viscoelastic behavior. In the remaining part of this description, the term “micelle” will be used as a generic term for organized interacting species.
Viscoelastic surfactant solutions are usually formed by the addition of certain reagents to concentrated solutions of surfactants, frequently consisting of long-chain quaternary ammonium salts such as cetyltrimethylammonium bromide (CTAB). Common reagents that generate viscoelasticity in the surfactant solutions are salts such as ammonium chloride, potassium chloride, sodium salicylate and sodium isocyanate and non-ionic organic molecules such as chloroform. The electrolyte content of surfactant solutions is also an important control on their viscoelastic behavior.
There has been considerable interest in using such viscoelastic surfactants in wellbore-service applications. Reference is made for example to U.S. Pat. Nos. 4,695,389; 4,725,372; 5,551,516, 5,964,295, and 5,979,557.
The rheological properties of aqueous mixtures of surfactants are determined by their tendency to seclude their hydrophobic part, and expose their hydrophilic part, toward the solvent. This behavior typically results in the formation of three-dimensional network structure, called micelles. Depending in particular upon the structure of these micelles, the fluid viscosity is more or less increased, and the fluid may exhibit both viscous and elastic behavior.
The common approach to develop new viscoelastic-surfactant systems is to screen a large number of surfactants—and surfactant mixtures—until one meets specific performance specifications. This approach is obviously time-consuming. Moreover, wellbore services fluids tend to be used under a large variety of conditions, notably temperature, salinity and shear stress. Unfortunately, viscoelastic-surfactants based-fluids are typically very sensitive to variations of the above-mentioned parameters. Therefore the “screening” approach tends to result in numerous systems that are tailored for specific conditions. This presents logistical issues and requires extensive training of field personnel.
Consequently, it would be desirable to have one system whose properties could be adjusted to meet a variety of specifications. For example, consider the possibility of using a particular viscoelastic surfactant system throughout a broad temperature range. It is known that the micelles responsible for the theological properties of viscoelastic surfactant-based fluids are normally stable within a narrow temperature range. Surfactants with longer carbon-atom hydrophobic chains (more than 18 carbon atoms) offer fluid stability at higher temperatures. However, increasing the chain length is also detrimental to the surfactant's hydrophilic properties; therefore, complete dissolution of the surfactant requires considerably more time than that of shorter chain counterparts. There is therefore a need for means to “boost” the viscosity of shorter-chain systems at higher temperatures. It should be further emphasized that some relatively inexpensive viscoelastic surfactants may provide an increase of viscosity that is less than it would be desirable for some applications. Providing means to boost the viscosity would be a way of allowing the use of “less than perfect” product—or to limit the quantity of surfactant to be added to the systems and therefore decreasing the total cost of the system.
Another property of viscoelastic surfactant-based systems is their shear sensitivity. For instance, in the oil industry, it is often favorable to provide fluids that exhibit high viscosity at little or no shear and low viscosity at high shear. Such fluids are easy to pump but will be highly viscous after placement in the well. Though the shear-sensitivity is an intrinsic property of most viscoelastic systems, an independent aspect is the degree of viscosity-recovery or re-healing once the fluid is no more subject to high shear. Controlling the degree of reassembling (re-healing) is necessary to maximize performance of the surfactant system for different applications. For example, in hydraulic fracturing it is critical for the fluid to regain viscosity as quickly as possible after exiting the high-shear region in the tubulars and entering the low-shear enviroment in the hydraulic fracture. On the other hand, it is beneficial in coiled tubing cleanouts to impart a slight delay in regaining full viscosity in order to more efficiently “jet” the solids from the bottom of the wellbore into the annulus. Once in the annulus the regained viscosity will ensure that the solids are effectively transported to the surface. Improving the viscosity-recovery and minimizing the time required for such recovery is therefore desirable.
Finally, it is well known that the introduction of certain components to a viscoelastic surfactant-based system can cause a dramatic decrease in the fluid viscosity, called “breaking”. Breaking can also occur by varying the amount of water or electrolyte or other components that may already be present in the fluid. For example, in oilfield applications, the viscosity of viscoelastic surfactant fluids is reduced or lost upon exposure to formation fluids (e.g., crude oil, condensate and/or water). The viscosity reduction effectuates cleanup of the reservoir, fracture, or other treated area.
However, in some circumstances, it would be suitable to have a better control of that breaking, for instance, when breaking of the fluid is desired at a particular time or condition, when it is desired to accelerate viscosity reduction or when the natural influx of reservoir fluids (for example, in dry gas reservoirs) does not break or breaks incompletely the viscoelastic surfactant fluid.
This disclosure describes compositions and methods employed to modify the rheology of aqueous solutions comprising a thickening amount of a viscoelastic surfactant.
UK Patent GB2332223, “Viscoelastic surfactant based gelling composition for wellbore service fluids” by Hughes, Jones and Tustin describes methods to delay and control the build-up of viscosity and gelation of viscoelastic surfactant based gelling compositions. These methods are used to facilitate placement of the delayed (“pre-gel”) fluid into a porous medium and then to trigger formation of the viscoelastic gel in-situ.
Rose et. al. describe in U.S. Pat. No. 4,735,731 several methods to reversibly break the viscosity of viscoelastic-surfactant based solutions through an intervention at surface. These methods include heating/cooling the fluid, adjusting the pH or contacting the fluid with an effective amount of a miscible or immiscible hydrocarbon and then, subjecting the fluid to conditions such that the viscosity of the fluid is substantially restored. The reversible treatment of Rose is useful for drilling fluids so that the fluid pumped into the well is viscous enough to carry cuttings to the surface but able to be broken at surface for solids removal. The breaking methods discussed in Rose are not used to break a viscoelastic solution down a well and further appear to have an immediate impact on the viscosity of the fluid.
U.S. patent application Ser. No. 09/826,127 filed Apr. 4, 2001 and published under Ser. No. 20020004464 discloses different types of breaking agents and different means to achieve a delayed release of the breaking agents downhole so that the rheological properties of the aqueous fluids are not altered at surface or during the injection phase. U.S. application Ser. No. 10/194,522 filed Jul. 12, 2002 further discloses that some polymers, in particular some polyelectrolytes, can be used as breaking agents.
However, it was further found that the same types of polymers could also have completely different effects on the rheology of aqueous solutions comprising thickening amount of viscoelastic surfactants. Therefore, there exists a need for methods for breaking/enhancing/healing viscoelastic surfactant fluids after subterranean oil- or gas-well treatments, at predetermined times or conditions.
SUMMARY OF THE INVENTION
The authors of the present invention have found that, at given viscoelastic-surfactant concentration, a polymer can perform different functions (breaker, viscosity enhancer or viscosity recovery enhancer), depending upon its molecular weight and its concentration in the fluid, or more precisely, depending on the ratio of the concentration of added polymer and the concentration of viscoelastic surfactant.
According to a first aspect of the invention, the added polymer has a low molecular weight, typically less than about 25,000. In this case, it was found that the polymer mainly acts as a breaking agent.
According to a second aspect of the invention, the added polymer has a molecular weight higher than about 25,000. In this case, it was found that, at small concentrations (with regard to the amount of viscoelastic surfactant), the polymer promotes a rapid recovery of the viscosity after shear-degradation, and that at higher concentration (typically above 7 wt %), the polymer provides an increase in viscosity of the aqueous fluid.
The methods of the present inventions are focused upon but not limited to rheology-modifiers for viscoelastic surfactant systems based upon cationic surfactants such as erucyl methyl bis(2-hydroxyethyl) ammonium chloride (“EMHAC”); zwitterionic surfactants such as betaine surfactants; and anionic surfactants such as the oleic acid derivatives. However, the methods and compositions described herein are also presented for adjusting the viscosity of viscoelastic surfactant fluids based on anionic, cationic, nonionic and zwitterionic surfactants.
It is one aspect of the invention to provide methods and compositions for the delayed adjustment of the viscosity of the viscoelastic surfactant gelling compositions without significantly or substantially compromising the initial fluid properties required for proppant suspension and transport during a fracturing treatment. The invention thus concerns a method of treating a subterranean formation by injecting down a well an aqueous fluid comprising a thickening amount of a viscoelastic surfactant and also comprising a viscosity-adjuster or a precursor thereof. Optimized formulations ensure that the viscoelastic gel is rapidly formed under surface conditions remains stable during pumping and placement into the fractures. Then, at a later time, the gel viscosity is significantly altered by the added polymer.
The shear sensitivity and hydration of the viscoelastic system fluid can be fine-tuned based on the need for the application. This can be achieved via adjusting the molecular weight distribution of the same polymer or switching to another polymer. The addition of polymer also increases the viscosity of viscoelastic fluid at 100 sec −1 shear rate in certain temperature range.
Yet another aspect of the present invention relates to the use of polyelectrolytes and polyerthylene glycol, polypropylene glycol, or block copolylmers of polyethylene glycol and polyproylane glycol as breakers of viscoelastic surfactant based solutions. Polyelectrolytes useful in the invention may be anionic, cationic, or zwitterionic. Although it should be understood that any suitable polymer may be used, the following are preferred; sulfonated polynaphthalenes, sulfonated polystyrenes and sulfonated styrene/maleic anhydride polymers. More specifically, polyethylene glycol PEG, polypropylene glycol (PPG), block co-polymers of PEG and PPG, polynphthalene sulfonate and polystyrene sulfonate are preferred. The polymers may be encapsulated.
It should be also understood that the fracturing compositions of the invention may contain components in addition to water, electrolytes, surfactants and breakers. Such additional components are, for example, acids, bases, buffers, chelating agents for the control of multivalent cations, freezing point depressants, etc.
Even if the present application is focused on treatments of hydrocarbon wells, the methods and compositions of the invention can also be employed for other applications, including but not limited to water wells, recovery of coalbed methane, and the containment or remediation of ground or groundwater contamination.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plot of the polymer molecular weight vs. the weight ratio of polymer to viscoelastic surfactant and the effect of the addition of polymer to the aqueous solution comprising said viscoelastic surfactant.
FIG. 2 is a graph showing the effect of a low molecular weight sodium polystyrene sulfonate on a betaine based VES fluid at temperature ranging from 70° F. to 310° F.
FIG. 3 is a graph showing the effect of a low molecular weight sodium polystyrene sulfonate on a betaine based VES fluid at temperature ranging from 70° F. to 310° F.
FIG. 4 is a graph showing the effect of a high molecular weight sodium polynaphtalene sulfonate at high concentration on a betaine based VES fluid at temperature ranging from 50° F. to 300° F.
FIG. 5 is a graph showing the effect of a high molecular weight sodium polystyrene sulfonate at high concentration on a betaine based VES fluid at temperature ranging from 150° F. to 230° F.
FIG. 6 is a graph showing the effect of a high molecular weight sodium polystyrene sulfonate at high concentration on a cationic quaternary amine based VES fluid at temperature ranging from 50° F. to 250° F.
FIG. 7 is a graph showing the effect of a high molecular weight sodium polystyrene sulfonate at low concentration on a cationic quaternary amine based VES fluid after shear degradation of the viscosity.
FIG. 8 is a graph showing the effect of a high molecular weight sodium polynaphtalene sulfonate at low concentration on a betaine based VES fluid after shear degradation of the viscosity.
FIG. 9 is a graph showing the effect of a high molecular weight sodium polynaphtalene sulfonate at low concentration on a betaine based VES fluid after shear degradation of the viscosity.
FIG. 10 is a graph showing the effect of a short molecular weight polypropylene glycol on on a betaine based VES fluid at temperature ranging from 70° F. to 310° F.
DETAILED DESCRIPTION
EXAMPLE 1
Additions of Polymers to Adjust the Viscosity
In the application of viscoelastic surfactant based gelling compositions comprising viscoelastic surfactants in combination with polymers, drastically different effects may be achieved depending on the molecular weight of the polymer and the weight ratio of added polymers to the viscoelastic surfactant.
For examples, to an aqueous solution comprising a surfactant (in test A to F and I a zwitterionic surfactant noted Z1, Erucic amidopropyl dimethyl betaine) and in test G and H, a cationic quaternary amine) is added different type of polymers (PNS: polynaphtalene sulfonate or PSS:polystyrene sulfonate or PPG:polypropyenel glycol), whose molecular weight is listed in table I below. The weight ratio of polymer to the surfactant is noted by Wt %. Table I
TABLE I
Molecular
Test #
Surfactant
Polymer
Weight
Wt %
Effect
A
Z1
PNS
30000
17.5
Booster
B
Z1
PNS
100000
10
Booster
C
Z1
PNS
30000
2.5
Healer
D
Z1
PNS
70000
2.5
Healer
E
Z1
PSS
15000
2.5
Breaker
F
Z1
PSS
3000
2.5
Breaker
G
C1
PNS
30000
10
Booster
H
C1
PNS
30000
5
Healer
I
Z1
PPG
4000
12.5
Breaker
Based on the above data, FIG. 1 was drawn by plotting the different tests using as X-axis the molecular weight of the added polymer and as Y-axis the weight ratio Wt %. This diagram can be divided in three sectors. With polymers of lower molecular weights, the viscosity is broken. With polymers of higher molecular weights, the viscosity of the solution is either enhanced (if the concentration of polymer is high enough) or the additive promotes the recovery of the viscosity after shear-degradation (healer effect).
EXAMPLE 2
Polymer as Breaking Agent
A base fluid was prepared by adding to water 2.4 weight percent of erucic amidopropyl dimethyl betaine. 0.06 wt % (weight percent) of polystyrene sulfonate (having a molecular weight estimated between 15000 and 20000) is added to the solution so that the value of Wt % is equal to 2.5%. The fluid viscosities with and without the polymer additive were determined at 100 sec −1 from 70° F. to 310° F. and plotted FIG. 2 . FIG. 2 shows that a substantial decrease in fluid viscosity is observed when the polystyrene sulfonate breaker is present. This reduction in fluid viscosity is permanent.
EXAMPLE 3
Polymer as Breaking Agent
A base fluid was prepared by adding to water 2.4 weight percent of erucic amidopropyl dimethyl betaine. 0.06 wt % of polystyrene sulfonate (having a molecular weight estimated between 3000 and 5000) is added to the solution so that the value of Wt % is equal to 2.5%. The fluid viscosities with and without the polymer additive were determined at 100 sec −1 from 70° F. to 310° F. and plotted FIG. 2 . FIG. 3 shows that a substantial decrease in fluid viscosity is achieved upon adding the polystyrene sulfonate breaker. This reduction in fluid viscosity is permanent.
EXAMPLE 4
Polymer as Viscosity Booster
A base fluid was prepared by adding to water 2.4 wt % of erucic amidopropyl dimethyl betaine. 0.42 wt % of polynaphthalene sulfonate (having a molecular weight estimated to be about 30000) is added to the solution so that the value of Wt % is equal to 17.5%. The fluid viscosities with and without the polymer additive were determined at 100 sec −1 from 50° F. to 300° F. and plotted FIG. 4 . FIG. 4 shows that a substantial increase in fluid viscosity is achieved by adding the polymer, and this increase is especially significant at temperatures between about 200–220° F.
EXAMPLE 5
Polymer as Viscosity Booster
A base fluid was prepared by adding to water 2.0 wt % of erucic amidopropyl dimethyl betaine. 0.24 wt % % of polystyrene sulfonate (having a molecular weight estimated of about 1,000,000) is added to the solution so that the value of Wt % is equal to 10%. The fluid viscosities with and without the polymer additive were determined at 100 sec −1 from 150° F. to 230° F. and plotted FIG. 5 . Again, a substantial increase in fluid viscosity is achieved by the addition of the polymer.
EXAMPLE 6
Polymer as Viscosity Booster
A base fluid was prepared by adding to water 4 weight percent of cationic quaternary amine and 4% potassium chloride. Polystyrene sulfonate (having a molecular weight of about 30,000) is added at a concentration of 20 lb 1000 gal of base fluid, corresponding to a weight ratio of 10%. The viscosity of the base fluid with/without the polymer additive were determined at 100 sec −1 from 50° F. to 260° F. and plotted FIG. 6 . A significant increase of the viscosity was observed at the lower and higher temperatures. Some viscosity reduction was observed within the intermediate temperature range.
EXAMPLE 7
Polymer as Healer
A base fluid was prepared by adding to water 4 wt % of cationic quaternary amine and 4% potassium chloride. Polystyrene sulfonate (having a molecular weight of about 30,000) is added at a concentration of 10 lb/1000 gal of base fluid, corresponding to a weight ratio of 5%. The fluid is subject to a shear of 5,000 sec −1 for 3 minutes. The viscosity of the base fluid with/without the polymer additive was determined at 1 sec −1 and 70° F. and is plotted along time FIG. 7 . The addition of the polymer provides a quick recovery of the viscosity when the high shear was terminated.
EXAMPLE 8
Polymer as Healer
A base fluid was prepared by adding to water 2.0 wt % of erucic amidopropyl dimethyl betaine. 0.06 wt % of polystyrene sulfonate (having a molecular weight estimated to be about 30,000) is added to the solution so that the value of Wt % is equal to 2.5% The fluid is subject to a shear of 5,000 sec −1 for 3 minutes. The viscosity of the base fluid with/without the polymer additive were determined at 1 sec −1 and 70° F. is plotted along time FIG. 8 . The addition of the polymer provides a quick recovery of the viscosity when the high shear was terminated.
EXAMPLE 9
Polymer as Healer
A base fluid was prepared by adding to water 2.4 wt % of erucic amidopropyl dimethyl betaine. 0.06 wt % of polynaphthalene sulfonate (having a molecular weight estimated of about 70,000) is added to the solution so that the value of Wt % is thus equal to 2.5% The fluid is subject to a shear of 5,000 sec −1 for 3 minutes. The viscosity of the base fluid with/without the polymer additive were determined at 1 sec −1 and 70° F. is plotted along time FIG. 9 . The addition of the polymer provides a quick recovery of the viscosity at no shear.
EXAMPLE 10
Polymer as Breaker
A base fluid was prepared by adding to water 6 weight percent of erucic amidopropyl dimethyl betaine VES fluid. 0.3 weight percent % of polypropylene glycol (having a molecular weight estimated of about 4,000) is added to the solution so that the value of Wt % is thus equal to 12.5% The viscosity of the base fluid with/without the polymer additive were determined at 100 sec −1 and plotted along temperature FIG. 10 . The addition of the polymer provides a decrease of viscosity.
The preceding description of specific embodiments of the present invention is not intended to be a complete list of every possible embodiment of the invention. Persons skilled in this field will recognize that modifications can be made to the specific embodiments described here that would be within the scope of the present invention. In particular, though the different embodiments of the present invention were optimised for hydraulic fracturing applications, the invention is also applicable to numerous other oil field applications using surfactant-based complex fluids such as acidizing, gravel packing, coiled tubing cleanup, and other novel chemical treatments. | It was found that the addition of polymers to viscoelastic surfactant base system allows to adjust the rheological properties of the base fluid. Depending in particular on one side of the ratio of the concentration of added polymer and the concentration of viscoelastic surfactant and on the other side of the molecular weight of the added polymer, the same polymer—or the same type of polymer—may perform different functions such as viscosity enhancer, viscosity breaker or viscosity-recovery enhancer. | 8 |
FIELD OF THE INVENTION
[0001] This application relates to circuit topologies and associated control processes for converting power generated via an electromagnetic machine into usable power, and more particularly for converting power generated from a multi-stage electrical generator into a usable form of power for consumption by an electrical load, such as, but not restricted to, an electric utility power grid.
BACKGROUND OF THE INVENTION
[0002] For conventional fluid-flow electrical-generation turbine systems, such as wind turbine systems, in which the energy source is variable (i.e. the fluid speed and the rate of flow of the fluid varies over time), the amount of energy captured from the energy source may only be a fraction of the total of the energy that may be capturable over time. For example, in a typical wind farm, that fraction may be one half, or less.
[0003] The power flow though a variable-speed conventional turbine/generator/transformer system is restricted in the range of power it can output, i.e., from a minimum output power to a rated output power, because of limitations of the generator, the power converter (if present), and the output transformer used within the system. This restriction arises because a conventional electromagnetic generator has reduced efficiency at lower power levels, as does the power converter (if present) and particularly the transformer that couples power to the electrical load. As a result, for the conventional variable-speed turbine/generator/transformer system an engineering design decision is usually made to limit the power rating of the generator (and any associated power converter, power conditioner or power filter, if present) and the associated output transformer so as to optimize efficiency over a restricted range of power. Therefore, at the extremes of normal-operating fluid speeds, i.e., at a low fluid speed and especially at a high fluid speed, less power is coupled into the turbine than it is possible to extract from the fluid energy source. For a given design of turbine diameter (and possibly axial length) this translates, over time, into less energy capture than the turbine may be capable of transmitting to the generator.
[0004] To increase energy capture in situations in which the energy source has a variable speed of fluid driving the turbine, and in which the turbine may have a variable speed of rotation, a multi-stage generator may be used in the turbine system. A multi-stage generator is an electromagnetic machine operating as an electrical generator that takes mechanical energy from a prime mover and generates electrical energy, usually in the form of AC power. Such a multi-stage generator is disclosed in U.S. Pat. No. 7,081,696 and U.S. Patent Application Publication No. 2008/0088200, which are both hereby incorporated by reference. An advantage of a multi-stage generator over a conventional generator is that a multi-stage generator can be dynamically sized depending on the power output of the turbine. A conventional generator is effective at capturing energy from the energy source over a limited range of fluid speeds, whereas a multi-stage generator is able to capture energy over an extended range of fluid speeds of the energy source, due to staged power characteristics.
[0005] The electrical power that is generated from a multi-stage generator is variable in nature, meaning the output power waveforms produced may vary from time to time, for example in: voltage amplitude; current amplitude; phase; and/or frequency. Additionally a multi-stage generator may include a number of induction elements, each of which generates its own power waveform, which may differ in voltage amplitude, current amplitude, phase, and/or frequency, from that generated by other induction elements within the generator. An electrical load such as an electric utility power grid may not be capable of consuming directly the electrical power that is generated by a multi-stage generator, as the power generated may not be in the correct form, for example, with respect to waveform shape as a function of time, voltage amplitude, current amplitude, phase, and/or frequency, as may be required by the electrical load. An electrical load such as a utility power grid typically expects from a turbine electrical generation system a single-phase, or split-phase, or 3-phase voltage or current waveform that is usually sinusoidal, and relatively stable, but a multi-stage generator generates varying waveforms.
[0006] A power converter circuit may be used to transform electrical power waveforms from one form to another form. Converters may be designed for a specific rating of the input voltage range (e.g. 1000 VAC-rms to 2000 VAC-rms) and input current range rating (e.g. 100 A-rms to 500 A-rms), but if the input voltage or input current (and therefore power level) do not meet or exceed the levels for which the converter is designed, then the converter may not be capable of operation, or the converter may operate in an inefficient manner. For a multi-stage generator a single power converter is unlikely to accommodate the widely varying voltage waveforms and power range that is generated. Moreover, a single power transformer delivering power to the electrical load, connected to one or more converters, is unlikely to accommodate with reasonable efficiency the wide range of power that may be generated by a multi-stage generator.
SUMMARY OF THE INVENTION
[0007] To take advantage of the electrical energy generated by the multi-stage generator, it is desirable to provide a power conversion system that combines and converts a portion, or all, of the electrical power waveforms generated by the multi-stage generator into a usable form consumable by an electrical load. The conversion system should maintain a high level of efficiency and facilitate the multi-stage generator to operate efficiently and effectively over the power range that the generator is capable of producing; meaning the power conversion process should not limit the range (from the lowest level to highest level) of power that may be generated by the multi-stage generator.
[0008] A suitable power conversion system, including an associated control process, is desirable to take advantage of the benefits of using a multi-stage generator within a turbine electrical generation system, resulting in a higher energy capture of the energy source over a wider range of fluid speeds (or over a wider range of fluid flow-rates) compared to conventional turbine electrical generation systems.
[0009] Further, for a multi-stage generator to function near-optimally (such as delivering a near-maximum power to the electrical load with a near-minimum of losses in the turbine/generator/converter system), over a wide range of fluid speeds or a wide range of fluid flow-rates, with existing turbines, a controller can be used to control the power conversion electronics that process the output power waveforms of the generator. When desirable, a controller can also allow the system to seek to maximize the amount of energy capture from the energy source by seeking to optimize the turbine's parameters, such as blade pitch and turbine yaw, in response to time-dependent characteristics of the energy source such as the fluid speed and direction of flow. Based on these and other inputs, the system's electronic power conversion process would choose the near-optimal conversion strategy for delivering power to the electrical load.
[0010] An electric power generation system is provided, including a power generator having a plurality of machine configurations, the configurations selectively engageable by a prime mover; and a plurality of branches for connecting the configurations to an electrical load, each of the branches having a switch for connecting or disconnecting the branch to the configuration.
[0011] A method of connecting a power generator having a plurality of stages, to an electrical load, is provided, each of the stages being connected to the load via a corresponding branch having a converter, each of the converters having a differing power range, including the steps of: (a) determining a power output of the generator; (b) selecting one of the branches, wherein the power output of the selected branch has a converter capable of accepting the power output; and (c) passing the power output to the electrical load along the selected branch.
[0012] A method of connecting a power generator having a plurality of stages, to an electrical load is provided, each of the stages connected to the load via a corresponding branch having a converter and a parallel series selector, each of the converters having the same power range, including the steps of: (a) determining a power output of the generator; (b) configuring at least one of the parallel series selector for the power output; (c) selecting one or more of the branches corresponding to the configured parallel series selectors; and (d) passing the power output to the electrical load along the selected branches.
[0013] An electric power generation system is provided, including a power generator having a plurality of stages, each of the stages having at least an induction element, the induction elements engaged by a turbine; a plurality of branches for connecting the stages to an electrical load, each of the branches having a switch for connecting or disconnecting the branch to the stages; a turbine; and a system controller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The following figures set forth embodiments of the invention in which like reference numerals denote like parts. Embodiments of the invention are illustrated by way of example and not by way of limitation in the accompanying figures.
[0015] FIG. 1 is a block diagram of an embodiment of a turbine/generator/converter (TGC) system;
[0016] FIG. 2 is a block diagram of an embodiment of a multi-stage generator;
[0017] FIG. 3 is a flowchart showing an example of a control process by which a bank of converters converts the electric power into a useable form;
[0018] FIG. 4 is a block diagram of an alternative embodiment of a turbine/generator/converter system including a parser conversion topology;
[0019] FIG. 5 is a block diagram of an alternative embodiment of a multi-stage generator illustrating induction elements that may not need to be hardwired for interface to a parser conversion topology;
[0020] FIGS. 6A and 6B are a flowchart showing an example of a control process by which a parser conversion system converts electric power into a useable form;
[0021] FIG. 7 is a block diagram of an embodiment of a turbine/generator/converter system wherein the interface includes a hybrid conversion topology;
[0022] FIG. 8 is a block diagram of an embodiment of a multi-stage generator illustrating induction elements that may be hardwired to facilitate interface to a hybrid conversion topology;
[0023] FIGS. 9A and 9B are a flowchart showing an example of a control process by which a hybrid conversion system converts electric power into a useable form;
[0024] FIG. 10 is a block diagram of an embodiment of a branch having a fork to allow selection of a converter;
[0025] FIG. 11 is a block diagram of an alternative embodiment of a branch, wherein the branch has a fork to allow selection of a transformer; and
[0026] FIG. 12 is a block diagram of a further alternative embodiment of a turbine/generator/converter system, wherein the interface includes a hybrid conversion topology employing a forked branch.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0027] In this document, the following terms will have the following meanings:
[0028] “energy source” means a fluid medium, for example such as air, water, or steam, in motion, possessing kinetic energy due to translational motion.
[0029] “prime mover” means a device, such as a turbine or drive motor acted on by a power source, such as an energy source, to produce mechanical energy.
[0030] “turbine” means a device, usually including blades or fins, connected to a shaft, that are acted upon by an energy source to produce mechanical energy in the form of rotational motion of the shaft. It includes turbines used to harness energy from wind, tide, run-of-river and solar and other renewable energy sources.
[0031] “multi-stage generator” means an electromagnetic machine that converts mechanical energy from a turbine into electrical energy. Electrical power may be generated by a multi-stage generator from a number of induction elements that can each produce a voltage. Some induction elements may be hardwired, either within the multi-stage generator casing or external to the casing (although a casing need not be present). The multi-stage generator may be a motor operating in generation mode.
[0032] “induction element” means a coil of insulated metallic wire that generates a voltage across terminals as the wire passes though a magnetic field.
[0033] “stage” means a logical grouping of induction elements. The induction elements within a stage may have an almost equal frequency of the voltage waveform. A stage may have all induction elements operating in phase, or poly-phase induction elements may be present in the stage. A stage may or may not have a phase equal to another stage.
[0034] “machine configuration” means the sizing and configuration of induction elements, and may including the staging of induction elements.
[0035] “parallel series selector” or “parser” means an electronic or mechanical or electro-mechanical switching device that connects induction elements together in a number of configurable arrangements of parallel and/or series combinations. A parser may also be referred to as a “configurator”.
[0036] “power converter” or “converter” means an electronic circuit that changes the form (e.g. waveform shape as a function of time, voltage amplitude, current amplitude, phase, and/or frequency) of electrical power waveforms. A converter may include a rectification step.
[0037] “turbine/generator/converter system” or “TGC system” means a system including a turbine, an electrical generator (such as a multi-stage generator) and a power converter. A TGC system may optionally further include some or all of the following components: ring gear or gearbox; parser(s); transformer(s); switch(es); and control system(s). A TGC system transforms a portion of the kinetic energy of an energy source into electrical energy.
[0038] “electrical load” means a consumer of electrical energy, and may be a stand-alone off-grid application, for example electrical devices within a residence, commercial building or industrial process; or may be a micro-grid system providing electrical energy for an isolated rural village; or a large electric utility power grid; or other application.
[0039] “power conversion topology” means an arrangement of hardware components, such as one or more, parsers, power converters, transformers, and switches. A power conversion topology may be used as an interface between a multi-stage generator and an electrical load.
[0040] “power conversion system” means a power conversion topology and its associated controller. A power conversion system may be a subsystem of a TGC system.
[0041] “branch” means an arrangement including any, but not necessarily all, of the following elements: a parser, input switch or switches; a converter; a transformer; output switch or switches; connected in series. A branch may be a subsystem of a power conversion topology.
[0042] “bank of converters system” means a power conversion system including a bank of converters topology and an associated controller.
[0043] “parser conversion system” means a power conversion system including a parser conversion topology and an associated controller.
[0044] “hybrid conversion system” means a power conversion system including a hybrid conversion topology with one or more branches, and an associated controller.
[0045] “system controller” means a computer, microcontroller, digital signal processor, embedded system, analog circuit or other implementation that performs monitoring functions and issues commands to various subsystems and/or components of a system, such as a TGC system. In addition, a system controller may also monitor an energy source and/or electrical load, and may provide information to an electrical load (for example, if the electrical load is an electric utility power grid).
[0046] “fluid flow-rate” means the quantity of fluid, such as air, water or steam, per unit time that moves through a turbine, measured in units such as cubic feet per minute, gallons per minute, liters per second, or kilograms per second.
[0047] “average-power” means the mean power as evaluated over one or more cycles of power delivery, for example as evaluated over a period of 16.67 milliseconds in a 60 Hz system.
[0048] “rated-power” or “name-plate power” means the highest value continuous average-power that a device (e.g. turbine, generator, converter, power conversion system, transformer, or TGC system) is specified to deliver.
[0049] “machine utilization” means the proportion of an electromagnetic machine, such as a multi-stage generator, not including the machine casing, that is active and delivering power when the machine is operating at rated-power, i.e. at the maximum continuous average-power capability of the machine. This proportion may be specified in various manners, including the ratio of the weight, e.g. in Kg, of the active portion of the machine to the weight of the machine not including the machine casing, or the ratio of the number of active induction elements to the total number of induction elements within the machine.
[0050] “maximum energy capture mode” means a mode of operation of a TGC system wherein, for a given fluid flow-rate through the turbine, the system controller delivers as much power as possible (i.e. the designed-maximum continuous average-power at that fluid flow-rate) from the energy source to the electrical load up to and including the rated-power of the TGC system. Maximum energy capture mode may also be referred to as “maximum power point tracking” (MPPT).
[0051] “throttling” means a mode of operation of a TGC system wherein the system controller limits and regulates the average-power delivered to the electrical load to a value less than that which may be delivered for a given flow-rate of fluid through the turbine. In practice, throttling of a TGC system may sometimes be necessary; however extended use of such a mode of operation may considerably reduce the energy capture over time of a given TGC system. Note that in maximum energy capture mode, the TGC system enters throttling mode when the system is operating at its rated-power.
[0052] “functional” means a component of a system that is capable of performing its intended function.
INTRODUCTION
[0053] A system controller may be used to automatically maintain the efficient conversion of power during operation of a multi-stage generator turbine/generator/converter system. The system controller may exist as a single controller which controls all functions of the turbine/generator/converter system, or may be separated into a number of sub-controllers with their own functions.
[0054] In some embodiments, a major function of the system controller is to control the turbine, such as monitoring and adjusting the pitch of the blades and the yaw of the turbine. A second major function of the system controller may be to monitor and control the power conversion electronics to provide an efficient and controlled transfer of power between the output of the multi-stage generator and the electrical load.
[0055] A system controller can be used to facilitate communication between components of the system; for example, in some embodiments it monitors sensors and/or receives information about system components and/or about the electrical load; it provides the relevant components with the necessary information to operate near-optimally and correctly; it instructs subsystems and components by providing adjustments and/or command signals. Inputs for the system controller may include, but are not restricted to, fluid speed; fluid direction; fluid statistical information; the position information and/or the derivatives of position information for casing or supporting structural elements; turbine position and/or speed and/or acceleration; blade pitch angle; turbine pitch and/or yaw; current, voltage, power, reactive power, distortion, measurements at various points within the system or of the electrical load; sensory or data information about characteristics of the electrical load. The system controller typically receives sensor and/or data information and issues commands to the turbine and components of the power conversion system to ensure the safe and efficient transfer of power from the turbine to the electrical load. For controlling the power conversion process of a multi-stage generator turbine/generator/converter system, the system controller may initiate and activate power generated from a stage, including the engagement, transfer, and disengagement of power through any given stage. The system controller preferably provides a smooth transfer of power between stages and an uninterrupted power flow to the electrical load, and when desirable may do so in such a way as to increase or maximize the energy capture from the fluid that is flowing through the turbine.
Bank of Converters System
[0056] In this document, the letters i, j, k, x, y and z will be used with reference numbers to refer to specific components referenced in the drawings. A reference number without a subscript may apply to any of the subscripted components sharing the same reference number.
[0057] Illustrated in FIG. 1 is a TGC system, which includes one embodiment of a power conversion topology, referred to here as a bank of converters topology 10 x . Bank of converters topology 10 x has one or more converters 20 in different branches 30 that are each connected to a stage of induction elements within multi-stage generator 40 x.
[0058] Shown in FIG. 2 is an illustration of multi-stage generator 40 x that may be interfaced with bank of converters topology 10 x . Within multi-stage generator 40 , such as 40 x , are a number of induction elements 50 , which can be grouped into two or more different logical groupings referred to as stages 60 , such as 60 i , 60 j , 60 k in FIG. 2 . A logical grouping means that the induction elements within a group 60 , for example stage 60 i , share a common set of characteristics, primarily spatial locality, so that the generated voltage, amplitude and phase of a single induction element 50 will match those of other induction elements 50 within the grouping 60 . Within one stage of a multi-stage generator 40 , the possibility exists for single-phase, split-phase, 3-phase, 4-phase, 6-phase or other poly-phase arrangements of induction elements 50 .
[0059] As illustrated in FIG. 2 , induction elements 50 within a stage 60 may be hardwired and connected together into a combination of parallel and/or series connections. Induction element terminals 70 may be hardwired within the casing of multi-stage generator 40 , or induction element terminals 70 may be hardwired external to the casing of multi-stage generator 40 . Alternatively, no casing is needed and terminals 70 may be hardwired within multi-stage generator 40 or external to multi-stage generator 40 . In general there may be any practical number of induction elements 50 within a stage 60 , possibly in poly-phase arrangements, and a variety of series, parallel, or mixed series-parallel connections are possible; also there may be no hardwiring of induction elements 50 .
[0060] The output terminal-block 80 from each stage 60 may connect to a branch 30 , which may include input switch 90 , converter 20 , optional transformer 100 , and output switch 110 , all connected in series. The outputs of each branch 30 may be connected to electrical load 120 . Each input switch 90 , such as 90 i , includes several poles of switches, which may close or open simultaneously, to accommodate the terminals of a terminal-block 80 , such as 80 i , for a given stage 60 , such as 60 i , of a multi-stage generator 40 . Each output switch 110 , such as 110 i , includes several poles of switches, which may close or open simultaneously, to accommodate the terminals of electrical load 120 .
[0061] For bank of converters topology 10 x , the power rating of converter 20 and/or transformer 100 may increase geometrically from one stage to the next, so that if at the first stage 60 i a relatively low power converter 20 i is required, the next stage 60 j may require a significantly higher power converter 20 j , etc. For multi-stage generator 40 x , this allows for stage 60 j to contain many more induction elements 50 than that of stage 60 i , and similarly stage 60 k may have many more induction elements than stage 60 j , etc.
[0062] Turbine 130 , acting as a prime mover, may be directly connected to a multi-stage generator 40 or there may be a ring-gear or gearbox 140 coupling turbine 130 to multi-stage generator 40 . Turbine 130 , as the prime mover, engages multi-stage generator 40 thereby inducing a voltage across induction elements 50 .
[0063] Components and/or subsystems of the TGC system may be interfaced to a system controller 150 , such as 150 x , including but not limited to the following components: turbine 130 , induction elements 50 , branches 30 , input switches 90 , converters 20 , transformers 100 , output switches 110 and electrical load 120 . Among other turbine related tasks, system controller 150 may provide commands to control the pitch of the turbine blades. System controller 150 may also monitor the fluid medium, for example sensing the speed of the fluid at various possible locations in and around the turbine. System controller 150 may also monitor the rotational speed of turbine 130 and/or of multi-stage generator 40 . System controller 150 may also monitor power variables at various points in the TGC system. System controller 150 may also monitor various current, voltage, phase angle, power or other variables of electrical load 120 and may also provide information to electrical load 120 . System controller 150 , or a dedicated sub-controller (not shown), may also synchronize the output voltage or current of branch 30 with the voltage waveform of electrical load 120 , which may be an electric utility power grid.
[0064] To accommodate the entire or near-entire range of output power that multi-stage generator 40 may be capable of producing, multiple converters 20 and/or transformers 100 may be used in a TGC system. For bank of converters topology 10 x , these multiple converters 20 and/or transformers 100 are arranged so that power flows, with reasonably high efficiency, through one branch 30 corresponding to a given power level range that may be generated by a given stage 60 of multi-stage generator 40 x , (except during a transition period when power is being transferred from one branch to another branch, such as from 30 i to 30 j ). There may be a slight overlap in the power level ranges for stages 60 of multi-stage generator 40 x . For example, the top value of the power range for stage 60 i may be a small percentage higher than the lowest value of the power range for stage 60 j . Similarly, and correspondingly, there may be a slight overlap in the power level ranges for branches 30 of bank of converters 10 x . For example, the top value of the power range for branch 30 i may be a small percentage higher than the lowest value of the power range for branch 30 j . The overlap of power ranges aids system controller 150 to effect a smooth transfer of power flow from one stage (branch) to the next stage (branch) as the power level of the prime mover, i.e. the turbine, varies with time.
[0065] Input switch 90 , such as 90 i , may be connected to a corresponding converter 20 , such as 20 i , and used by system controller 150 to select a branch 30 , such as 30 i , which may then be activated by system controller 150 and then transform power from a multi-stage generator 40 (alternatively power switching devices within converter 20 may serve a similar purpose so that input switches 90 are not needed). An output switch 110 , such as 100 i , may be opened to prevent excitation of a transformer 100 , such as 110 i , within an inactive branch, such as 30 i . Output switches 110 also act as a fail-safe to prevent power being delivered to electrical load 120 from inactive converter branches 30 , and may facilitate the transfer of power from one branch 30 to another branch 30 , and provide additional isolation (with manually operated circuit breakers) for maintenance purposes.
[0066] Referring to the flowchart of FIG. 3 , system controller 150 , and/or a delegated sub-controller, may perform the monitoring of variables, such as, but not restricted to, the monitoring of power flow from a multi-stage generator 40 (multi-stage generator 40 power output may also be obtained by measurement of the input power to power conversion topology 10 ). System controller 150 also makes decisions and executes tasks, using a control process outlined in the flowcharts, such as illustrated in FIG. 3 . The control process that is used generally seeks to maximize energy capture mode when, for a given fluid flow-rate, it is desirable to deliver as much power as possible from the energy source to electrical load 120 , up to and including the rated-power of the TGC system. A variation of the maximum energy capture mode of operation is a throttling mode wherein a system controller 150 is instructed by an operator (which may be a person or another controller, for example a controller that governs operation of a wind farm) to deliver a limited and/or regulated average-power to electrical load 120 that may be less than the rated-power of the TGC system. Even in maximum energy capture mode, once the rated-power delivery of the TGC system is obtained, system controller 150 may enter a throttling mode wherein the average output power of the TGC system is regulated to be the rated-power of the TGC system, and multi-stage generator 40 is operating at its rated-power level.
[0067] FIG. 3 is a flowchart showing an embodiment of a control process by which system controller 150 x may control bank of converters topology 10 x to transform the electric power produced by multi-stage generator 10 x into a useable form for electrical load 120 . The bank of converters system may be in a standby mode (step 300 ) when there is no power output from the multi-stage generator 40 x . In standby mode all branches 30 may be disconnected from electrical load 120 , i.e. input switches 90 may all be open and output switches 110 may be all open.
[0068] Under control of system controller 150 , voltage may be induced in induction elements 50 if there is sufficient fluid flow of an energy source in turbine 130 to rotate of the shaft of multi-stage generator 40 . A power conversion topology 10 , such as bank of converters topology 10 x , remains inactive and in standby mode (step 300 ) until multi-stage generator 40 produces power exceeding a pre-defined threshold level, defined herein as “P1+” (step 305 ), where P1+ is generally a small percentage greater than the minimum operating input power of power conversion topology 10 , defined herein as “P1−”. At this point, referring to the bank of converters system and conversion topology 10 x , switch 90 i , connected to the lowest level stage 60 i , may close and under control of system controller 150 x branch 30 i becomes active, including converter 20 i and/or transformer 100 i , but no power is yet flowing to electrical load 120 . It may be desirable at this time to control the voltage at the output of converter 20 i or the output voltage of transformer 100 i such that the voltage is in the correct form for electrical load 120 , at which time output switch 110 i may be closed (step 310 ) (it is also possible to close switch 90 i after closing switch 110 i ) thereby connecting transformer 100 i to electrical load 120 , and then power is delivered, under control of system controller 150 x , from stage 60 i of multi-stage generator 40 x though the lowest power-range converter 20 i of branch 30 i to electrical load 120 (step 315 ). At this point a single converter branch 30 i is active and transforming power, meaning that converter 20 i and transformer 100 i have power flowing through them.
[0069] In general for the illustrated bank of converters system embodiment, if the power level for the currently active converter branch 30 decreases past a certain level (which, referring to the “−” notation, may be slightly less than the threshold necessary to begin power flow in that branch), then the flow of power is transferred to the preceding branch. If there is no previous branch then the bank of converters topology 10 x and system controller 150 x return to standby mode. Likewise, if the power level for the currently active converter branch 30 increases past a certain level (referring to the “+” notation), then flow of power is transferred to the next branch having a higher power rating (for example branch 30 j may be capable of transforming power at higher levels than branch 30 i ). If there is no next branch then the TGC system is operating at its rated-power level, and a multi-stage generator 40 , such as 40 x , is delivering its rated-power defined herein as “P max ” where P max is the rated-power of a multi-stage generator 40 , such as 40 x , corresponding to and slightly greater than the rated-power of the TGC system, due to losses in power conversion topology 10 .
[0070] For example, referring again to FIG. 3 , as power flows through branch 30 i (step 315 ), system controller 150 X monitors the output power level of multi-stage generator 40 x (step 320 ), and if the power level drops below P1−, the system returns to standby mode (step 300 ), meaning that power flow in branch 30 i is reduced to zero by system controller 150 x and then switches 110 i and 90 i are opened, preferably in that order. Note that system controller 150 x may return the system to standby from other steps, such as, but not restricted to, steps 345 or 382 .
[0071] If (at step 320 ) the power level is between P1− and P2+, then system controller 150 x retains the power flow through branch 30 i (step 315 ). If (at step 320 ) the power level exceeds P2+, then the switches for the next branch 30 , branch 30 j , switches 90 j and 110 j , are closed, preferably, but not necessarily, in that order (step 325 ). Power flow is then transferred by system controller 150 x to branch 30 j (step 330 ), and at least one of switches 110 i and 90 i are opened (step 335 ), and power flows only through branch 30 j (step 340 ).
[0072] As power flows through branch 30 j (step 340 ), system controller 150 x monitors the output power level of multi-stage generator 40 x (step 345 ), and if the power level is between P2− and P3+, then the system controller 150 x retains the power flow through branch 30 j (step 340 ).
[0073] If (at step 345 ) the power level drops below P2−, then system controller 150 x returns power flow in bank of converters topology 10 x to branch 30 i , possibly using the following sequence of steps. Switches 90 i and 110 i are closed (step 350 ), then system controller 150 x causes power flow to transfer to branch 30 i (step 355 ), after which switches 110 j and 90 j are opened (step 360 ).
[0074] If (at step 345 ) the power level exceeds P3+, then switches 90 k and 110 k are closed (step 365 ), and power is transferred by system controller 150 x from branch 30 j to branch 30 k (step 370 ), following which switches 110 j and 90 j are opened (step 375 ) so that the transfer of power from branch 30 j to branch 30 k is complete and power flows only though branch 30 k (step 380 ).
[0075] As power flows through branch 30 k (step 380 ), system controller 150 x monitors the output power level of multi-stage generator 40 x (step 382 ), and if the power level is between P3− and P max , then system controller 150 x retains the power flow through branch 30 k (step 380 ). Note that when power level P max is obtained system controller 150 x may enter a throttling mode (also step 380 ). If (at step 382 ) the power level drops below P3−, system controller 150 x returns power flow in bank of converters topology 10 x to branch 30 j possibly using the following sequence of steps. Switches 90 j and 110 j are closed (step 384 ), then system controller 150 x causes power flow to transfer to branch 30 j (step 386 ), after which switches 110 k and 90 k are opened (step 388 ).
[0076] If (at step 382 ), or at other steps including, but not restricted to, steps 320 and 345 , an emergency condition arises (for example a storm or hurricane winds applied to a wind turbine), it may be necessary for system controller 150 x to shut down operation of the TGC system by setting power flow through the TGC system to zero and preferably stopping rotation of turbine 130 (step 390 ).
[0077] If the fluid flow-rate in turbine 130 exceeds a threshold value, herein designated “f max ”, corresponding to the power rating P max , and possibly also corresponding to a specific speed of the fluid at some point in or around the turbine, system controller 150 then enters a throttling mode and regulates the power flow through the TGC system to be at the maximum level of P max (hence the “≦” condition in the monitoring and decision step 382 of FIG. 3 , where for fluid flow-rate greater than f max , it may be desirable for system controller 150 to operate the TGC system with power from multi-stage generator 40 at a constant average power of P=P max ; aside from inefficiency in power conversion topology 10 a power of approximately P max would in this case be delivered to electrical load 120 , as implied by the loop from step 382 to step 380 ). If the fluid flow-rate continues to increase to or beyond a second threshold value, herein designated “f excess ” (possibly corresponding to a specific speed of the fluid at some point in or around the turbine that may be measured by system controller 150 , or possibly corresponding to a specific rotational speed of the shaft of turbine 130 or a specific shaft speed of multi-stage generator 40 , any of which may be measured by system controller 150 ), then the fluid flow-rate may be excessive for turbine 130 to maintain its mechanical integrity. Such a situation is one example of an emergency condition, wherein it may be necessary for system controller 150 to shut down operation of the TGC system by setting power flow through the TGC system to zero and preferably stopping rotation of turbine 130 (step 390 ).
[0078] For the bank of converters embodiment, and for other embodiments, the activation or deactivation of a branch 30 may be initiated when a power threshold is crossed (e.g. for the bank of converters power conversion system there may be a transfer of power flow from branch 30 i to branch 30 j initiated when multi-stage generator 40 x output power exceeds P2+). However, a system controller 150 , such as 150 x , may initiate the activation or deactivation of a branch 30 using system variables other than the power from a multi-stage generator 40 , such as but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 ; the output voltage of stages 60 as measured at a terminal-block 80 or directly across one or more induction elements 50 of multi-stage generator 40 ; and/or the input voltage to a power conversion topology 10 . For example, in a power throttling mode, when it is desirable to control the power delivered by the TGC system to electrical load 120 to be at a level less than the maximum possible for a given fluid flow-rate, the transfer of power from one branch 30 to the next branch 30 (or addition or removal of a branch 30 for the embodiments discussed below) may be initiated when the voltage output from a given stage exceeds (or drops below) a voltage threshold (e.g. for the bank of converters power conversion system there may be a transfer of power flow from branch 30 i to branch 30 j when the output voltage of stage 60 i exceeds a voltage threshold defined herein as “V2+”, following which stage 60 i could be inactivated). Such operation by the system controller 150 would maintain the voltage input to each converter within a specified range and thus prevent damage to, or maintain high efficiency operation of, the converters 20 and transformers 100 of the power conversion topology 10 .
[0079] The above discussed principles of operation for the bank of converters system may be extended (or simplified) in the case where there are more than (or fewer than) three branches 30 . In general, there may be any practical number of branches 30 within a power conversion topology 10 , such as bank of converters topology 10 x.
Parser Conversion System
[0080] The above discussed embodiment of a power conversion system, a bank of converters system, has an elegance of process control as only one stage 60 and one corresponding branch 30 is active at a given time, aside from periods when power is being transferred from one branch 30 to another branch 30 . However, at the highest power level, P max , there are unused inactive stages 60 within the multi-stage generator 40 . For the above-described bank of converters embodiment, the highest power stage 60 , which may be stage 60 k as in FIG. 2 , may contain the largest number of induction elements 50 compared to other stages, at the TGC system rated-power (corresponding to power P max delivered by multi-stage generator 40 x ) machine utilization of multi-stage generator 40 x may be less than 100%, for example on the order of 75% at a rated-power on the order of one megawatt to ten megawatts, meaning that 75% of induction elements 50 within multi-stage generator 40 x are activated and 25% are inactive when the TGC system is operating at its rated-power level (when multi-stage generator 40 x is operating at its rated-power level P max ).
[0081] Another embodiment of a power conversion system, which may have up to 100% machine utilization of a multi-stage generator 40 is referred to herein as a parser conversion system, and includes parser conversion topology 10 y and its associated controller, system controller 150 y , as shown in FIG. 4 . An illustration of a multi-stage generator 40 y which may be interfaced with parser conversion topology 10 y is shown in FIG. 5 . For this embodiment, multi-stage generator 40 y may require no hardwiring of induction elements 50 , i.e., all induction element terminals 70 within a stage 60 , such as 60 i , are connected to terminal-block 80 , such as 80 i , as indicated in FIG. 5 . A corresponding process control flowchart that could be employed by system controller 150 y in the control of parser conversion topology 10 y is shown in FIG. 6 .
[0082] As seen in FIG. 4 parser conversion topology 10 y includes one or more branches 30 . In FIG. 4 , three branches i, j, and k, are represented, although any practical number of branches may be present. Each branch 30 may include a parser 170 , an input switch 90 , a converter 20 , an optional transformer 100 , and an output switch 110 , all connected in series. The output switch 110 from each branch 30 is connected to electrical load 120 , which may be an electric utility power grid. A key concept of the parser conversion topology 10 y , is the modular design, in that each branch 30 may be substantially identical in form with all other branches, i.e. all of the parsers 170 i , 170 j , 170 k (as shown in FIG. 4 ) may be substantially identical, as may be input switches 90 i , 90 j , 90 k , converters 20 i , 20 j , 20 k , transformers 100 i , 100 j , 100 k , and output switches 110 i , 110 j , 110 k.
[0083] FIG. 5 shows a multi-stage generator 40 y which may have any practical number of stages 60 , each of which may be substantially identical, each stage 60 including a number of induction elements 50 . Thus multi-stage generator 40 y may also have a modular design. The modularity of parser conversion topology 10 y and of the multi-stage generator 40 y enables one stage-branch pair to function in place of a second stage-branch pair should the latter be damaged. For example if stage 60 i is damaged (and multi-stage generator 40 y is otherwise intact) or if branch 30 i is damaged, then stage 60 j and branch 30 j may provide power flow to electrical load 120 in place of stage 60 i and branch 30 i , as decided by system controller 150 y , after the performance of diagnostic tests to determine the functionality of stages 60 and branches 30 . Such replacement of damaged stages 60 and/or branches 30 is facilitated by input switches 90 and output switches 110 , permitting normal TGC system operation or a reduction in TGC system operation until repairs are affected. In the above example, input switch 90 i and output switch 110 i may both be kept open isolating the damaged component from electrical load 120 , or in the specific case of a damaged stage 60 , isolating that stage 60 from its branch 30 of parser conversion topology 10 y.
[0084] For the illustrated parser conversion system embodiment, assuming no damaged stages 60 or branches 30 , as the power level of turbine 130 increases, more stage-branch pairs may be activated, until the rated-power condition is obtained, and the power output of multi-stage generator 40 y may be P max and all stages 60 of multi-stage generator 40 y may be active and correspondingly all branches 30 of parser conversion topology 10 y may be active, thus achieving 100% utilization of multi-stage generator 40 y.
[0085] The output from each stage 60 of the multi-stage generator 40 y is connected through terminal-block 80 to the input for parser 170 . Parsers 170 are used to configure the terminals 70 of the induction elements 50 such that the voltage outputs for parser 170 are within an acceptable level for the corresponding converter 20 in branch 30 . For example, at a low power level range (for example from P1− to P2+) perhaps one or more sets of induction elements 50 within an active stage 60 , such as 60 i , are connected in series by parser 170 . At the next higher power level range (for example from P2− to P3+), when the voltage across each individual induction element 50 has increased in response to increased rotational speed of turbine 130 , a mix of series and parallel connections of induction elements 50 may be arranged by parser 170 . The process continues until multi-stage generator 40 y is operating at the maximum continuous average-power of P max in which case there may be one or more sets of induction elements 50 within all stages 60 that are connected in parallel. By doing so, it is possible to keep the variation of input voltage to converter 20 to within a reasonable range and permitting more efficient operation of converter 20 and its associated transformer 100 , such as converter 20 i and its associated transformer 100 i.
[0086] Parser 170 may be used to arrange induction elements 50 within a stage 60 to meet the voltage requirements of a corresponding converter 20 as needed. If a higher voltage level is required by converter 20 then parser 170 arranges the induction elements 50 in a more series-like manner; likewise if a lower voltage level is required then induction elements 50 are arranged in a more parallel-like manner. The configuration of each parser 170 is a function of system controller 150 y , responding to changing variables such as fluid speed or turbine 30 rotational speed, or generator 40 rotational speed, or direct measurement of voltages at terminal block 80 .
[0087] FIG. 6 is a flowchart showing an embodiment of a control process by which system controller 150 y may control parser conversion topology 10 y to transform the electric power produced by multi-stage generator 10 y into a useable form for electrical load 120 . System controller 150 y , or a delegated sub-controller, makes decisions and executes tasks as outlined in the flowchart shown in FIG. 6 . The illustrated control process generally seeks maximum energy capture mode and includes throttling of parser conversion topology 10 y when multi-stage generator 40 y is delivering its rated-power of P max to parser conversion topology 10 y.
[0088] As seen in FIG. 6 , the parser conversion system may be in a standby mode (step 600 ) when there is no power output from multi-stage generator 40 y . In standby mode all branches 30 of parser conversion topology 10 y are disconnected from electrical load 120 , i.e., input switches 90 and output switches 110 are open, and parsers 170 may be pre-configured for a parallel-like arrangement of induction elements 50 (this is a fail-safe configuration that prevents excess voltage application to converters 20 in the event of accidental closing of input switch 90 ).
[0089] An internal diagnostic system check may be performed by a system controller 150 , such as 150 y , to determine if any of the induction elements 50 or branches 30 in the TGC system is malfunctioning (step 603 ). If a malfunctioning induction element 50 or malfunctioning branch 30 is found then it is disabled, by keeping open at all times the associated input switch 90 and output switch 110 (until a suitable time can be found for repair of the malfunctioning part).
[0090] Under control of a system controller 150 , such as 150 y , voltage may be induced in induction elements 50 if there is sufficient fluid flow in turbine 130 to rotate of the shaft of multi-stage generator 40 . System controller 150 y maintains all branch output switches 110 in an open state (steps 600 and 603 ) until a multi-stage generator 40 , such as 40 y , is capable of producing power exceeding a pre-defined threshold level, P1+ (step 606 ), when a functional branch 30 , for example branch 30 i , may be selected (step 609 ) by system controller 150 y and the corresponding parser 170 i is configured for the lowest power level P1, i.e. parser 170 i is configured for power level range P1− to P2+ (step 612 ). This typically means that parser 170 i may connect one or more sets of induction elements 50 within stage 60 i in a series-like arrangement since at low power it is likely that the voltage across individual induction elements is relatively low and placing the elements 50 in series increases the voltage applied to converter 20 i . The corresponding input and output switches 90 i and 110 i may then be closed, preferably in that order (step 615 ) and power begins to flow from multi-stage generator 40 y though the stage 60 i and branch 30 i to electrical load 120 (step 618 ).
[0091] As power flows through branch 30 i (step 618 ), system controller 150 y monitors the output power level of multi-stage generator 40 y (step 621 ), and if the power level is between P1− and P2+, then system controller 150 y retains the power flow through branch 30 i (step 618 ).
[0092] If (at step 621 ) the power level drops below P1−, the system returns to standby mode (step 600 ), meaning that power flow in branch 30 i may be reduced to zero, and switches 110 i and 90 i , may be opened, preferably in that order. Note that in general it may be possible for system controller 150 y to return the system to standby from other steps such as but not restricted to steps 648 or 679 .
[0093] If (at step 621 ) the power level exceeds P2+, another functional branch that is not currently active, for example branch 30 j , is selected (step 624 ) and its parser 170 j configured for power level range P2− to P3+ (step 627 ). Then switches 90 j and 110 j may be closed (step 630 ). Power flow may be transferred out of branch 30 i by system controller 150 y to branch 30 j (step 633 ) temporarily, so that switches 110 i and 90 i may be opened if necessary (step 636 ), and system controller 150 y may now configure parser 170 i for the next higher power range P2− to P3+ (step 639 ). Input and output switches 90 j and 110 j may be then closed (step 642 ), and power is controlled by system controller 150 y to flow though both branches 30 i and 30 j (step 645 ). The above steps (and those discussed below) may be performed by system controller 150 , such as 150 y , in such a way that there is no interruption of power delivery to electrical load 120 .
[0094] As power flows through branches 30 i and 30 j (step 645 ), system controller 150 y monitors the output power level of multi-stage generator 40 y (step 648 ), and if the power level is between P2− and P3+, then the system controller 150 y retains the power flow through branches 30 i and 30 j (step 645 ).
[0095] If (at step 648 ) the power level drops below P2−, the controller returns power flow in parser conversion topology 10 y to branch 30 i possibly using the following sequence of steps. All power is transferred temporarily from branch 30 i to 30 j (step 651 ). Switches 110 i and 90 i are opened (step 653 ). Parser 170 i is reconfigured for power level range P1− to P2+ (step 655 ). Switches 90 i and 110 i are closed (step 657 ). All power is transferred from branch 30 j to 30 i (step 659 ). Switches 110 j and 90 j are opened (step 661 ), and power now flows through branch 30 i (step 618 ).
[0096] If (at step 648 ) the power level exceeds P3+, another functional branch, for example branch 30 k , may be selected (step 663 ) and parser 170 k configured for power level range P3− to P max (step 665 ). Then switches 90 k and 110 k are closed (step 667 ). All power flow in branch 30 i is transferred out of branch 30 i and into branch 30 j (step 669 ) temporarily, so that switches 110 i and 90 i are opened if necessary (step 671 ), and system controller 150 y now configures parser 170 i for the next higher power range P3− to P max (step 671 ). Input and output switches 90 i and 110 i are then be closed (step 671 ), and the power flowing in branch 30 j is now temporarily transferred from branch 30 j to 30 i (step 673 ), so that switches 110 j and 90 j may be opened (step 675 ), and system controller 150 y now configures parser 170 j for the next higher power range P3− to P max (step 675 ). Input and output switches 90 i and 110 i may then be closed (step 675 ), and after transferring some power to branch 30 j (from either or both of branches 30 i and 30 k ), power is controlled by system controller 150 y to flow though all branches, such as branches 30 i , 30 j , and 30 k (step 677 ).
[0097] As power flows through branches 30 i , 30 j , and 30 k (step 677 ), system controller 150 y monitors the output power level of multi-stage generator 40 y (step 679 ), and if the power level is between P3− and P max , then system controller 150 y retains the power flow through all branches, such as branches 30 i , 30 j , and 30 k (step 677 ). Note that P max is the rated-power of multi-stage generator 40 y , and hence system controller 150 y may enter throttling mode when this power level is achieved.
[0098] If (at step 679 ) the power level drops below P3−, system controller 150 y returns power flow in parser conversion topology 10 y to branches 30 i and 30 j (i.e., deactivating branch 30 k ) possibly using the following sequence of steps. All power is transferred temporarily from branch 30 i to branches 30 j and 30 k (preferably with equal power levels in branches 30 j and 30 k ) (step 681 ). With no power in branch 30 i , switches 90 i and 110 i are opened if necessary (step 683 ) and parser 170 i reconfigured for power level range P2− to P3+ (step 683 ). Switches 90 i and 110 i are then closed (step 683 ). All power in branch 30 j is then transferred from branch 30 j to branch 30 i (step 685 ). With no power in branch 30 j , switches 90 j and 110 j are opened if necessary (step 687 ) and parser 170 j reconfigured for power level range P2− to P3+ (step 687 ). Switches 90 j and 110 j are then closed (step 687 ). Power may then be transferred out of branch 30 k , possibly to branch 30 j (step 689 ), so that power flow in branches 30 i and 30 j is approximately equal and switches 110 k and 90 k are opened (step 691 ), and power now flows through branches 30 i and 30 j (step 645 ).
[0099] If (at step 679 ) or for that matter at other steps, including but not restricted to steps 621 and 648 , an emergency condition arises, it may be necessary for system controller 150 y to shut down operation of the TGC system by setting power flow through the TGC system to zero and preferably stopping rotation of turbine 130 (step 693 ).
[0100] For the illustrated parser conversion system embodiment, the activation or deactivation of a branch may be initiated when a power threshold is crossed, however, system controller 150 y may alternatively initiate the activation or deactivation of a branch 30 using other system variables such as, but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 y ; the output voltage of stages 60 as may be measured at a terminal-block 80 or directly across one or more induction elements 50 of a multi-stage generator 40 ; and/or the input voltage to parser conversion topology 10 y.
[0101] The above discussed principles of operation for a parser conversion system may be extended (or simplified) to the case where there are more than (or fewer than) three branches. In general, there may be any practical number of branches 30 within a parser conversion topology 10 y.
Alternative Parser Conversion System and its Variations
[0102] An issue with a parser conversion system is that at a low power level (at or near P1 for example), it may be difficult to maintain high efficiency of the one branch 30 in operation. At a loss of some modularity, this issue may be remedied by allowing one branch 30 to fork into two sub-branches, each sub-branch having a converter and/or an optional transformer. Thus, at low power operation (at or near P1 for example), the sub-branch with the lowest power rating, which has been designed for high efficiency at that lower power level, may be the only branch activated. In this embodiment, one stage, such as stage 60 i , could have two branches, branch 30 i 1 and branch 30 i 2 , as shown in FIG. 10 , with the provision that branch 30 i 2 may have a higher rated-power specification than that of branch 30 i 1 . It may be reasonable to set the rated-power of branch 30 i 2 to be equal to the remaining branches 30 , such as branch 30 j , branch 30 k etc, which are configured as shown in FIG. 4 . By having a designated low power branch fork into two or more sub-branches, as shown in FIG. 10 , it may be possible to employ less complex parsers for the remaining branches, i.e., parsers 170 j , 170 k , etc., may have a simpler structure than parser 170 i.
[0103] A variation of this embodiment is that the forking of a branch 30 may take place at the output of the converter. For example, as seen in FIG. 11 , branch 30 i could have input switch 90 i followed by (i.e. in series with) converter 20 i , following which is the fork with optional multi-pole switch 180 i 1 in a fork prong connected to lower power transformer 100 i 1 , and optional multi-pole switch 180 i 2 connected to higher power transformer 100 i 2 on the other prong.
[0104] Another variation in the forking embodiment is that there may be three or more sub-branches, for example 30 i 1 , 30 i 2 , 30 i 3 , etc., or in the case of the fork taking place following a converter, three or more sub-transformers, for example 100 i 1 , 100 i 2 , 100 i 3 , etc. Also, there is the possibility that more than one stage 60 may employ forked branches or forked transformers.
Hybrid Conversion System
[0105] The above discussed embodiment of a parser conversion system, and its forked-branch variations, has the advantage of permitting the design of a multi-stage generator 40 , such as 40 y , that has almost, if not all, 100% machine utilization at rated power. However the design of parser 170 for some or all of stages 60 may require a large number of switches within the parser, and this may add to the construction cost of parser conversion topology 10 y , and may also reduce the reliability of the parser conversion system.
[0106] The hybrid power conversion system discussed below is an embodiment of a power conversion system for a turbine driven multi-stage electrical generator. With this embodiment, very high machine utilization may be achievable for a multi-stage generator 40 , and with significantly simplified parsers 190 (as seen in FIG. 7 ) by comparison to parsers 170 of the parser conversion system.
[0107] The complexity of a parser 190 may be significantly less than that of a parser 170 because each parser 190 may need only arrange sets of partially hardwired induction elements 50 in perhaps just two or three possible arrangements (each arrangement corresponding to a power range of multi-stage generator 40 z ) instead of a potentially much larger number of arrangements as may be the case for a parser 170 of the parser conversion system. For example consider that there may be N induction elements 50 in one set of induction elements of one phase of stage 60 , then it is reasonable to construct a parser 170 for parser conversion topology 10 y that has up to 3(N−1) switches for that set of induction elements. However the parsers 190 , of the hybrid power conversion topology 10 z , may contain as few as just three switches for the same set of N induction elements. Note that for either parser 170 or parser 190 , each switch therein may require that electrical current be capable of flowing in either direction through the switch, which would then be a requirement of the physical realization of the switches in the construction of the parser.
[0108] As seen in FIG. 7 , hybrid conversion topology 10 z includes one or more branches 30 . Each branch 30 may include a parser 190 if needed, an input switch 90 if needed, a converter 20 , an optional transformer 100 , and an output switch 110 , all connected in series. The output switch 110 from each branch 30 is connected to electrical load 120 , which may be an electric utility power grid. A key concept of hybrid conversion topology 10 z , is that a given stage 60 of multi-stage generator 40 z may be partially hardwired so that the stage may deliver power over more than one power range but not necessarily over the entire power range of the multi-stage generator 40 z (for example stage 60 i may operate over power range P1− to P2+ as well as power range P2− to P3+ but perhaps not power range P3− to P max ), thus two or more stages 60 may be delivering power simultaneously through two or more corresponding branches 30 of hybrid conversion topology 10 z . The intention with this hybrid power conversion system embodiment is that when the TGC system is operating at its rated-power with multi-stage generator 40 z operating at its rated-power, P max , multiple high-power stages 60 (each containing a large number of induction elements 50 ) are actively delivering power, and hence the high machine utilization of multi-stage generator 40 z.
[0109] FIG. 8 is an illustration of a partially hardwired multi-stage generator 40 z . The partial hardwiring of induction element terminals 70 may be done within the casing of multi-stage generator 40 z , or external to the casing. Alternatively, no casing is needed and terminals 70 may be within multi-stage generator 40 or external to multi-stage generator 40 . As an example of partial hardwiring, it can be seen in FIG. 8 that in low power stages such as 60 i , many induction elements 50 may be hardwired in a series-like manner. Thus, as power increases from multi-stage generator 40 z , parser 190 i may have the relatively simple task, under control of system controller 150 z , of connecting two (or more) subsets of induction elements 50 (two subsets are illustrated within stage 60 i in FIG. 8 ) in an extended series arrangement at the lower power levels, or the induction element subsets may be arranged in more parallel-like arrangements as the power increases from multi-stage generator 40 z . Such reconfiguring of induction elements may be done to maintain the voltage to a converter 20 , such as 20 i , within a restricted range. Similarly, for higher power stages, such as stage 60 j , it may be desirable to have subsets of induction elements 50 partially hardwired (in FIG. 8 this is illustrated by a parallel arrangement within each subset) and parser 190 j has the task, under control of system controller 150 z , of connecting two (or more) subsets of induction elements 50 (two subsets are illustrated within stage 60 j in FIG. 8 ) in a series arrangement, or the subsets may be arranged in a more parallel-like arrangement as power increases from multi-stage generator 40 z , to maintain the voltage to converter 20 j within a restricted range. Note that the hardwired connections shown in FIG. 8 are purely illustrative, and in general there may be any practical number of induction elements 50 within a stage 60 , possibly in poly-phase arrangements, and a variety of series, parallel, or mixed series-parallel connections are possible.
[0110] For hybrid conversion topology 10 z , in a similar fashion as the bank of converters topology 10 x , the power rating of converter 20 and/or transformer 100 may increase geometrically from one stage 60 to the next, so that if at first stage 60 i a relatively low power converter 20 i is required, the next stage 60 j may require a significantly higher power converter 20 j , etc. For multi-stage generator 40 z , it is possible for stage 60 j to contain many more induction elements 50 than that of stage 60 i , and similarly stage 60 k might have many more induction elements than stage 60 j . The power rating for converters 20 and transformers 100 within a hybrid conversion topology 10 z may be higher than in the case of the bank of converters topology 10 x , but there may be fewer branches in the hybrid conversion topology 10 z given a specified power of the multi-stage generator 40 . A parser 190 may not be needed for the highest power stage 60 , such as 60 k ; a set of induction elements 50 of the highest power stage 60 , such as 60 k , may be connected in a hardwired manner, for example all induction elements 50 within one set of induction elements 50 for one phase of stage 60 k may be hardwired in parallel as illustrated in FIG. 8 .
[0111] FIG. 9 is a flowchart showing an embodiment of a control process by which system controller 150 z may control hybrid conversion topology 10 z to transform the electric power produced by multi-stage generator 10 z into a useable form for electrical load 120 . System controller 150 z , or its delegated sub-controller, makes decisions and executes tasks as outlined in the flowchart shown in FIG. 9 . The illustrated control process generally seeks maximum energy capture mode and includes throttling of hybrid conversion topology 10 z when multi-stage generator 40 z is delivering its rated-power of P max to hybrid conversion topology 10 z.
[0112] As seen in FIG. 9 , the hybrid conversion system begins in a standby mode (step 900 ) when there is no power output from the multi-stage generator 40 z . In standby mode all branches 30 of hybrid conversion topology 10 z are disconnected from electrical load 120 , i.e. input switches 90 and output switches 110 are all open, and any parsers 190 are pre-configured for a parallel arrangement of sub-sets of induction elements 50 (this is a fail-safe configuration that prevents excess voltage application to converters 20 in the event of accidental closing of input switch 90 ).
[0113] An internal system check may be done to determine if any of the induction elements 50 or branches 30 in the TGC system is malfunctioning. If a malfunctioning induction element 50 or branch 30 is found, it is disabled by keeping open at all times associated input switch 90 and output switch 110 , and the induction element 50 or branch 30 is not used during power delivery (until a suitable time can be found for repair of the malfunctioning part).
[0114] Under control of system controller 150 z voltage is induced in induction elements 50 if there is sufficient fluid flow in turbine 130 to rotate of the shaft of multi-stage generator 40 z . System controller 150 z maintains all branch input switches 90 open and/or all branch output switches 110 open (step 900 ) until multi-stage generator 40 z produces power exceeding pre-defined threshold level, P1+ (step 903 ), when parser 190 i is configured for the lowest power level P1, i.e. parser 190 i is configured for power level range P1− to P2+ (step 906 ). Therefore parser 190 i may connect one or more sub-sets of induction elements 50 within stage 60 i in a series-like arrangement. The corresponding input and output switches 90 i and 110 i then are closed, preferably in that order (step 909 ) and power begins to flow from multi-stage generator 40 z though the stage 60 i and branch 30 i to electrical load 120 (step 912 ).
[0115] As power flows through branch 30 i (step 912 ), system controller 150 z monitors the output power level of multi-stage generator 40 z (step 915 ), and if the power level is between P1− and P2+, then the system controller 150 z retains the power flow through branch 30 i (step 912 ).
[0116] If (at step 915 ) the power level drops below P1−, the system returns to standby mode (step 900 ), meaning that power flow in branch 30 i is reduced to zero and switches 110 i and 90 i are opened, preferably in that order. Note that in general it may be possible for system controller 150 z to return the system to standby from other steps such as, but not restricted to, steps 939 or 978 .
[0117] If (at step 915 ) the power level exceeds P2+, parser 190 j is configured for power level range P2− to P3+ (step 918 ). Then switches 90 j and 110 j are closed (step 921 ). Power flow is transferred out of branch 30 i by system controller 150 z to branch 30 j (step 924 ) temporarily, so that switches 110 i and 90 i are opened if necessary (step 927 ), and system controller 150 z now configures parser 190 i for the next higher power range P2− to P3+ (step 930 ). Input and output switches 90 i and 110 i are then closed (step 933 ), and power is controlled by system controller 150 z to flow though both branches 30 i and 30 j (step 936 ), possibly with approximately equal power in each branch. All the above steps (and those discussed below) may be conducted by system controller 150 z so that there is no interruption of power delivery to electrical load 120 .
[0118] As power flows through branches 30 i and 30 j (step 936 ), system controller 150 z monitors the output power level of multi-stage generator 40 z (step 939 ), and if the power level is between P2− and P3+, then the system controller 150 z retains the power flow through branches 30 i and 30 j (step 936 ).
[0119] If (at step 939 ) the power level drops below P2−, then system controller 150 z returns power flow in hybrid conversion topology 10 z to branch 30 i possibly using the following sequence of steps. All power is transferred temporarily from branch 30 i to 30 j (step 942 ). Switches 110 i and 90 i are opened (step 945 ). Parser 190 i is reconfigured for power level range P1− to P2+ (step 948 ). Switches 90 i and 110 i are closed (step 951 ). All power is transferred from branch 30 j to branch 30 i (step 954 ). Switches 110 j and 90 j are opened (step 957 ), and power now flows through branch 30 i (step 912 ).
[0120] If (at step 939 ) the power level exceeds P3+, switches 90 j and 110 j are closed (step 960 ). Power flow may be transferred out of branches 30 i and 30 j by system controller 150 z to branch 30 k (step 963 ) temporarily, so that switches 110 j and 90 j are opened if necessary (step 966 ), and system controller 150 z now configures parser 190 j for the next higher power range P3− to P max (step 969 ). Input and output switches 90 j and 110 j are then closed (step 972 ), and power is controlled by system controller 150 z to flow though branches 30 j and 30 k (step 975 ), possibly with approximately equal power in each branch.
[0121] As power flows through branches 30 j and 30 k (step 975 ), system controller 150 z monitors the output power level of multi-stage generator 40 z (step 978 ), and if the power level is between P3− and P max , then system controller 150 z retains the power flow through branches 30 j and 30 k (step 975 ). Note that P max is the rated-power of multi-stage generator 40 z , and hence system controller 150 z may enter throttling mode when this power level is achieved.
[0122] If (at step 978 ) the power level drops below P3−, the controller returns power flow in hybrid conversion topology 10 z to branches 30 i and 30 j possibly using the following sequence of steps. All power is transferred temporarily from branch 30 j to 30 k (step 981 ). Switches 110 j and 90 j are opened (step 984 ). Parsers 190 j and 190 i are reconfigured for power level range P2− to P3+ (step 987 ). Switches 90 j and 110 j are closed (if desirable, some power transfer into branch 30 j may begin at this time) and also switches 90 i and 110 i are closed (step 990 ). All power is transferred from branch 30 k to branches 30 j and 30 i (step 993 ). Switches 110 k and 90 k are opened (step 996 ), and power now flows through branches 30 i and 30 j (step 936 ). Note there may be variations in how system controller accomplishes this transfer of power to branches 30 i and 30 j , for example power transfer from branch 30 k to branch 30 i may take place first, followed by a transfer of power from branch 30 k to branch 30 j.
[0123] If (at step 978 ) or for that matter at other steps, including, but not restricted to, steps 915 and 939 , an emergency condition arises, it may be necessary for system controller 150 z to shut down operation of the TGC system by setting power flow through the TGC system to zero and preferably stopping rotation of turbine 130 (step 998 ).
[0124] For the illustrated hybrid conversion system embodiment, the activation or deactivation of a branch may be initiated when a power threshold is crossed, however, system controller 150 z may alternatively initiate the activation or deactivation of a branch 30 using other system variables such as, but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 z ; the output voltage of stages 60 as may be measured at a terminal-block 80 or directly across one or more induction elements 50 of a multi-stage generator 40 ; and/or the input voltage to hybrid conversion topology 10 z.
[0125] The above discussed principles of operation for a hybrid conversion system may be extended (or simplified) to cases where there are more than (or fewer than) three branches. In general, there may be any number of branches 30 within a hybrid conversion topology 10 z . Note, for the hybrid conversion system, that there is no theoretical restriction on the number stages 60 of multi-stage machine 40 z , and no theoretical restriction on the number of branches 30 of hybrid conversion topology 10 z , that may be active and delivering power. As an example, consider the situation illustrated in FIG. 7 , if it is desirable that branches 30 i , 30 j , 30 k are all delivering power to electrical load 120 when multi-stage generator 40 z is operating at a power between P2− and P max , and parser 190 j is configured for that power range as discussed above, but in addition, parser 190 i may reconfigured the arrangement of induction elements 50 within stage 60 i for power range P2− to P max . This means that the partial hardwiring of stage 60 i and the design of parser 190 i both accommodate this possibility.
Variations of the Hybrid Conversion System
[0126] An issue with a hybrid conversion system is that the stages 60 and branches 30 designed for the lower power ranges, for example stage 60 i and branch 30 i , are each inherently less efficient in power transformation than the higher power stages and branches. Thus, the advantage of using parser 190 i to extend the power range over which stage 60 i and branch 30 i may operate is compromised, particularly at the lowest power levels, such as P1− or P1+. For example, in the above discussion of the hybrid conversion system, referring to FIG. 9 , stage 60 i and branch 30 i may be designed to operate over power range P1− to P2+ as well as over range P2− to P3+, thus at power level P1−, the efficiency of stage 60 i and/or branch 30 i may be poor.
[0127] To overcome the efficiency degradation at lower power levels, a variation of the hybrid conversion system may employ no parser within the lowest power branch(es) 30 of the hybrid conversion topology. For example, a hybrid conversion topology that includes three branches may be constructed such that branch 30 i may be structured as shown in FIG. 1 and branches 30 j and 30 k may be structured as shown in FIG. 7 . Thus stage 60 i and branch 30 i of this hybrid conversion topology may operate only over power range P1− to P2+ and will likely be much more efficient than the stage 60 i and branch 30 i pair of FIG. 7 designed to operate over power range P1− to P3+. With this variation of the hybrid conversion system there is, once again, no theoretical restriction on the number of stages or the number of branches.
[0128] Another variation of the hybrid conversion system is to employ forked branches for one or more stages 60 . For example, an embodiment may have a hybrid conversion topology with four branches: 30 h , 30 i , 30 j , and 30 k . Branch 30 h , the lowest power branch, may be structured to have no parser. Branch 30 i may be forked with two sub-branches, sub-branch 30 i 1 and sub-branch 30 i 2 . Branches 30 j and 30 k may be structured as in FIG. 7 . An example of this variation of the hybrid conversion system is shown in FIG. 12 . In this embodiment, when the multi-stage generator 40 is operating within its highest power range, up to and including rated-power P max , sub-branch 30 i 2 , branch 30 j and branch 30 k may all be active and delivering power to electrical load 120 . In this variation of the hybrid conversion system there is, once again, no theoretical restriction on the number of stages or the number of branches.
[0129] The various embodiments described above can be combined to provide further embodiments. All of the commonly assigned US patent application publications, U.S. patent applications, foreign patents, and foreign patent applications referred to in this specification and/or listed in the Application Data Sheet, including but not limited to U.S. application Ser. No. 13/062,191, filed Jun. 17, 2011; PCT application Serial No. PCT/CA2009/001233, filed Sep. 3, 2009; and U.S. provisional patent application Ser. No. 61/094,007, filed Sep. 3, 2008 are incorporated herein by reference, in their entirety. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
[0130] Specific embodiments have been shown and described herein. However, modifications and variations may occur to those skilled in the art. All such modifications and variations are believed to be within the scope and sphere of the present invention. | An electric power generation system is provided, including a generator having a plurality of stages engaged by a prime mover; and a plurality of branches for connecting the stages to an electrical load, each of the branches having a switch for connecting or disconnecting the branch to the stages. Power from a prime mover, such as a turbine, is sent by a controller to one or more of the branches as appropriate to handle the power level generated. | 5 |
FIELD OF THE INVENTION
The invention relates to blowing agent inhibitors and their use. In particular, the invention is directed to water soluble triazole derivatives, and more particularly to water soluble triazole derivatives having a plurality of polyethylene oxide monomer moieties, preferably at least one polyethylene oxide (PEO) chain, which derivatives are effective blowing agent inhibitors.
BACKGROUND OF THE INVENTION
It is well known to those skilled in the art that foamed plastic surfaces may be textured by the process commonly referred to as "chemical embossing", wherein the surface of a foamable polymer composition is printed with an ink composition containing an agent which inhibits foaming in the printed areas when the surface is subsequently subjected to a heat treatment. The areas which have not been printed over thus expand normally on heating while expansion in the printed areas containing the inhibitor is retarded, resulting in a textured surface with depressions in those areas printed with the inhibited ink.
A wide range of compounds have been claimed to act as inhibitors for chemical embossing of floor and wall covering surfaces. Carboxylic acid anhydrides such as trimellitic anhydride (TMA), disclosed in Nairn et al. U.S. Pat. No. 3,293,094, being among the most commonly used industrially. However, compounds such as TMA, while suitable for solvent-based printing inks, are hydrolytically unstable and thus are not readily usable in the aqueous ink formulations rapidly gaining in importance in large scale printing operations due to environmental concerns over VOC emission from solvent-based inks.
Triazole compounds such as benzotriazole (BTA) and tolyltriazole (TTA) are also widely used in solvent-based inks for chemical embossing. These compounds do not hydrolyze to inactive form on contact with water as do carboxylic acid anhydrides like TMA. However their use in aqueous ink systems is hindered by a lack of substantial water solubility.
The excellent embossing characteristics, stability and low toxicity of the aromatic triazoles have prompted considerable research into ways that these compounds could be successfully adapted to aqueous ink systems. The prior art, specifically Hamilton U.S. Pat. No. 4,083,907 and Hamilton U.S. Pat. No. 4,191,581, has established that sufficient BTA or aminotriazole for acceptable embossing can be solubilized into an aqueous ink by addition of a water soluble alcohol and buffering agents to raise the pH of the ink formulation to between 8-12.
Certain carboxylic acids, acid anhydrides and acid halides have also been claimed to act as foam-expansion inhibitors in aqueous ink formulations where the acidic species have been neutralized and the formulation pH adjusted to the same 8-12 range (Brixius U.S. Pat. No. 4,369,065 and Brixius U.S. Pat. No. 4,421,561).
Benzotriazole and other inhibitor species have also been solubilized in alcohol-containing aqueous inks where the system pH is in the acidic range from 3-5 (Sherman et al. U.S. Pat. No. 5,169,435).
Modified aromatic triazole derivatives have also been cited as foam-expansion inhibitors. These compounds are substituted on the 1-N of the triazole ring with dialkylaminomethyl groups of varying structure and are claimed to be easily incorporated into aqueous inks which contain alcohols or other water soluble organic solvents, and do not require the use of a pH regulator (Hauser et al. U.S. Pat. No. 4,407,882). Compounds of this general structure in which the alkyl groups of the aminomethyl substituent are simple hydrocarbons (D'Errico U.S. Pat. No. 4,522,785) and perfluoroalkyls (Clark et al. U.S. Pat. No. 4,788,292) have also been claimed as corrosion inhibitors.
Insoluble aromatic and cycloaliphatic azole-based chemical embossing inhibitors are disclosed in Sideman et al. U.S. Pat. No. 5,441,563 and Remar et al. U.S. patent application Ser. No. 515,110, filed Aug. 14, 1995.
In order to enhance the solubility of such derivatives in a wide range of functional fluids of varying polarity, a dialkylaminomethyl benzotriazole corrosion inhibitor has also been claimed (Poplewell et al. U.K. Patent No. 1,466,558) wherein one of the aminomethyl alkyl groups may be a short polyethyleneoxide chain of 1-4 repeat units.
As the triazole-based foam-expansion inhibitors established in the patent literature to date are not soluble in water unless alcohols or other suitably water-miscible organic co-solvents are also present, there continues to exist a need in the art for a water-soluble triazole-based inhibitor which does not require such co-solvents, in order to reduce VOC emissions during the printing and drying process.
SUMMARY OF THE INVENTION
The dialkylaminomethyltriazole derivatives cited previously as foam-expansion inhibitors and corrosion inhibitors are readily prepared by the known reaction of the starting triazole with a secondary amine and formaldehyde in a suitable solvent at varying temperatures. It has also been established that if the alkylamine which is to be incorporated as the aminomethyl group is primary rather than secondary, and a suitable ratio of triazole to amine is used, the product will have two methyltriazoyl groups on the original amine nitrogen (Frankenfeld et al. U.S. Pat. No. 5,076,946).
In the present invention, by using primary or secondary mono- or diamines in which at least one of the substituents is a polyethylene oxide (PEO) oligomer of sufficient molecular weight, or a polypropylene oxide (PPO)/PEO/PPO triblock oligomer with a sufficiently high PEO/PPO ratio, the resulting aminomethyltriazole will be completely soluble in water without the need for alcohol or other water-miscible organic co-solvents. The PPO/PEO/PPO triblock oligomer has the general formula PPO x PEO y PPO z , where x, y and z are positive integers.
The number of PEO repeat units required to confer water solubility to the molecule is related to the number of aminomethyltriazole moieties attached to the molecule. The triazole derivatives of the present invention will be soluble in water if the ratio of polyethylene oxide monomer moieties to triazole moieties is at least six and preferably at least eight. The chemical embossing inhibitors embodied in this invention have the advantage that they are inherently soluble in water and can be completely dissolved in aqueous ink formulations without the necessity of added alcohols or other water-soluble co-solvents, or surfactants. However, such co-solvents or surfactants can be added without destroying the present invention.
Accordingly, it is the object of the present invention to provide a printing ink composition for the production of textured foamed surface, which composition comprises a resin, water, and as inhibitor for preventing the foaming of a foamable material containing a blowing agent, a PEO or PEO/PPO substituted triazole derivative of the formula ##STR1## R 2 =--(C 1 -C 4 ) alkyl, --(CH 2 CH 2 O) m CH 3 , --(CH 2 CH 2 O) m CH 2 CH 3 , or --R 1 ;
R 3 =--CH 2 CH 2 --, --CH(R 6 )CH 2 --, or --CH 2 CH(R 6 )--;
R 4 =--(C 1 -C 4 ) alkyl, or ##STR2## R 5 =--H or --(C 1 -C 4 ) alkyl; R 6 =--(C 1 -C 4 ) alkyl;
n=3-45;
m=1-6; and
Each of R 1 , R 2 , R 3 , R 5 , and R 6 may be the same or different.
R 3 is preferably --CH 2 CH 2 --, --CH(CH 3 )CH 2 --, or --CH 2 CH(CH 3 )--. R 5 is preferably --H or --CH 3 .
When R 4 is --R 3 N(R 1 )alkyl, n is preferably 10 to 25. When R 4 is --R 3 N(R 1 ) 2 , n is preferably 20 to 45, more preferably 20 to 35, and most preferably 20 to 30.
When R 2 is R 1 and R 4 is --(C 1 -C 4 )alkyl, n is preferably 10 to 30, and more preferably 15 to 25. When R 2 is not R 1 and R 4 is --(C 1 -C 4 ) alkyl, n is preferably 5 to 25, and more preferably 7 to 25.
Another object of the invention is to provide a water soluble triazole derivative which includes a plurality of polyethylene oxide monomer moieties, preferably a ratio of polyethylene oxide monomer moieties to triazole moieties of at least six, and more preferably a ratio of polyethylene oxide monomer moieties to triazole moieties of at least eight.
A further object of the invention is to provide a PEO or PEO/PPO substituted triazole derivative of Formula (1), except n=5-45.
A still further object of the invention is to provide a method of embossing a heat-foamable resinous material by applying the printing ink composition of the present invention to selected areas of the surface of a heat-foamable resinous material, which material contains a blowing agent, and subsequently heating the material to at least the decomposition temperature of the blowing agent.
DETAILED DESCRIPTION OF THE INVENTION
Structures for some representative examples of the water soluble triazole derivatives of the present invention are shown in the following Tables I and II in which the substituents of Formula (1) are identified. R 1 is identified as aromatic to indicate the first moiety set forth for R 1 , supra, or cyclohexyl to indicate the second moiety set forth for R 1 , supra. R 2 is sometimes identified in the same manner. The parenthetical numbers following the moieties of R 3 indicate the average number of the OR 3 moieties in the compound. The average number of polyethylene oxide monomer moieties and polypropylene oxide monomer moieties is one greater than n.
TABLE I__________________________________________________________________________Mono- and Vicinal Di-substituted DerivativesCmpd R.sup.1 R.sup.5 R.sup.4 R.sup.2 R.sup.3 n__________________________________________________________________________1 Aromatic --CH.sub.3 --CH.sub.3 --CH.sub.2 CH.sub.2 OCH.sub.3 --CH.sub.2 CH.sub.2 -- 3-92 Aromatic --CH.sub.3 --CH.sub.3 Aromatic --CH.sub.2 CH.sub.2 -- (19), 22 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3 )-- (4)3 Aromatic --CH.sub.3 --CH.sub.3 Aromatic --CH.sub.2 CH.sub.2 -- (13), 15 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3 )-- (3)4 Aromatic --H --CH.sub.3 Aromatic --CH.sub.2 CH.sub.2 -- (13), 15 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3 )-- (3)5 Cyclohexyl --CH.sub.3 --CH.sub.3 Aromatic --CH.sub.2 CH.sub.2 -- (13), 15 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3 )-- (3)6 Aromatic --CH.sub.3 --CH.sub.3 --CH.sub.3 --CH.sub.2 CH.sub.2 -- (13), 15 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.2 )-- (3)__________________________________________________________________________
TABLE II__________________________________________________________________________Symmetrical Di- and Tetra-substituted DerivativesCmpd R.sup.1 R.sup.5 R.sup.2 R.sup.4 R.sup.3 n__________________________________________________________________________7 Aromatic --CH.sub.3 --CH.sub.3 --CH.sub.2 CH(CH.sub.3)NR.sup.1 R.sup.2 --CH.sub.2 CH.sub.2 -- (15.5) 18 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3)-- (3.5)8 Aromatic --H --CH.sub.3 --CH.sub.2 CH(CH.sub.3)NR.sup.1 R.sup.2 --CH.sub.2 CH.sub.2 -- (15.5) 18 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3)-- (3.5)9 Cyclohexyl --CH.sub.3 --CH.sub.3 --CH.sub.2 CH(CH.sub.3)NR.sup.1 R.sup.2 --CH.sub.2 CH.sub.2 -- (15.5) 18 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3)-- (3.5)10 Aromatic --CH.sub.3 Aromatic --CH.sub.2 CH(CH.sub.3)NR.sup.1 R.sup.2 --CH.sub.2 CH.sub.2 -- (39.5) 42 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3)-- (3.5)11 Aromatic --H Aromatic --CH.sub.2 CH(CH.sub.3)NR.sup.1 R.sup.2 --CH.sub.2 CH.sub.2 -- (39.5) 42 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3)-- (3.5)12 Cyclohexyl --CH.sub.3 Cyclohexyl --CH.sub.2 CH(CH.sub.3)NR.sup.1 R.sup.2 --CH.sub.2 CH.sub.2 -- (39.5) 42 --CH(CH.sub.3)CH.sub.2 --/--CH.sub.2 CH(CH.sub.3)-- (3.5)__________________________________________________________________________
For acceptable processing, it is advantageous to use 5 to 25 parts by weight of the polyalkyleneoxide-derivatized aminomethyltriazoles in the aqueous printing ink composition. Those skilled in the art will recognize that a very wide range of printing ink compositions exist with varying combinations of solubilized and/or dispersible binders, pigments, and rheology-control additives. The pigments are optional, since it may be desirable to use a colorless, inhibitor containing printing ink. The water-soluble triazoles of the present invention are potentially useful in many other aqueous ink formulations not specifically outlined in the Examples as to their exact composition.
Those skilled in the art will also recognize that varying amounts of water will be required to adjust the viscosity of the ink composition to a range suitable for typical rotogravure printing. Other methods of printing the ink composition onto the foamable plastic surface, such as screen printing, relief printing, or planographic printing, may also be used with these ink compositions.
Although this invention is primarily concerned with polyvinylchloride-based plastisol compositions thermally blown with azodicarbonamide as the printing substrate, there likewise exists a wide range of thermoplastic resins which can be thermally foamed with azodicarbonamide and thus are potential substrates for aqueous inhibitor printing ink compositions of the type claimed. Such other compositions include polyvinylacetate, copolymers of vinyl chloride and vinyl acetate, polyacrylate, polymethacrylate, polyethylene. polystyrene, butadiene/styrene copolymers, butadiene/acrylonitrile copolymers, and natural or synthetic rubbers.
The specific combinations of PVC, other thermoplastic resins, filler, stabilizers, liquid plasticizer and chemical blowing agent that make up a typical foamable plastisol substrate vary widely within certain limits and those skilled in the art can reasonably anticipate systems which would be encompassed by the scope of this invention.
The invention is illustrated by the following examples related to synthesis of the water-soluble triazole derivatives, preparation of the aqueous printing ink formulations and demonstration of the chemical embossing behavior of the claimed compounds. Unless otherwise stated, all amounts and percentages given in the Examples are on a weight basis.
EXAMPLE 1
Synthesis of Compound 1
1-N- (2-Methoxyethylmethoxypolyethyleneoxy)aminomethyl!tolyltriazole
Sixteen and one-half parts of commercial tolyltriazole (TT100, an isomer mixture from PMC Specialties) and 50.4 parts of the PEO-substituted secondary amine (laboratory prepared) were combined in 150 parts methanol and cooled to zero degrees Centigrade. While holding the reaction mixture at this temperature, 10.1 parts of commercial 37% aqueous formaldehyde solution was added slowly over several hours with continual agitation. The reaction mixture was allowed to warm to ambient temperature and worked up after 18 hours by removing the solvent under moderate heat/vacuum. The resulting oil was then vacuum stripped at higher temperature to remove any residual water, unreacted formaldehyde or other volatiles. The final product was 67.1 parts (quantitative yield) of a clear, mobile reddish oil which was identified by standard spectroscopic techniques as the expected Compound 1, 1-N- (2-methoxyethylmethoxypolyethyleneoxy)aminomethyl!tolyltriazole. The compound was found to be completely miscible with water in all proportions.
EXAMPLE 2
Synthesis of Compound 2
N,N-Bis(1-N-Tolytriazoylmethyl)polyethylene-Co-Polypropyleneoxyamine
Twenty-six and seven-tenths parts of commercial tolyltriazole and 100.0 parts of the PEO/PPO-substituted primary amine (JEFFAMINE M1000 from Texaco Chemical Co.) were combined in 150 parts methanol and cooled to zero degrees Centigrade. While holding the reaction mixture at this temperature, 16.3 parts of commercial 37% aqueous formaldehyde solution was added slowly over several hours with continual agitation. The reaction mixture was allowed to warm to ambient temperature and worked up after 18 hours by removing the solvent under moderate heat/vacuum. The resulting oil was then vacuum stripped at higher temperature to remove any residual water, unreacted formaldehyde or other volatiles. The final product was 128.7 parts (quantitative yield) of a clear, mobile reddish oil which was identified by standard spectroscopic techniques as the expected Compound 2, N,N-bis(1-N-tolytriazoylmethyl)polyethylene-co-polypropyleneoxyamine. The compound was found to be completely miscible with water in all proportions.
EXAMPLE 3
Synthesis of Compound 3
N,N-Bis(1-N-Tolytriazoylmethyl)polyethylene-Co-Polypropyleneoxyamine
Thirty-seven and three-tenths parts of commercial tolyltriazole and 100.0 parts of the PEO/PPO-substituted primary amine (JEFFAMINE M715 from Texaco Chemical Co.) were combined in 150 parts methanol and cooled to zero degrees Centigrade. While holding the reaction mixture at this temperature, 22.7 parts of commercial 37% aqueous formaldehyde solution was added slowly over several hours with continual agitation. The reaction mixture was allowed to warm to ambient temperature and worked up after 18 hours by removing the solvent under moderate heat/vacuum. The resulting oil was then vacuum stripped at higher temperature to remove any residual water, unreacted formaldehyde or other volatiles. The final product was 163.9 parts (quantitative yield) of a clear, mobile reddish oil which was identified by standard spectroscopic techniques as the expected Compound 3. This compound differed from Compound 2 only in the number of repeat units in the PEO/PPO chain and was also found to be completely miscible with water in all proportions.
EXAMPLE 4
Synthesis of Compound 4
N,N-Bis(1-N-Benzotriazoylmethyl)polyethylene-Co-Polypropyleneoxyamine
Twenty-three and eight tenths parts of commercial benzotriazole and 71.5 parts of the PEO/PPO-substituted primary amine (JEFFAMINE M715 from Texaco Chemical Co.) were combined in 100 parts of methanol and cooled to zero degrees Centigrade. While holding the reaction mixture at this temperature, 16.2 parts of commercial 37% aqueous formaldehyde solution was added slowly over several hours with continual agitation. The reaction mixture was allowed to warm to ambient temperature and worked up after 18 hours by removing the solvent under moderate heat/vacuum. The resulting oil was then vacuum stripped at higher temperature to remove any residual water, unreacted formaldehyde or other volatiles. The final product was 97.0 parts (99.3% yield) of a clear, mobile oil, slightly yellow in color, which was identified by standard spectroscopic techniques as the expected Compound 4, N,N-bis(1-N-benzotriazoylmethyl)polyethylene-co-polypropyleneoxyamine. The compound was found to be completely miscible with water in all proportions.
EXAMPLE 5
Synthesis of Compound 5
N,N-Bis(1-N-Methylcyclohexyltriazoylmethyl)polyethylene-Co-Polypropylene-Oxyamine
Forty and four-tenths parts of hydrogenated tolyltriazole (Cobratec 911 from PMC Specialties) and 103.8 parts of the PEO/PPO-substituted primary amine (JEFFAMINE M715 from Texaco Chemical Co.) were combined in 150 parts of methanol and cooled to zero degrees Centigrade. While holding the reaction mixture at this temperature, 23.5 parts of commercial 37% aqueous formaldehyde solution was added slowly over several hours with continual agitation. The reaction mixture was allowed to warm to ambient temperature and worked up after 18 hours by removing the solvent under moderate heat/vacuum. The resulting oil was then vacuum stripped at higher temperature to remove any residual water, unreacted formaldehyde or other volatiles. The final product was 146.8 parts (quantitative yield) of a clear, mobile oil, slightly yellow in color, which was identified by standard spectroscopic techniques as the expected Compound 5, N,N-bis(l-N-methylcyclohexyltriazoylmethyl)polyethylene-co-polypropylene-oxyamine. The compound was found to be completely miscible with water in all proportions.
EXAMPLE 6
Synthesis of Compound 10
N,N,N',N'-Tetra(1-N-Tolyltriazoylmethyl)polyethylene-Co-PolypropyleneOxydiamine
Twenty-six and seven-tenths parts of commercial tolyltriazole and 100.0 parts of the PEO/PPO-substituted primary diamine (JEFFAMINE ED-2001 from Texaco Chemical Co.) were combined in 150 parts of methanol and cooled to zero degrees Centigrade. While holding the reaction mixture at this temperature, 16.3 parts of commercial 37% aqueous formaldehyde solution was added slowly over several hours with continual agitation. The reaction mixture was allowed to warm to ambient temperature and worked up after 18 hours by removing the solvent under moderate heat/vacuum. The resulting oil was then vacuum stripped at higher temperature to remove any residual water, unreacted formaldehyde or other volatiles. The final product was 128.6 parts (99.6% yield) of a clear, mobile oil, slightly yellow in color, which was identified by standard spectroscopic techniques as the expected Compound 10, N,N,N',N'-tetra(1-N-tolyltriazoylmethyl)polyethylene-co-polypropylene-oxydiamine. The compound was found to be completely miscible with water in all proportions.
EXAMPLES 7 TO 10
Preparation and Testing of Inks (10% Concentration)
Four inks were made using the compounds from Examples 1, 2, 3 and 6. These compounds were added directly to Sicpa's anionic water-based ink extender 694550 at a concentration of 10% active inhibitor. These compounds readily solubilized into the ink extender without any adverse reactions. Two controls were evaluated at the same time (i.e., 10% Benzotriazole and 8% Trimellitic anhydride) in a solvent-base extender.
All five inks were printed into 9 mils of an expandable plastisol coated on flooring felt and on 7 mils of an expandable plastisol coated onto a saturated glass mat. The plastisol formulation coated on the flooring felt was 100 parts by weight PVC resin, 50 parts plasticizer, 30 parts limestone filler, 7.0 parts titanium dioxide pigment, 3.0 parts mineral spirits viscosity modifier, 2.1 parts stabilizers, 2.0 parts azodicarbonamide blowing agent and 0.6 parts zinc oxide blowing agent activator. The printing was done on a flat-bed gravure proof press using a 100 line screen step-wedge engraved plate. The steps ranged from a deep shadow tone to a shallow highlight tone.
The printed samples were coated with 10 mils of a clear plastisol wearlayer, and fused and expanded in a Werner Mathis oven. The clear wearlayer was 100 parts by weight PVC resin, 40 parts plasticizer, 4.0 parts stabilizers and 4.0 parts mineral spirits. The felt backed structure was heated for 1.3±0.1 minutes at an air temperature of 201°±1° C. to a blow ratio of about 2.8 to 1.
The plastisol formulation coated on the glass mat was 100 parts by weight PVC resin, 55 parts plasticizer, 30 parts limestone filler, 5.0 parts titanium dioxide pigment, 3.0 parts mineral spirits viscosity modifier, 2.0 parts azodicarbonamide blowing agent and 0.5 parts zinc oxide blowing agent activator. The printing was done on a flat-bed gravure proof press using a 100 line screen step-wedge engraved plate. The steps ranged from a deep shadow tone to a shallow highlight tone.
The printed samples were coated with 10 mils of a clear plastisol wearlayer, and fused and expanded in a Werner Mathis oven. The clear wearlayer was 100 parts by weight PVC resin, 50 parts plasticizer and 2.0 parts stabilizers. The glass backed structure was heated for 1.9±0.1 minutes at an air temperature of 185°±2° C. to a blow ratio of about 2.0 to 1.
The thickness of the printed areas (i.e., restricted area) was measured in mils and compared to the thickness of the unprinted expanded surrounding areas. This difference is reported as the depth of chemical embossing and is shown in Table III.
TABLE III______________________________________ DEPTH OF DEPTH OF WEIGHT EMBOSSING EMBOSSING PERCENT FOR FELT FOR GLASS OF COMPOUND STRUCTURE STRUCTUREINHIBITOR IN INK in mils in mils______________________________________Example 7 10% 5.7 4.7(Compound 1)Example 8 10% 4.4 2.9(Compound 2)Example 9 10% 5.5 3.9(Compound 3)Example 10 10% 3.0 3.2(Compound 10)BTA 10% 11.8 3.5TMA 8% 8.6 5.9______________________________________
EXAMPLES 11 TO 13
Preparation and Testing of Inks (15% Concentration)
The following three inks were made using compounds from Examples 3, 4 and 5. They were mixed with Sicpa's anionic water-based ink extender 694556 at a concentration of 15% by weight, without any problems. A 10% Benzotriazole solvent-based ink control was used for this evaluation. These inks were printed on the same felt backed and glass backed structures used in Table III and evaluated by the same method for the depth of chemical embossing (see Table IV).
TABLE IV______________________________________ DEPTH OF DEPTH OF WEIGHT EMBOSSING EMBOSSING PERCENT FOR FELT FOR GLASS OF COMPOUND STRUCTURE STRUCTUREINHIBITOR IN INK in mils in mils______________________________________Example 11 15% 6.8 4.9(Compound 3)Example 12 15% 8.6 4.8(Compound 4)Example 13 15% 8.9 4.3(Compound 5)BTA 10% 11.7 3.9______________________________________
EXAMPLES 14 TO 16
Preparation and Testing of Compound 3 Inks
(10%, 15% & 20% Concentration)
Example 3 (Compound 3) was evaluated at three concentrations to see if the depth of chemical embossing would improve with higher concentrations. This compound was added to Siopa's anionic water-based ink extender 694556 at three concentrations (i.e., 10%, 15% and 20%). A 10% Benzotriazole solvent-based ink control was used on the same felt backed structure coated with 9 mils of expandable plastisol The same method used previously was used to evaluate the chemical embossing depth (see Table V).
TABLE V______________________________________ DEPTH OF EMBOSSING WEIGHT PERCENT OF FOR FELT STRUCTUREINHIBITOR COMPOUND IN INK in mils______________________________________Example 14 10% 5.7(Compound 3)Example 15 15% 8.1(Compound 3)Example 16 20% 10.0(Compound 3)BTA 10% 13.1______________________________________ | This invention provides an aromatic or cycloaliphatic triazole-based chemical embossing inhibitor which is completely soluble in water and compatible with water-based printing inks for use in producing textured foamed plastic surfaces. The triazoles comprise a general class of mono- and multi-functional 1-N substituted aminomethyl derivatives which are rendered soluble in water by the presence of at least one polyethyleneoxide (PEO) oligomer chain, or polypropylene (PPO)-polyethyleneoxide copolymer oligomer chain or PPO/PEO/PPO triblock oligomer chain with a sufficiently high PEO/PPO ratio for water solubility. Preferably the triazole derivative has at least six polyethylene oxide monomer moieties per triazole moiety. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally pertains to integrated optical circuits, and particularly to a method for manufacturing an integrated optical circuit.
2. Technical Background
Integrated optical circuits are usually constituted by optical and/or optoelectronic devices formed on a substrate. The optical and/or optoelectronic devices may be active devices (such as resonators, lasers, detectors, switches, etc.) or passive devices (such as waveguides, filters, couplers, etc.)
An interesting feature of integrated optical circuits resides in their compactness. However, these circuits experience optical losses as light propagates from one device to another on the substrate.
Light between the optical devices of an integrated circuit propagates through waveguides. Conventionally, waveguides are composed of a continuous structure made of a material having a higher refractive index than the surrounding substrate. Light propagates inside the waveguide by virtue of internal reflections off the faces thereof. Introduction of light into the waveguide is carried out so that the angle of reflection off the internal faces of the waveguide, as light propagates, is smaller than a critical angle depending on the refractive indices inside and outside the waveguide. This angle requirement may generally be fulfilled when the waveguide is in the form of a straight line. However, when the waveguide is bent (bent portions are needed in integrated circuits in order to reduce their size), optical losses occur due to the fact that the reflection angle at the faces of the waveguide is too large, which gives rise to refractive waves.
One technique for reducing optical losses in integrated optical circuits, using a photonic crystal, consists in providing, around optical devices, a dielectric periodic structure which creates a frequency band gap. A frequency band gap is a range of frequencies (or photonic energy) at which propagation through the periodic structure is impossible. The parameters of the dielectric periodic structure, such as the period length, the refractive index of the structure, the shape of the periodic lattice, etc., are calculated so that the frequency of the light propagating inside the waveguides that interconnect the various optical circuits on the substrate is within the frequency band gap. Thus light remains confined inside the optical circuits and waveguides since it cannot radiate outside these optical devices, in the dielectric periodic structure.
FIG. 1 illustrates an example of such an integrated optical circuit. For the purpose of simplification, the integrated optical circuit of FIG. 1 essentially consists of a waveguide 1 surrounded by a dielectric periodic structure 2 . The waveguide 1 receives light on one lateral side thereof as shown by arrow 3 . Light propagates inside the waveguide to emerge from the other lateral side as shown by arrow 4 .
The integrated circuit comprises a substrate 5 coated with a dielectric layer 6 having a higher refractive index than the substrate 5 . The dielectric periodic structure 2 is arranged along the longitudinal sides of the waveguide 1 . The structure 2 typically consists of an array of holes 2 a formed throughout the layer 6 and substrate 5 , perpendicularly to the longitudinal axis of the waveguide 1 , but, as a variant, may also consist of an array of rods. The waveguide 1 is defined by the central portion of the dielectric layer 6 bounded by the periodic structure 2 . Horizontal radiation of light out of the longitudinal sides of the waveguide 1 is prevented by the periodic structure 2 , which reflects, according to a diffraction phenomenon, optical waves having frequencies within the corresponding band gap. Light is further vertically confined within the waveguide by virtue of the fact that the refractive index of the waveguide is higher than that of the substrate 5 and that of air. Alternatively, it is also possible to provide a three-dimensional dielectric periodic structure around the waveguide, instead of the two-dimensional structure as illustrated in FIG. 1, in order to confine the light within the waveguide both horizontally and vertically.
SUMMARY OF THE INVENTION
The present invention provides a reliable method for manufacturing an integrated optical circuit in which an optical device, such as a waveguide, a resonator, etc., is associated with an optical structure, such as an array structure defining a frequency band gap region. Both the optical device and the optical structure may be formed with great accuracy.
The method generally comprises the steps of: forming a first mask on a face of a substrate, the first mask defining a pattern corresponding to at least one optical device to be formed in a first region of the substrate; forming a second mask on the face of the substrate, the second mask defining a pattern corresponding to an optical structure to be formed in a second region of the substrate, distinct from the first region; and etching the substrate having thereon the first and second masks, in order to form the at least one optical device and the optical structure in the substrate.
By virtue of the simultaneous use of the first and second masks, each one corresponding to a region of the substrate, it becomes possible to form the optical device(s) and the optical structure(s) on the substrate in a simple manner and with great accuracy.
A reason for this is that the two masks may be formed separately and, therefore, two respective specific patterning methods may be applied to form the two masks. In other words, the patterning technique used to form the second mask, corresponding to the second region of the substrate, may be different from that used to form the first mask, corresponding to the first region of the substrate.
This is particularly important, especially in the context of photonic crystals, when it is desired to manufacture integrated optical circuits having one or more optical devices, such as waveguides, couplers, etc., and an array structure defining a photonic band gap proximate to the optical device(s). Indeed, in such a case, the optical device(s) and the array structure have quite different shapes. The array structure to be formed in the substrate is periodic or quasi periodic, with a period which may be small, in the order of 250-500 nm. The construction of this periodic structure requires a specific technique suitable for forming a mask with small irregularities, such as holes, disposed according to a periodic lattice. A typical such technique may consist of interference or holographic lithography, which uses two interfering laser beams irradiating the wafer. Interference lithography however is not appropriate for forming a mask corresponding to the optical devices (waveguides, resonators, couplers . . . ), because these devices generally do not consist of a periodic or quasi periodic structure. A conventional lithography technique employing UV (ultra-violet) exposure will, on the contrary, enable such a mask to be satisfactorily formed. Thus, the present invention makes it possible to select, for each of the first and second regions of the substrate, a specific appropriate patterning technique for forming the corresponding mask.
By contrast, using a single mask for both the optical device(s) and the optical structure would require, in many cases, a complicated lithography method for producing the mask, namely a method which would be adapted to all kinds of shape contained in the pattern to be created in the substrate. The known UV or electron beam exposure lithography techniques, although suitable for producing masks corresponding to optical devices such as waveguides, lasers, etc., cannot offer, for the time being, a sufficient accuracy for forming frequency band gap structures.
Another advantage of the present invention resides in that the two masks are used simultaneously, so as to form the optical device(s) and the optical structure together. The present invention thus provides a simple process, requiring only one etching step for the substrate.
Preferably, the method according to the invention further comprises the step of removing the first and second masks.
The step of etching the substrate may consist of a dry etching step using a predetermined etching gas, for example a fluorine-bearing gas such as SF 6 . In this case, the first and second masks are each made of a material which substantially resists the predetermined etching gas.
Preferably, in order to simplify the manufacturing method, the step of forming the first mask and the step of forming the second mask are carried out in such a manner that one of the first and second masks overlays the other. There is then no need to define two separate zones where, respectively, the first and second masks have to be formed, since one of the two masks may overlay the other. In practice, one of the first and second masks has a first portion which overlays the other mask and a second portion which is in direct contact with the substrate.
According to the invention, one of the first and second masks may be formed using an interference lithography technique, whereas the other may be formed using a UV exposure technique.
Advantageously, the second mask is formed by carrying out an interference lithography technique, and the first mask is made of a material which is substantially insensitive to the radiation used in the interference lithography technique, so that the second mask may be formed after the formation of the first mask without affecting the first mask.
The step of forming the second mask may then comprise the steps of: forming a photoresist layer on the face of the substrate supporting the first mask, and forming the pattern corresponding to the optical structure in the photoresist layer using the interference lithography technique.
According to a first embodiment of the present invention, the first and second masks are respectively made of metal and a photoresist material. The metal may typically consist of at least one of the following metals: nickel, chromium and gold.
According to this first embodiment, the step of forming the first mask comprises the steps of: forming a first layer on the substrate, the first layer being made of a material which is substantially insensitive to light; forming a photoresist layer on the first layer; patterning the photoresist layer using a UV exposure technique, so as to obtain a photoresist pattern corresponding to the first region of the substrate; etching the first layer using the photoresist pattern as a mask; and removing the photoresist pattern.
The above-mentioned step of etching the first layer may consist of a wet etching step.
According to a second embodiment of the present invention, the first and second masks are both made of a photoresist material, the first mask being however constituted by a photoresist material which has been heated in order to remove its sensitivity to light.
According to this second embodiment, the step of forming the first mask comprises the following steps: forming a photoresist layer on the substrate; patterning the photoresist layer using a UV exposure technique, so as to obtain a pattern corresponding to the first region of the substrate; and heating the photoresist pattern in order to remove its sensitivity to light.
According to a third embodiment of the present invention, the first mask is formed using a UV exposure technique, and the second mask is made of a material which is substantially insensitive to UV, so that the first mask may be formed after the formation of the second mask without affecting the second mask.
In this third embodiment, the step of forming the second mask comprises the steps of: forming a first layer on the substrate, the first layer being made of the material which is substantially insensitive to UV; forming a photoresist layer on the first layer; patterning the photoresist layer using an interference lithography technique, so as to obtain a photoresist pattern corresponding to the second region of the substrate; etching the first layer using the photoresist pattern as a mask; and removing the remaining photoresist pattern.
The step of forming the first mask then comprises the steps of: forming a photoresist layer on the second mask, and forming the pattern corresponding to the at least one optical device in the photoresist layer using the UV exposure technique.
The substrate used in the three embodiments above is preferably a silicon on insulator substrate.
The optical structure formed in the substrate typically consists of an array structure proximate to the optical device. In practice, the integrated optical circuit as obtained by the method according to the invention may comprise a waveguide, as the optical device, and an array structure having a frequency bandgap, as the optical structure. The array structure may take the form of a periodic array of holes or a periodic array of rods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a known integrated optical circuit;
FIGS. 2A to 2 J are section views diagrammatically showing a method for manufacturing an integrated optical circuit according to a first embodiment of the present invention;
FIG. 3 is a perspective view showing an integrated optical circuit with an array of holes obtained by the method according to the first embodiment of the invention;
FIG. 4 is a perspective view showing an integrated optical circuit with an array of rods obtained by the method according to the first embodiment of the invention;
FIGS. 5A to 5 H are section views diagrammatically showing a method for manufacturing an integrated optical circuit according to a second embodiment of the present invention; and
FIGS. 6A to 6 F are section views diagrammatically showing a method for manufacturing an integrated optical circuit according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 2A to 2 J diagrammatically show a method for manufacturing an integrated optical circuit according to a first embodiment of the invention. For the purpose of simplification, the method illustrated in FIGS. 2A to 2 J is directed to the manufacture of a waveguide surrounded by an array structure. However, optical devices other than waveguides may be produced by the method according to this first embodiment.
At a first step (FIG. 2 A), a metal layer 8 and a photoresist layer 9 are successively formed on a substrate 7 . The substrate 7 is preferably a silicon on insulator (SOI) substrate, i.e. a substrate composed of a silicon base substrate 7 a , coated with a thin silica layer 7 b which in turn is coated with a thin silicon layer 7 c . The silicon layer 7 c has a higher refractive index than the silica layer 7 b , for reasons which will be explained below. The metal constituting the layer 8 may consist, for example, of nickel, chromium or gold.
At a second step (FIG. 2 B), a silica mask 10 is applied onto the photoresist layer 9 , in a manner known to the skilled person. The silica mask 10 supports, on a portion of its upper surface, a chromium pattern 10 a taking the shape of the optical waveguide to be formed in the substrate 7 , namely, in the embodiment as illustrated in FIG. 2B, the shape of a strip. The chromium pattern 10 a is located on the upper surface of the silica mask 10 so as to face a region 7 d of the silicon layer 7 c where the optical waveguide is to be formed. The wafer 7 , 8 , 9 as shown in FIG. 2B is then exposed to UV radiation through the silica mask 10 . The portions of the silica mask 10 which are not covered by the chromium pattern 10 a are transparent to UV. The chromium pattern 10 a , on the contrary, reflects UV light and therefore prevents a region 9 a of the photoresist layer 9 situated below the pattern 10 a to be exposed.
At a third step (FIG. 2 C), the silica mask 10 is removed and the photoresist 9 is developed. Development of the photoresist 9 results in removal of the portions thereof which have been exposed to UV light. At the end of the third step, only a portion 9 a of the photoresist layer 9 , having the same shape as the chromium pattern 10 a and the optical waveguide to be formed, remains on the metal layer 8 .
At a fourth step (FIG. 2 D), the metal layer 8 is wet etched, using the photoresist portion 9 a as a mask, thereby forming a metal pattern or mask 8 a on the substrate 7 . Wet etching of the metal layer 8 is carried out by means of an appropriate acid capable of attacking the metal while leaving the photoresist mask 9 a substantially unaffected. Examples of such an acid may be the commercially available Gold-Etch (registered trade mark) acid, when the metal is gold, and Nickel-Etch (registered trade mark) acid, when the metal is nickel. The photoresist mask 9 a is then removed using a solvent (FIG. 2 E).
At a fifth step (FIG. 2 F), a photoresist layer 11 is formed on the substrate 7 and the metal mask 8 a , so that the metal mask 8 a is sandwiched between the thin silicon layer 7 c of the substrate and the photoresist layer 11 . More specifically, a portion of the layer 11 directly covers the upper face 7 e of the substrate while another portion covers the metal mask 8 a which is formed on the upper face 7 e . The portion of the layer 11 which is in direct contact with the face 7 e corresponds to a region of the substrate 7 , denoted by reference numeral 7 f in FIG. 2F, where the array structure is to be formed.
At a sixth step (FIG. 2 G), two interfering laser beams 12 are directed towards the wafer to expose the photoresist layer 11 to a light interference pattern. The interfering laser beams 12 are arranged in such a manner that, after development of the photoresist layer 11 (FIG. 2 H), the latter defines a pattern 111 a in the form of a periodic array of holes. Due to the fact that the mask 8 a is made of a material, i.e. metal, which is substantially insensitive to light, the formation of the pattern 11 a may be carried out without affecting the mask 8 a . Thus, at the end of the sixth step, the substrate 7 supports a first mask 8 a and a second mask 11 a , which are respectively associated with the regions 7 d and 7 f of the substrate 7 where the waveguide and the array structure are to be formed. The two masks 8 a , 11 a are made of different materials, i.e. metal for the first mask and photoresist for the second mask. Both of these materials are able to resist the dry etching step that is described below.
At a seventh step (FIG. 21 ), the substrate 7 , and more particularly the silicon layer 7 c , is dry etched. To this effect, the wafer 7 , 8 a , 11 a is placed in a plasma chamber containing a process gas, and a plasma is generated inside the chamber from the process gas. The plasma includes reactive species which are able to selectively etch the silicon layer 7 c , i.e. without eroding the first and second masks 8 a , 11 a . Typically, the process gas may contain a fluorine-bearing etching gas such as SF 6 .
At an eight step (FIGS. 2 J), the first and second masks 8 a , 11 a are removed by appropriate solvents. The integrated optical circuit as obtained is constituted by the silicon base substrate 7 a , the silica layer 7 b , a waveguide 12 and a periodic array of holes 13 . The periodic array of holes 13 has a frequency band gap which prevents horizontal radiation of light from the inside to the outside of the waveguide 12 . Light propagating inside the waveguide 12 is further confined vertically by virtue of the fact 20 that the waveguide exhibits a higher refractive index than the silica layer 7 b . The integrated optical circuit as diagrammatically shown in FIG. 2J, in section view, is represented in perspective in FIG. 3 .
As a variant to the integrated optical circuit as illustrated in FIGS. 2J and 3, the circuit obtained by the method according to the present invention may have an array structure which consists of a periodic array of rods, instead of holes. FIG. 4 shows such an alternative result. In FIG. 4, the same elements as in FIGS. 2J and 3 are designated by the same reference numerals. Thus, the integrated optical circuit of FIG. 4 comprises a base substrate 7 a , a silica layer 7 b , a waveguide 12 and a periodic array of rods 13 ′ formed in the silicon layer 7 c . With respect to the integrated circuit as shown in FIGS. 2J and 3, the circuit of FIG. 4 may be achieved by merely executing the dry etching step (seventh step above) for a longer time.
FIGS. 5A to 5 H diagrammatically show a method for manufacturing an integrated optical circuit according to a second embodiment of the invention. For the purpose of simplification, the method illustrated in FIGS. 5A to 5 H is directed to the manufacture of a waveguide surrounded by an array structure. However, optical devices other than waveguides may be produced by the method according to this second embodiment.
At a first step (FIG. 5 A), a photoresist layer 15 is formed on a substrate 14 . The substrate 14 is preferably a silicon on insulator (SOI) substrate, i.e. a substrate composed of a silicon base substrate 14 a , coated with a thin silica layer 14 b which in turn is coated with a thin silicon layer 14 c . The thin silicon layer 14 c has a higher refractive index than the thin silica layer 14 b , for the same reasons as in the first embodiment.
At a second step (FIG. 5 B), a silica mask 16 bearing a chromium pattern 16 a is laid on the photoresist layer 15 . The chromium pattern 16 a is located on the upper surface of the silica mask 16 so as to face a region 14 d of the silicon layer 14 c where the optical waveguide is to be formed. Then the wafer 14 , 15 is exposed to UV radiation through the mask 16 , in the same manner as in the second step of the first embodiment.
At a third step (FIG. 5 C), the silica mask 16 is removed and the photoresist layer 15 is developed. The result thereof is the removal of all the portions of the layer 15 which were exposed to UV radiation during the second step. At the end of this third step, only the portion of the photoresist layer 15 located below the chromium pattern 16 a remains on the substrate 14 , thus defining a photoresist pattern 1 Sa on the substrate. The photoresist pattern 15 a faces the region 14 d of the silicon layer 14 c where the optical waveguide is to be formed.
At a fourth step (not shown), the photoresist pattern 15 a is heated in order to remove, or at least greatly reduce, its sensitivity to light. This step is carried out by placing the wafer 14 , 15 a into a furnace, and by baking it at about 180° C. for approximately half an hour. The photoresist pattern 15 a obtained after this fourth step will be referred to hereinafter as “first mask 15 a”.
At a fifth step (FIG. 5 D), another photoresist layer 16 is deposited on the substrate 14 and the first mask 15 a , so that the first mask 15 a be sandwiched between the thin silicon layer 14 c of the substrate and the photoresist layer 16 . More specifically, a portion of the layer 16 directly covers the upper face 14 e of the substrate while another portion covers the first mask 15 a which is formed on the upper face 14 e . The portion of the layer 16 which is in direct contact with the face 14 e corresponds to a region of the substrate 14 , denoted by reference number 14 f in FIG. 5D, where the array structure is to be formed.
At a sixth step (FIG. 5 E), two interfering laser beams 17 are directed towards the wafer to expose the photoresist layer 16 to a light interference pattern. The interfering laser beams 17 are arranged in such a manner that, after development of the photoresist layer 16 (FIG. 5 F), the latter defines a pattern 16 a in the form of a periodic array of holes. Due to the fact that the first mask 15 a was made insensitive to light at the fourth step, the formation of the pattern 16 a may be carried out without affecting the first mask 15 a . Thus, at the end of the sixth step, the substrate 14 supports the first mask 15 a and a second mask 16 a , which are respectively associated with the regions 14 d and 14 f of the substrate 14 where the waveguide and the array structure are to be formed. Both of the first and second masks are made of a material which is able to resist the dry etching step that is described below.
At a seventh step (FIG. 5 G), the substrate 14 , and more particularly the thin silicon layer 14 c , is dry etched. To this effect, the wafer 14 , 15 a , 16 a is placed in a plasma chamber containing a process gas, and a plasma is generated inside the chamber from the process gas. The plasma includes reactive species which are able to selectively etch the silicon layer 14 c , i.e. without eroding the first and second masks 15 a , 16 a . Typically, the process gas may contain a sulphur-bearing etching gas such as SF 6 .
At an eighth step (FIG. 5 H), the first and second masks 15 a , 16 a are removed by appropriate solvents. The integrated optical circuit as obtained is constituted by the silicon base substrate 14 a , the silica layer 14 b , a waveguide 18 and a periodic array of holes 19 . Instead of the periodic array of holes 19 , a periodic array of rods may be formed by executing the dry etching step for a longer time.
FIGS. 6A to 6 F diagrammatically show a method for manufacturing an integrated optical circuit according to a third embodiment of the invention. For the purpose of simplification, the method illustrated in FIGS. 6A to 6 F is directed to the manufacture of a waveguide surrounded by an array structure. However, optical devices other than waveguides may be produced by the method according to this third embodiment.
The method according to this third embodiment differs from the first embodiment notably in that the second mask, corresponding to the optical structure, is formed prior to the formation of the first mask, corresponding to the optical waveguide. Furthermore, the second mask is made of metal, whereas the first mask is made of a photoresist material.
More specifically, the second mask, denoted by reference numeral 21 a , is formed by depositing a metal layer 21 on a SOI substrate 20 (FIG. 6 A), depositing a photoresist layer 22 on the metal layer 21 , patterning the photoresist layer 22 using an interference lithography technique so as to define therein a photoresist pattern 22 a (FIG. 6 B), and wet etching the metal layer 21 through the photoresist pattern 22 a (FIG. 6 C). The first mask, denoted by reference numeral 23 a , is formed after removal of the remaining photoresist pattern 22 a (FIG. 6D) by depositing a photoresist layer 23 on the second mask 21 a (FIG. 6 E), exposing the wafer to UV through a silica mask 24 having a chromium strip 24 a , and developing the photoresist 23 so as to define a pattern 23 a corresponding to the optical waveguide (FIG. 6 F). The etching step for etching the silicon layer 20 c of the substrate 20 is identical to that performed in the first and second embodiments.
The third embodiment as described above has the advantage that the position of the first mask 23 a on the second mask 21 a may be accurately selected using the holes of the second mask 21 a as references when laying the silica mask 24 on the photoresist layer 23 as shown in FIG. 6 E.
The first, second and third embodiments as described above are preferred embodiments for the present invention. However, it will be clearly apparent to the skilled person that the present invention may be carried out differently without departing from the scope of the appended claims. In particular, the SOI substrate used in these embodiments could be replaced, for example, by a substrate composed of a glass base substrate coated with a silicon layer.
Furthermore, the present invention is not limited to the manufacture of integrated optical circuits having a periodic array of holes or rods. The present invention could indeed be used for forming, in a same substrate, optical devices associated with Bragg reflectors. In a general manner, the method according to this invention may be applied when different optical devices or structures are to be formed in a substrate, and is particularly advantageous when the the optical devices or structures exhibit quite different shapes, requiring the use of different patterning techniques for producing the corresponding masks. | In order to manufacture an integrated optical circuit, a first mask is formed on a first region of a substrate and defines the shape of at least one optical device (such as a waveguide). A second mask is formed on a second region of the substrate and corresponds to an optical structure (such as a periodic array structure or photonic crystal) to be formed in a second region of the substrate distinct from the first region. The first mask and the second mask are each made of a material which substantially resists a predetermined etching gas. The second mask may formed, patterned, and etched without adversely affecting the characteristics of the first mask. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a splint for a fractured limb and in particular to a more efficient method of holding a fractured limb, such as a wrist, in reduction. The most common used method of maintaining reduction of a stable Colles' Fracture is by the use of a plaster cast. It is inexpensive and can be efficiently applied to the patient's limb. However, it does not offer any indication to the clinician applying the cast of the intra-cast pressures that may lead to compartment syndrome. Once the cast is set it is difficult to adjust. If the clinician then finds the fracture site is misaligned the cast must be redone. There is no easily made adjustment that allows loosening to accommodate swelling of the forearm and wrist, or tightening of the cast as the swelling reduces.
BRIEF SUMMARY OF THE INVENTION
The proposed preferred method of maintaining of Colles' fracture, a specific type of fracture, involves the use of a modular adjustable outer casing. This casing has a locking mechanism which can easily be adjusted by the clinician, but tamperproof by the patient. The adjustment is in small steps to allow objective recording of the splint settings. There are preferably three sizes of casing, covering a similar anthropometric range to that of functional bracing commercially available. The common incidence of Colles' fracture across the population is a further factor in detailing the splint dimensions. The internal contours of the casing are designed so as to avoid creating a complete collar around the limb. This feature gives a path for the flow of fluid from the trauma site, avoiding pressure build up.
BRIEF SUMMARY OF THE INVENTION
There is also preferred stepped adjustment of the hand support in the lateral and median planes. This support incorporates some adjustment to allow limited movement of the hand in palmar flexion, but not dorsiflexion, and lateral movement in both adduction and abduction. The flexibility of cast positioning gives the clinician more options to balance the maintenance of reduction of the fracture components and allowing movement of the forearm and hand promoting muscle tone. It can also reduce swelling conventionally occurring with Colles' fractures by promoting vascular flow induced by hand movement.
Plaster casting is recognized as providing poor maintenance of reduction. Other treatments, such as external and internal fixation, pose other post-reduction problems especially in relation to the elderly who may have poor bone structure due to Osteoporosis which does not provide a suitable site to hold the fixtures.
GB-A-2,156,226 discloses a fracture splint, suitable for example for trochanteric fractures, comprising an adjustable girdle for locating it on the patient's body, the girdle supporting an elongate member including means for restraining limb movement and incorporating an anchorage enabling pressure to be applied to the fracture area. The girdle may comprise two adjustably interconnected, molded segments engageable with the patients iliac crest, one segment supporting anchorage points for straps, the tension in which urges a pressure pad against the fracture area, and the other segment having mounted on it a semi-rigid rod supporting along its length the pressure pad, a knee retainer and a foot clamp.
According to an aspect of the present invention, there is provided a splint for supporting a fractured limb comprising a rigid outer casing including a plurality of spaced pressure sites located at the inner surfaces of the casing and operative to apply pressure to a limb to be supported while retaining a vascular flow path; longitudinally spaced proximal and distal collars, each provided with one or more pressure sites, said proximal and distal collars being spaced so as to envelop a common bone of the limb and being independently adjustable relative to one another so as to provide independent adjustment of the internal dimensions of the casing. This splint can be designed so as not to hinder tendon function and to allow space for free vascular flow, which can reduce swelling. It can also reduce reflex sympathetic dystrophy, nerve entrapment and compartment syndrome. The proximal and distal collars can provide visual access to the limb.
The pressure sites are preferably provided by resilient pressure pads located on the inner surface or surfaces of the casing. Each pressure pad can be individually chosen or adjusted to provide the appropriate individual pressure for its particular point of application. For example, some points of the limb may benefit from more pressure than others and vice versa. This is not possible with a conventional cast.
In the preferred embodiment, the splint comprises means to support the limb so as to allow limited movement of the limb extremity or extremities. The term extremity is intended to include a hand or foot or the like. Allowing movement of these body segments can reduce swelling commonly occurring with Colles' fractures by promoting vascular flow through movement of the extremity.
The splint may include pressure sensing means for sensing pressure exerted on one or more of the pressure sites. The pressure sensing means may be incorporated in one or more pressure pads.
In one embodiment, the pressure sites are adjustable in dependence upon the sensed pressure to adjust the pressure produced thereby.
According to another aspect of the present invention, there is provided a splint for a fractured limb comprising longitudinally-spaced proximal and distal collars and means for supporting a hand, foot or other body segment in relation to another as appropriate at the side of the distal collar remote from the proximal collar.
In preferred arrangements the collars are individually adjustable; in addition there are rigid interconnections between the collars and between the distal collar and the hand, foot or other body segment support.
According to another aspect of the present invention there is provided a splint for a fractured limb comprising at least one collar, the collar comprising an internal pad or cell, and means for sensing the pressure exerted on said pad or cell.
Preferably there are at least two collars and each collar has a plurality of pressure sensing means. In the light of the pressure sensed, the size of the collars and/or the pressure applied by said pads or cells may be individually adjusted.
According to another aspect of the present invention there is provided a method of adjusting a splint in accordance with the second aspect wherein the adjustment is made in dependence upon the sensed pressures. This method may be used during development of a splint, to determine the pressure to be applied at the various pressure sites. Subsequent splints may then omit any pressure sensing means.
Preferred embodiments may have one or more of the following features:
A rigid outer casing which is adjustable by a measured amount to accommodate a variation in dimensions within a section of the anthropometric range of the population.
A number of standard component sections which may be added to for specific holding positions after treatment. These sections may be removed as part of rehabilitation therapy.
One or more axes of adjustment dependent upon the holding position required.
A measurable adjustment achieved through the use of a spigot locating within a number of recess options available. This will result in a change in dimension of the splint by a known amount. This allows objective records to be kept of treatment given to a patient.
An outer casing which can be adjusted and a pressure indicator/alarm which can be reset without removal or replacement of the splint.
Incorporated within the outer casing are a number of pressure indicators. These are located where the holding pressures will be applied to the fracture site and the surrounding areas where the splint is supported on the body. The pressure indicator may comprise a small electronic pressure sensor, a mechanical diaphragm, or a reservoir with liquid which above a specified pressure, transfers to another container where it can be seen, or any other appropriate sensing or indicating device.
The indicator will also act as a warning alarm to the patient or clinician that excessive pressure has built up at the splint-body interface. The patient can then seek medical assistance to adjust the splint. The alarm may be given by an audible/visible or a vibratory method, or by a combination of these.
The splint will be made of materials that will allow x-rays to be taken with the splint in place.
Splints in accordance with the present invention may be based on the use of a modular outer casing and an option for the inner wall to be customized to the forearm or any other limb or body part using mechanical adjustable of the circumference of the splint collars or using air cells which can be inflated or deflated to take up the space between the outer casing and the body. The valve through which the air cell is inflated/deflated may also fasten the air cell in position within the casing of the splint.
Previous studies into plaster casting techniques for Colles' fracture show a potential for excessive pressure to build up within conventional plaster casts leading to compartmental syndrome. Plaster casts have a limited ability to be adjusted once set. The clinician relies heavily on experience to feel the cast wall is applying the correct pressure, and is in the correct position. There is a lack of objective information available to the clinician when applying the splint to maintain reduction. A commercially available system which incorporated such feedback has not yet been found.
BRIEF DESCRIPTION OF THE DRAWINGS
An earlier splint for Colles' fracture of the wrist that incorporated a pressure interface is known as the Aberdeen Brace. This system of splinting produces localized high interface pressures. It comprises a commercially available functional brace modified to accept monitoring components. The flexibility of the splint wall and a lack of a hand support contributes to the high intra-cast pressures.
The hand support of the present invention when applied to Colles' fracture of the wrist was found to reduce the forces applied to the forearm and wrist necessary to hold the position of the splint over the fracture site using the hand support as a locator and to reduce the effectiveness of forces generated by the muscles of the forearm that may cause misalignment.
Plaster casting is still the most popular method of maintaining reduction of Colles' fracture. Yet it has been acknowledged that this method is limited in its usefulness. There are commercially available air splints for use in emergency situations, which apply a uniform pressure over the whole forearm. These are not designed to maintain a holding pressure on specific areas of the forearm over a six week period. Thermoformed splinting materials are difficult to apply to Colles' fracture due to the heat of the material on the patient and the short manipulation time before the material cools and stiffens. It then requires reheating.
Preferred embodiments of the present invention as applied to Colles' fracture of the wrist will now be described, by way of example only, with reference to the accompanying drawings, of which:
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the forces necessary to maintain reduction of a Colles' fracture of the wrist;
FIGS. 2 a and 2 b indicate the locations of the applied holding pressures necessary on two perpendicular axes;
FIGS. 3 a and 3 b show a splint in accordance with a first embodiment of the present invention;
FIG. 4 shows a cross section of the splint of FIG. 3 .
FIG. 5 shows a splint of FIG. 3 about to be applied to a wrist;
FIG. 6 shows a splint of FIG. 3 in its closed configuration applied to a patients arm;
FIG. 7 shows a schematic view of the splint of FIG. 3 with various parts omitted to show the flow of blood; and
FIG. 8 shows a splint in accordance with a second embodiment of the present invention.
Colles' fracture is diagnosed as occurring 25 mm from the distal end of the radial bone. The vectorial components a, and b, resulting in the holding force R, that are required to maintain reduction of the fracture are shown in FIG. 1 . The three point loading technique used to apply the holding pressure at points 11 to 16 are shown in FIGS. 2 a and 2 b.
A first embodiment of the present invention is shown in FIG. 3. A splint 17 comprising two collars 18 and 19 made of engineering plastic and a main body 20 . These are contoured to apply pressure at the predetermined positions only via closed cell foam pads 21 to 27 or alternatively via air cells which are adjustable in pressure 54 and 55 as shown in FIG. 8 . The pressure indicators 30 to 33 are used to warn the patient and clinician when excessive intra-cast pressures occur during application of the splint and during use. The two collars are connected to the main body 20 that locates along the axis of the distal end of the ulna bone of the forearm. The two collars pivot at the attachment point to the main body on two flat hinges 34 and 35 .
A second feature relating to the pressure sensing indicator/alarm and their location within the collars of the splint is shown in FIG. 4 . The positions of the sensors/pads of the splint in position are shown in cross-section on the distal collar and defined as follows.
The pressure sensors 30 and 31 are incorporated into the rigid outer casing of the collar 19 under the closed cell foam pads 21 and 22 . The position and configuration of the pads in relation to the wrist and forearm provide the holding force in the directions of a and b shown in FIG. 1 . Opposing the applied force from the pads 21 , 22 on collar 19 are pads 23 , 27 set opposite and are attached to the main body of the splint 20 . The range of adjustment within the collar around the hinge does not affect the positioning of the pads enough to require repositioning of them. The holding pressure is applied to the bone fragment and the proximal shaft of the radial bone. The configuration of the pads 24 , 25 , 26 and integral sensors 32 , 33 is repeated in the proximal collar 18 . When a predetermined safe pressure threshold has been exceeded the sensor will trigger an alarm. The alarm may be visible, audible or vibration or a combination of two or more. The alarm and pressure sensor may be integral in the form of a diaphragm which is moved to allow a peg to be visible above the surface of the casing, or a colored liquid reservoir that is compressed forcing the liquid into a restricted tube which passes the outer surface of the casing where it can be seen. Alternatively, the alarm and sensor may be separate in the form of a strain gauge and miniature loudspeaker with a microprocessor that would be powered by a watch battery.
The pads 21 and 22 are 37 mm×40 mm long and apply a holding pressure that overlaps the fragment and shaft giving support to the realignment of the bone. The pads avoid applying pressure over the medial, radial or ulna nerve which pass through the wrist. Application of pressure over the dorsal and volar aspects of the forearm is kept to a minimum to allow free movement of the tendons promoting early mobilization of the hand and digits. Fluid can drain back into the body from the fracture site through areas where pressure is not applied as shown in FIG. 7 . The two collars are separated by a 15 mm gap 53 . The positioning of holding pressures on to the forearm in different axial planes avoids isolating sections of the circulatory system. The gap allows fluid flow between the pressure zones of the two collars 18 and 19 .
If a hand support is not used it is envisaged the proximal pads would need to exert a greater holding pressure on to the forearm to maintain stability of position. It would also be advantageous to maintain a three point loading on the fracture site. As the proximal forearm is not so badly affected by the fracture there are more options for the positioning of the holding pressure.
The range of travel within the casing had been determined from the previously mentioned anthropometric and commercial information. It was determined a 10 mm change in diameter of the splint collars was necessary to cover the variation of wrist dimensions across the proposed three sizes of splint casing.
An alternative to the preferred pad and sensor configuration is the use of air cells as sensors and adjustment FIG. 8 . The air cells 28 and 29 replace the foam pads and sensors within the proximal collar, shown in FIG. 8, and the distal collar of the splint. Valves 54 , 55 are used to inflate and deflate the bellows arrangement of the individual cells to fill the gap between the casing and the forearm/wrist. The air will be inserted through a hand pump that may have an integral pressure indicator 56 . When pressure is applied to the cell that exceeds the safe threshold an alarm will be triggered that is audible, visual or vibratory or any suitable combination.
A third feature, shown in FIG. 3 a, is the adjustment of the collars 18 and 19 . The spigot for the distal collar 46 and two ridges on either side at 47 are part of the main body 20 . The collar 19 has measured grooves 49 in the tongue 48 that overlaps the main body and spigot. Once the collar circumference has been set by the clinician the collar can be fixed in position using a tamperproof nut 50 . This configuration is repeated on the proximal collar 18 .
There is a detachable hand support 36 that limits movement in palmar and dorsiflexion, ulna and radial deviation. The hand support does not immobilize the hand completely. It allows a few millimeters of movement in all directions to avoid joint stiffness and to promote vascular flow. The support is adjustable laterally along the axis of the forearm using the same configuration of a locating spigot 38 on the main body of the splint into indentations at measured intervals on the hand support 37 . The support locked into position using a tamperproof nut 39 .
The cross bar support 40 is adjustable to accommodate varying hand widths when the hand support 36 is being set by the clinician. The cross bar 40 sleeve onto the main hand support section 41 and is fixed in position using a tamperproof screw 42 . The bar is covered in an inert closed cell foam 43 that helps to distribute the support load over a larger area just behind the metacarpophalangeal joints of the fingers. Where the thumb joins the hand, at the carpo-metacarpal joint, this area is used to locate the cross bar 40 and so avoid slippage of the splint along the axis of the forearm which would cause the splint to give an inappropriate support to the fracture site.
The hand support has an option to allow adjustment to the fixed holding angle of the hand 36 a. The main hand support would have the lateral adjustment bar 43 and the cross bar support 41 . The cross bar support will pivot on pin 44 and use grooves 51 and a spigot to give measured angular adjustment that is locked by a screw 45 and a tamperproof nut 52 .
FIGS. 5 and 6 show splint 20 that is preferably applied as follows:
1. The uninjured forearm/wrist is used to gauge which of the three sizes of brace or splint 20 will be fitted.
2. The hand support 36 with the correct degree of palmar flexion/ulna deviation pre-set is attached to the brace making sure the cross bar 40 , 41 lies just behind the metacarpophalangeal joints of the fingers.
3. Manipulation and reduction is carried out by the doctor.
4. The underlying stockinette is applied to the forearm.
5. The splint/brace 20 is applied whilst the forearm is held in reduction.
6. The hand is located into the cross bar 41 , which can be adjusted to fit different hand widths and thicknesses.
7. The proximal collar 18 is then closed around the arm until the collar “feels” to be at the correct pressure, and fastened together with the nut provided.
8. The above sequence is repeated with the distal collar 19 .
9. Alternatively if the air cells 28 , 29 are used the proximal and distal collars could be set close to the forearm/wrist. A pressure evaluation as made by Talley Ltd. 59 could be used to inflate the air cells to a pre-set pressure which would be achieved once the space had been filled between the casing and the forearm/wrist.
10. The radial bone is then checked to ensure reduction is being maintained properly.
11. The splint position and pressures are reviewed.
12. All nuts are tightened and locked.
Although the above-described modular splints are similar in weight to a plaster cast, and initially more expensive the benefits will be as follows:
Less incidence of compartment syndrome by the use of the intra-cast pressure monitor/alarm. This avoids surgery to restore some function to the hand when the median nerve is damaged through blood occlusion.
Patients can have an indicator that tells them when high pressures are occurring, and to return to the hospital. Less incidence of misalignment of the distal fragment and the proximal shaft of the radius. This may involve surgery to reset the original fracture where function of the hand has been severely affected.
Objective information may be available to the clinician during application of the splint. This should help less experienced staff apply the splint more accurately.
Records can be kept of the splint settings. This information will be useful to the clinician if complications arise after treatment. Adjustments to the splint can then be more objectively monitored and evaluated as part of assessment of the efficiency of the treatment.
The casing can be adjusted easily if the condition of the trauma site changes. An increase, or decrease in swelling will affect the compartment pressure and the holding pressure applied to hand and forearm.
Adjustment of the hand support allows an appropriate amount of movement to the hand.
The time taken to apply and monitor the splint and that taken using plaster treatment is similar. The skill of the clinician is enhanced by the objective feedback from the interface pressure indicator providing more considered treatment.
Physiotherapy time is also reduced due to improved function post-cast. The large potential market allows mass production techniques to be used to produce the finished product. This should bring the cost of the splint to within the cost of functional bracing, normally used post-cast.
The use of a hand support reduces the hand's ability to produce a force against the splint. It also acts as a locator for the splint casing onto the forearm/wrist.
Various modifications may be made to the above-described splints. They may comprise only a single collar or more than two collars. They may be designed for the upper arm in which case the hand support may be omitted. They may be modified to be applied to a leg or ankle with or without an appropriate foot support. They may also be modified for the limbs of animals.
The disclosures in U.K. patent application no. 94/11445.1, from which this application claims priority, and in the abstract accompanying this application are incorporated herein by reference. | A splint ( 17 ) includes first and second collars ( 18,19 ) pivotally supported on a body member ( 20 ) and adjustable so as to adjust the internal dimensions of the splint ( 17 ). A plurality of spaced resilient pads ( 21-27 ) are provided on the internal surfaces of the splint ( 17 ) so as to exert pressure on a limb ( 11 ) held in the splint ( 17 ) while allowing vascular flow. The splint ( 17 ) is provided with a support ( 36 ) for supporting the extremity of a limb, such as a hand ( 14 ) or foot. The support ( 36 ) allows some movement of the limb extremity to reduce swelling by promoting vascular flow. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. application Ser. No. 13/064,590, filed Apr. 1, 2011, which was a continuation application of U.S. application Ser. No. 12/801,952, filed Jul. 2, 2010, which issued as U.S. Pat. No. 7,942,026, which was a continuation of U.S. application Ser. No. 12/659,980, filed Mar. 26, 2010, which issued as U.S. Pat. No. 7,797,970, which was a divisional of U.S. application Ser. No. 11/806,245, filed May 30, 2007, which issued as U.S. Pat. No. 7,743,633, which in turn claims the benefit of Korean Patent Application Nos. 2006-49501 and 2006-49482, both filed on Jun. 1, 2006, in the Korean Intellectual Property Office, the disclosures of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates generally to a washing machine having at least one balancer, and more particularly to a washing machine having at least one balancer that increases durability by reinforcing strength and that is installed on a rotating tub in a convenient way.
[0004] 2. Description of the Related Art
[0005] In general, washing machines do the laundry by spinning a spin tub containing the laundry by driving the spin tub with a driving motor. In a washing process, the spin tub is spun forward and backward at a low speed. In a dehydrating process, the spin tub is spun in one direction at a high speed.
[0006] When the spin tub is spun at a high speed in the dehydrating process, if the laundry leans to one side without uniform distribution in the spin tub or if the laundry leans to one side by an abrupt acceleration of the spin tub in the early stage of the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, which thus causes noise and vibration. The repetition of this phenomenon causes parts, such as a spin tub and its rotating shaft, a driving motor, etc., to break or to undergo a reduced life span.
[0007] Particularly, a drum type washing machine has a structure in which the spin tub containing laundry is horizontally disposed, and when the spin tub is spun at a high speed when the laundry is collected on the bottom of the spin tub by gravity in the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, thus resulting in a high possibility of causing excess noise and vibration.
[0008] Thus, the drum type washing machine is typically provided with at least one balancer for maintaining a dynamic balance of the spin tub. A balancer may also be applied to an upright type washing machine in which the spin tub is vertically installed.
[0009] An example of a washing machine having ball balancers is disclosed in Korean Patent Publication No. 1999-0038279. The ball balancers of a conventional washing machine include racers installed on the top and the bottom of a spin tub in order to maintain a dynamic balance when the spin tub is spun at a high speed, and steel balls and viscous oil are disposed within the racers to freely move in the racers.
[0010] Thus, when the spin tub is spun without maintaining a dynamic balance due to an unbalanced eccentric structure of the spin tub itself and lopsided distribution of the laundry in the spin tub, the steel balls compensate for this imbalance, and thus the spin tub can maintain the dynamic balance.
[0011] However, the ball balancers of the conventional washing machine have a structure in which upper and lower plates formed of plastic by injection molding are fused to each other, and a plurality of steel balls are disposed between the fused plates to make a circular motion, so that the ball balancers are continuously supplied with centrifugal force that is generated when the steel balls make a circular motion, and thus are deformed at walls thereof, which reduces the life span of the balancer.
[0012] Further, the ball balancers of the conventional washing machine do not have a means for guiding the ball balancers to be installed on the spin tub in place, so that it takes time to assemble the balancers to the spin tub.
[0013] In addition, the ball balancers of the conventional washing machine have a structure in which a racer includes upper and lower plates fused to each other, so that fusion scraps generated during fusion fall down both inwardly and outwardly of the racer. The fusion scraps that fall down inwardly of the racer prevent motion of the balls in the racer, and simultaneously result in generating vibration and noise.
SUMMARY
[0014] Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and an object of the present invention is to provide a washing machine having at least one balancer that increases durability by reinforcing the strength of the balancer, which is installed on a rotating tub in a rapid and convenient way.
[0015] Another object of the present invention is to provide a washing machine having at least one balancer, in which fusion scraps generated by fusion of the balancer are prevented from falling down inward and outward of the balancer.
[0016] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0017] In order to accomplish these objects, according to an aspect of the present invention, there is provided a washing machine having a spin tub to hold laundry to be washed and at least one balancer. The balancer includes first and second housings, the first housing having at least one support for reinforcing a strength of the balancer. The first and second housings have an annular shape and are fused together to form a closed internal space.
[0018] Here, the first housing may have the cross section of an approximately “C” shape, and the support protrudes outwardly from at least one of opposite walls of the first housing.
[0019] Further, the spin tub may include at least one annular recess corresponding to the balancer such that the balancer is able to be coupled to the spin tub by being fitted within the recess.
[0020] Further, the support may protrude from the first housing and comes Into contact with a wall of the recess, and guides the balancer to be maintained in the recess in place.
[0021] Also, the supports may be continuously formed along and perpendicular to the opposite walls of the first housing.
[0022] Further, the supports may be disposed parallel to the opposite walls of the first housing at regular intervals.
[0023] Meanwhile, the washing machine may be a drum type washing machine. A front member may be attached to a front end of the spin tub and a rear member may be attached to a rear end of the spin tub. The recesses may be provided at the front and rear members of the spin tub, and the balancers may be coupled to opposite ends of the spin tub at the recesses of the front and rear members.
[0024] The foregoing and/or other aspects of the present invention can be achieved by providing a washing machine having at least one balancer. The balancer includes a first housing and a second housing fused to the first housing, and the first and second housings are fused together to form at least one pocket between the first housing and the second housing, the pocket capable of collecting fusion scraps generated during fusion.
[0025] Here, the first housing may include protruding fusion ridges protruding from ends of the first housing, and the second housing may include fusion grooves receiving the fusion ridges of the first housing when the first housing and the second housing are fused together.
[0026] Further, the first housing may further include inner pocket ridges protruding from the first housing and spaced inwardly, apart with respect to the fusion ridges of the first housing.
[0027] Further, the second housing may further include outer pocket flanges protruding from the second housing and being situated on outer sides of the fusion grooves when the first housing is fused together with the second housing so the outer pocket flanges are spaced apart from the fusion ridges of the first housing by a predetermined distance, causing an outer pocket to be formed between the fusion ridges and the outer pocket flanges.
[0028] Further, the second housing may include guide ridges protruding from the second housing and protruding toward the first housing to closely contact the inner pocket ridges of the first housing when the first and second housings are fused together.
[0029] Also, the balancer may further include a plurality of balls disposed within an internal space formed by fusing the first and second housings together, the balls performing a balancing function.
[0030] In addition, the washing machine may further include a spin tub disposed horizontally, and the balancers may be installed at front and rear ends of the spin tub.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other aspects, features and advantages of the present invention will be more apparent from the following detailed description of the embodiments, taken in conjunction with the accompanying drawings, in which
[0032] FIG. 1 is a sectional view illustrating a schematic structure of a washing machine according to the present invention;
[0033] FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub;
[0034] FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention;
[0035] FIG. 4 is an enlarged view illustrating section A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention;
[0036] FIG. 5 is a perspective view illustrating a balancer according to a second embodiment of the present invention;
[0037] FIG. 6 is an enlarged view illustrating the sectional structure of a balancer according to the second embodiment of the present invention;
[0038] FIG. 7 is a perspective view illustrating a disassembled balancer according to a third embodiment of the present invention;
[0039] FIG. 8 is a perspective view illustrating an assembled balancer according to the third embodiment of the present invention;
[0040] FIG. 9 is a partially enlarged view of FIG. 7 ; and
[0041] FIG. 10 is a sectional view taken line A-A of FIG. 8 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0042] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0043] Hereinafter, exemplary embodiments of the present invention will be described with reference to the attached drawings.
[0044] FIG. 1 is a sectional view illustrating the schematic structure of a washing machine according to the present invention.
[0045] As illustrated in FIG. 1 , a washing machine according to the present invention includes a housing 1 forming an external structure of the washing machine, a water reservoir 2 installed in the housing 1 and containing washing water, a spin tub 10 disposed rotatably in the water reservoir 2 which allows laundry to be placed in and washed therein, and a door 4 hinged to an open front of the housing 1 .
[0046] The water reservoir 2 has a feed pipe 5 and a detergent feeder 6 both disposed above the water reservoir 2 in order to supply washing water and detergent to the water reservoir 2 , and a drain pipe 7 installed therebelow in order to drain the washing water contained in the water reservoir 2 to the outside of the housing 1 when the laundry is completely done.
[0047] The spin tub 10 has a rotating shaft 8 disposed at the rear thereof so as to extend through the rear of the water reservoir 2 , and a driving motor 9 , with which the rotating shaft 8 is coupled, installed on a rear outer side thereof. Therefore, when the driving motor 9 is driven, the rotating shaft 8 is rotated together with the spin tub 10 .
[0048] The spin tub 10 is provided with a plurality of dehydrating holes 10 a at a periphery thereof so as to allow the water contained in the water reservoir 2 to flow into the spin tub 10 together with the detergent to wash the laundry in a washing cycle, and to allow the water to be drained to the outside of the housing 1 through a drain pipe 7 in a dehydrating cycle.
[0049] The spin tub 10 has a plurality of lifters 10 b disposed longitudinally therein. Thereby, as the spin tub 10 rotates at a low speed in the washing cycle, the laundry submerged in the water is raised up from the bottom of the spin tub 10 and then is lowered to the bottom of the spin tub 10 , so that the laundry can be effectively washed.
[0050] Thus, in the washing cycle, the rotating shaft 8 alternately rotates forward and backward by of the driving of the driving motor 9 to spin the spin tub 10 at a low speed, so that the laundry is washed. In the dehydrating cycle, the rotating shaft 8 rotates in one direction to spin the spin tub 10 at a high speed, so that the laundry is dehydrated.
[0051] When spun at a high speed in the dehydrating process, the spin tub 10 itself may undergo misalignment between the center of gravity and the center of rotation, or the laundry may lean to one side without uniform distribution in the spin tub 10 . In this case, the spin tub 10 does not maintain a dynamic balance.
[0052] In order to prevent this dynamic imbalance to allow the spin tub 10 to be spun at a high speed with the center of gravity and the center of rotation thereof matched with each other, the spin tub 10 is provided with balancers 20 or 30 according to a first or a second embodiment of the present invention (wherein only the balancer 20 according to a first embodiment is shown in FIGS. 1-4 ) at front and rear ends thereof. The structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 2 through 6 .
[0053] FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub.
[0054] As illustrated in FIG. 2 , the spin tub 10 includes a cylindrical body 11 that has open front and rear parts and is provided with the dehydrating holes 10 a and lifters 10 b, a front member 12 that is coupled to the open front part of the body 11 and is provided with an opening 14 permitting the laundry to be placed within or removed from the body 11 , and a rear member 13 that is coupled to the open rear part of the body 11 and with the rotating shaft 8 (see FIG. 1 ) for spinning the spin tub 10 .
[0055] The front member 12 is provided, at an edge thereof, with an annular recess 15 that has the cross section of an approximately “C” shape and is open to the front of the front member 12 in order to hold any one of the balancers 20 . Similarly, the rear member 13 is provided, at an edge thereof, with an annular recess 15 (not shown) that is open to the rear of the front member 12 in order to hold the other of the balancers 20 .
[0056] The front and rear members 12 and 13 are fitted into and coupled to the front or rear edges of the body 11 in a screwed fashion or in any other fashion that allows the front and rear members 12 and 13 to be maintained to the body 11 of the spin tub 10 .
[0057] The balancers 20 , which are installed in the recesses 15 of the front and rear members 12 and 13 , have an annular shape and are filled therein with a plurality of metal balls 21 performing a balancing function and a viscous fluid (not shown) capable of adjusting a speed of motion of the balls 21 .
[0058] Now, the structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 3 through 6 .
[0059] FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention, and FIG. 4 is an enlarged view illustrating part A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention.
[0060] As illustrated in FIGS. 3 and 4 , a balancer 20 according to a first embodiment of the present invention has an annular shape and includes first and second housings 22 and 23 that are fused to define a closed internal space 20 a.
[0061] The first housing 22 has first and second walls 22 a and 22 b facing each other, and a third wall 22 c connecting ends of the first and second walls 22 a and 22 b, and thus has a cross section of an approximately “C” shape. The second housing 23 has opposite edges that protrude toward the first housing 22 and that are coupled to corresponding opposite ends 22 d of the first housing 22 by heat fusion.
[0062] The opposite ends 22 d of the first housing 22 protrude outward from the first and second walls 22 a and 22 b of the first housing 22 , and the edges of the second housing 23 are sized to cover the ends 22 d of the first housing 22 .
[0063] Thus, when the balancer 20 is fitted into the recess 15 of the front member 12 of the spin tub 10 , the first and second walls 22 a and 22 b are spaced apart from a wall of the recess 15 because of the ends and edges of the first and second housings 22 and 23 which protrude outward from the first and second walls 22 a and 22 b. Further, because the first and second walls 22 a and 22 b are relatively thin, the first and second walls 22 a and 22 b are raised outward when centrifugal force is applied thereto by the plurality of balls 21 that move in the internal space 20 a of the balancer 20 in order to perform the balancing function.
[0064] In this manner, the plurality of balls 21 make a circular motion in the balancer 20 , so that the first and second walls 22 a and 22 b, are deformed by the centrifugal force applied to the first and second walls 22 a and 22 b of the first housing 22 . In order to prevent this deformation, the second housing 22 is provided with supports 24 according to a first embodiment of the present invention.
[0065] The supports 24 protrude from and perpendicular to the first and second walls 22 a and 22 b of the first housing 22 which are opposite each other, and may be continued along an outer surface of the first housing 22 , thereby having an overall annular shape.
[0066] The supports 24 have a length such that they extend from the first housing 22 to contact the wall of the recess 15 . Hence, the first and second walls 22 a and 22 b are further increased in strength, and additionally function to guide the balancer 20 so as to be maintained in the recess 15 in place.
[0067] Here, when the plurality of balls 21 make a circular motion in the first housing 22 , the centrifugal force acts in the direction moving away from the center of rotation of the spin tub 10 . Hence, the centrifugal force acts on the first wall 22 a to a stronger level when viewed in FIG. 4 . Thus, the supports 24 may be formed only on the first wall 22 a.
[0068] In the balancer 20 according to the first embodiment of the present invention, when the first and second housings 22 and 23 are fused together and fitted into the recess 15 of the spin tub 10 , the supports 24 are maintained in place while positioned along the wall of the recess 15 . Finally, the balancer 20 is coupled and fixed to the front member 12 of the spin tub 10 by screws (not shown) or in any other fashion that allows the balancer 20 to be coupled to the front member 12 .
[0069] Although not illustrated in detail, the balancer 20 is similarly installed on the rear member 13 of the spin tub 10 .
[0070] The ends 22 d of the first housing 22 include fusion ridges 42 a that protrude toward the second housing 23 . The fusion ridges 42 a are inserted within fusion grooves 43 a of the second housing 23 .
[0071] FIGS. 5 and 6 correspond to FIGS. 3 and 4 , and illustrate a balancer 30 according to a second embodiment of the present invention.
[0072] The balancer 30 according to the second embodiment of the present invention has an annular shape and includes first and second housings 32 and 33 that are fused together forming an Internal space 30 a therebetween in which a plurality of balls 31 are disposed. The balancer 30 according to the second embodiment of the present invention is similar to that of balancer 20 according to the first embodiment of the present invention, except the structure of supports 34 of balancer 30 is different from that of the structure of the supports 24 of balancer 20 .
[0073] As illustrated in FIGS. 5 and 6 , the supports 34 according to the second embodiment of the present invention protrude parallel to first and second walls 32 a and 32 b of a first housing 32 which are opposite each other, and the supports 34 are disposed at regular intervals along the first and second walls 32 a and 32 b. The first housing 32 further includes a third wall 32 c. Ends 22 d of the first housing 32 extend from an end of the first and second walls 32 a and 32 b.
[0074] Similar to the supports 24 according to the first embodiment, the supports 34 of the second embodiment have a length such that the supports 34 extend from the first housing 32 to contact the wall of the recess 15 . The surfaces of the supports 34 thereby abut portions of the front member 12 . Hence, the first and second walls 32 a and 32 b are further increased in strength, and additionally function to guide the balancer 30 so as to be maintained in the recess 15 in place.
[0075] Next, the construction of a balancer 40 according to a third embodiment of the present invention will be described with reference to FIGS. 7 through 10 .
[0076] FIGS. 7 and 8 are perspective views illustrating disassembled and assembled balancers according to the third embodiment of the present invention, FIG. 9 is a partially enlarged view of FIG. 7 , and FIG. 10 is a sectional view taken along line A-A of FIG, 8 .
[0077] As illustrated in FIGS. 7 and 8 , a balancer 40 includes a first housing 42 having an annular shape and a second housing 43 having an annular shape that is fused to the first housing 42 , thereby forming an annular housing corresponding to the recess 15 (see FIG. 2 ) of the spin tub 10 . The first and second housings 42 and 43 may be, for example, formed of synthetic resin, such as plastic by injection molding.
[0078] As illustrated in FIG. 9 , the first housing 42 has a cross section of an approximately “C” shape, includes fusion ridges 42 a protruding to the second housing 43 at opposite ends thereof which are coupled with the second housing 43 , and inner pocket ridges 42 b protruding to the second housing 43 spaced inwardly apart from the fusion ridges 42 a.
[0079] The second housing 43 , which is coupled to opposite ends of the first housing 42 in order to form a closed internal space 40 a for holding a plurality of balls 41 and a viscous fluid, includes fusion grooves 43 a recessed along edges thereof so as to correspond to the fusion ridges 42 a, outer pocket flanges 43 b and guide ridges 43 c. The outer pocket flanges protrude to the first housing 42 on outer sides of the fusion grooves 43 a so as to be spaced apart from the fusion ridges 42 a of the first housing 42 by a predetermined distance. The guide ridges 43 c protrude to the first housing 42 on inner sides of the fusion grooves 43 a and closely contact the inner pocket ridges 42 b of the first housing 42 .
[0080] The guide ridges 43 c of the second housing 43 move in contact with the inner pocket ridges 42 b of the first housing 42 when the second housing 43 is fitted into the first housing 42 , to thereby guide the fusion ridges 42 a of the first housing 42 to be fitted into the fusion grooves 43 a of the second housing 43 rapidly and precisely.
[0081] Thus, when the fusion ridges 42 a of the first housing 42 are fitted into the fusion grooves 43 a of the second housing 43 in order to fuse the first housing 42 with the second housing 43 , as shown in FIG. 10 , an inner pocket 40 b having a predetermined spacing is formed between the fusion ridges 42 a and inner pocket ridges 42 b, and an outer pocket 40 c having a predetermined spacing is formed between the fusion ridges 42 a and the outer pocket flanges 43 b.
[0082] In this state, when heat is generated between the fusion ridges 42 a of the first housing 42 and the fusion grooves 43 a of the second housing 43 , the fusion ridges 42 a and the fusion grooves 43 a are firmly fused with each other. At fusion, fusion scraps that are generated by heat and fall down inward of the first housing 42 are collected in the inner pocket 40 b, so that the scraps are not introduced into the internal space 40 a of the balancer 40 in which the balls 41 move. Fusion scraps falling down outward of the first housing 42 are collected in the outer pocket 40 c, and thus are prevented from falling down outward of the balancer 40 .
[0083] In the embodiments, the balancers 20 , 30 and 40 have been described to be installed on a drum type washing machine by way of example, but it is apparent that the balancers can be applied to an upright type washing machine having a structure in which a spin tub is vertically installed.
[0084] As described above in detail, the washing machine according to the embodiments of the present invention has a high-strength structure in which at least one balancer is provided with at least one support protruding outward from the wall thereof, so that, although the strong centrifugal force acts on the wall of the balancer due to a plurality of balls making a circular motion in the balancer, the wall of the balancer is not deformed. Thus, the plurality of balls can make a smooth circular motion without causing excess vibration and noise, and thus increasing the durability and life span of the balancer.
[0085] Further, the washing machine according to the embodiments of the present invention has a structure in which the balancer can be rapidly and exactly positioned in the recess of the spin tub by the supports, so that an assembly time of the balance can be reduced.
[0086] In addition, the washing machine according to the present invention has a structure in which fusion scraps generated when the balancer is fused are collected in a plurality of pockets, and thus are prevented from falling down inward and outward of the balancer, so that the internal space of the balancer, in which a plurality of balls are filled and move in a circular motion, has a smooth surface without the addition of fusion scraps. As a result, the balls are able to move more smoothly, and excess noise and vibration are minimized. The balancer may have a clear outer surface to provide a fine appearance without the fusion scraps, so that it can be exactly coupled to the spin tub without obstruction caused by the fusion scraps.
[0087] Although a few embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims and their equivalents. | A front loading washing machine including a housing; a water reservoir installed in the housing to contain washing water; a spin tub provided in the water reservoir to hold laundry to be washed, the spin tub rotatable with respect to a horizontal axis of the washing machine, the spin tub including a cylindrical body, a front cover and a rear cover, the front cover having a front wall with an opening formed therein for receiving laundry and an annular recess having a predefined depth formed in the front wall of the front cover such that an outer annular side wall defining the annular recess establishes direct physical contact with a predefined area of an inner surface of the cylindrical body; and at least one balancer installed in the annular recess of the spin tub, the balancer comprising an annular shaped race formed of a plastic material. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an oil pressure circuit for an automatic transmission.
2. Description of Related Art
Automatic transmissions are designed such that a power transmission system of a multistage transmission of a planetary geartrain type is controlled, that is, its speed stages are shifted, by switching coupled or engaged states of transmission coupling or engaging friction elements such as clutches, brakes and so on.
The friction elements for shifting speed stages of an automatic transmission are operated by hydraulic actuators. Oil pressures are supplied or released to or from the hydraulic actuators through oil pressure circuits provided in the automatic transmission. The oil pressure circuits contains at least plural shift valves such as a 1-2 shift valve and a 2-3 shift valve, and the shift valves are shifted by pilot pressures. Recently, many automatic transmissions are designed such that shifting speed stages is controlled by electronically regulating the pilot pressure for the shift valves by means of solenoids. Japanese Patent Publication (Kokai) No. 92,351/1986 discloses a control system in which such a solenoid is provided each for the shift valves.
Japanese Patent Publication No. 18,780/1987 discloses another oil pressure control system of an automatic transmission in which solenoids are incorporated into the oil pressure control circuit system, enabling an electronic control of shifting speed stages. This system is such that a multistage transmission gear mechanism is provided with first and second coupling means (friction coupling elements) which provides four speed stages from first to fourth speed stages in accordance with a combination of engagement and disengagement of the first and second coupling means.
In this transmission gear mechanism, a first shift valve is provided to alternatively select a supply or a suspension of the supply of an operating oil for coupling the second coupling means and the first shift valve in turn is shifted by means of first pilot pressure generated by a first solenoid that is arranged to generate the first pilot pressure in such a manner that the second coupling means is brought into engagement at second, third and third speed stages and into disengagement at first speed stage. A supply or a suspension of the supply of an operating oil for coupling the first coupling means is shifted by a second shift valve. Shifting of the second shift valve is effected by second pilot pressure generated by a second solenoid which in turn generates the second pilot pressure so as to engage the first coupling means at third and fourth speed stages and to disengage it at first and second speed stages.
In this prior art transmission gear mechanism, a third solenoid is additionally provided which can generate a pilot pressure at third speed stage in a manner to prevail over the first pilot pressure and consequently act on the second coupling means for releasing the disengagement of the second coupling means. Accordingly, at the third speed stage, the disengagement of the second coupling means can be actually released even if the first solenoid would generate a pilot pressure which acts for engagement of the second coupling means.
In addition to the first and second coupling means, a third coupling means is further provided so as to permit a transmission of a torque in a reverse direction to the input shaft side from the output shaft side of the multistage transmission gear mechanism when the third coupling means is coupled or engaged, thereby ensuring engine braking. Although the third coupling means is designed so as to be engaged at any arbitrary speed stage, it is impossible to have the third coupling means engaged at all of the four speed stages because, if it were engaged at all of the first, second and third coupling means, the multistage transmission gear mechanism causes a so-called "internal lock", whereby no power can be transmitted. More specifically, the transmission gear mechanism as disclosed in this published Japanese patent application is designed such that the third coupling means is disengaged at fourth speed stage when the first and second coupling means are both engaged and it is engaged at the first, second, and third speed stages. In order to engage or disengage the third coupling means, it can be conceived that a fourth solenoid is additionally provided for controlling the third coupling means. However, such a fourth solenoid makes a structure of the oil pressure circuit more complex and expensive.
When the speed stage is shifted between the second and third speed stages where coupling the third coupling means is effected, a deviation in timings of switching the first and second coupling means gives rise to a temporary state of the fourth speed stage where an internal lock is caused, whereby a shock is likely to occur at the time of shifting the speed stages. More specifically, given an uncoupled state of the first coupling means and a coupled state of the second coupling means at the second speed stage as well as a coupled state of the first coupling means and an uncoupled state of the second coupling means at the third speed stage, on the one hand, if a timing of engaging or coupling the first coupling means would be earlier than a timing of releasing the coupling of or disengaging the second coupling means at the time of upshifting from the second to the third speed stages, there can be temporarily caused a situation in which the first and second coupling means are both in a coupled state, that is, in a state in which the speed stage is at fourth speed stage. Given the above, on the other hand, there can be likewise caused a situation in which a state of the fourth speed stage is temporarily caused if a timing of engaging the second coupling means would be earlier than a timing of disengaging the first coupling means at the time of downshifting from the third speed stage to the second speed stage.
The transmission gear mechanism having substantially the same apparatus structure as shown in FIG. 1 of this application is disclosed in pending U.S. Patent Application Ser. No. 926,840 filed Nov. 3, 1986 based on U.S. Ser. No. 665,044 filed Oct. 26, 1984 claiming Japanese Patent Application No. 202,042/1983 published as Publication (kokai) No. 95,236/1985. U.S. Pat. No. 4,665,774 issued May 19, 1987 based on U.S. Patent Application Ser. No. 746,071 filed June 18, 1985 claiming Japanese Patent Application No. 128,026/1984 published as Publication (kokai) No. 6,451/1986, pending U.S. Patent Application Ser. No. 31,612 filed Mar. 30, 1987 claiming Japanese Patent Application No. 75,697/1986 published as Publication (kokai) No. 233,547/1987, and pending U.S. Patent Application Ser. No. 32,611 filed Mar. 31, 1987 claiming Japanese Patent Application No. 77,090/1986 published as Publication (kokai) No. 233,551/1987, all of which are assigned to Mazda Motor Corporation.
SUMMARY OF THE INVENTION
The present invention has the first object to provide an oil pressure circuit of an automatic transmission so as to cause no transmission shock at the time of shifting between the second and third speed stages where engine braking is ensured in each case by using a third coupling means.
The present invention further has the second object to provide an oil pressure circuit of an automatic transmission in which switching the third coupling means is controlled by effectively utilizing a solenoid provided for controlling a first and second coupling means in order to prevent a transmission shock likely to be caused at the time of shifting between the second and third speed stages.
In order to achieve the above objects, the present invention consists of an oil pressure circuit of an automatic transmission comprising:
a multistage transmission gear mechanism having a shifting speed stage representing a ratio of rotation of an output shaft to rotation of an input shaft, said shifting stage being adapted to provide at least four speed stages from first speed stage to fourth speed stage;
a first coupling means and a second coupling means being each of a type operable hydraulically and being adapted to shift a power transmission passage of said multistage transmission gear mechanism, said first coupling means being arranged so as to be shifted between a coupled or engaged state and an uncoupled or disengaged state between first and second speed stages and third and fourth speed stages, said second coupling means being arranged so as to be shifted between a coupled or engaged state and an uncoupled or engaged state between first and third speed stages and second and fourth speed stages, and said four speed stages being alternatively selected in accordance with a combination of the coupled state and the uncoupled state of said first and second coupling means;
a third coupling means being of a type operable hydraulically and capable of transmitting a torque in a reverse direction toward the side of said input shaft from the side of said output shaft at least at second and third speed stages;
a first actuator containing a first solenoid adapted to generate a first pilot pressure shifting a state between the first speed stage and the second, third and fourth speed stages, said first actuator being adapted to regulate a supply of operating oil pressure to said second coupling means in accordance with a state in which said first pilot pressure is generated;
a second actuator containing a second solenoid adapted to generate a second pilot pressure shifting a state between the first and second speed stages and the third and fourth speed stages, said second actuator being adapted to regulate a supply of operating oil pressure to said first coupling means in accordance with a state in which said second pilot pressure is generated;
a third actuator containing a third solenoid adapted to generate a third pilot pressure, said third actuator adapted to allow said third pilot pressure to cancel a regulation of said second coupling means by said first actuator at third speed stage; and
at the time of shifting between second and third speed stages, said second pilot pressure being set to act on said first actuator and prevail over said first pilot pressure so as to retain and fix said first actuator in a state at second, third and fourth speed stages and said first pilot pressure being adapted so as to regulate shifting said third coupling means.
With this arrangement, the present invention permits the first actuator as the second coupling means to be forcibly retained in a state of being fixed at the second, third and fourth speed stages while coupling and releasing the coupling of the second coupling means are effected using the third actuator. Accordingly, the speed stages are shifted between the second and third speed stages can be effected in such a manner that the third coupling means is temporarily brought by means of the first pilot pressure into a state where no internal lock is caused. Of course, the third coupling means can be engaged again after the first and second coupling means were switched to a predetermined state after the speed stage has been shifted, thus ensuring engine braking.
In accordance with the present invention, the coupling or engagement and the uncoupling or disengagement of the third coupling means at the time of shifting between the second and third speed stages can be controlled using the solenoid each for the first and second coupling means. This arrangement has the advantage that a additional disposition of a solenoid for exclusive use for controlling the switching of the third coupling menas can be avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating one embodiment of a transmission gear mechanism.
FIG. 2 is a circuit view illustrating one example of oil pressure circuits according to the present invention, to be used for a transmission mechanism.
FIGS. 3 and 4 are each a flow chart illustrating an example of preferred embodiments of a transmission control.
FIG. 5 is a circuit view illustrating a variant of oil pressure circuits according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described more in detail in conjunction with the drawings attached hereto.
BASIC STRUCTURE OF AN AUTOMATIC TRANSMISSION
FIG. 1 is a schematic skelton structural view of an automatic transmission incorporating an oil pressure control apparatus according to the present invention.
Referring to FIG. 1, reference numeral 1 denotes a crank shaft of an engine (not shown), which functions as an input shaft. Coaxially with the crank shaft 1 are disposed a torque converter 2 and a multistage transmission geartrain apparatus 10 in this order from the engine side. The torque converter 2 comprises a pump 3, a turbine 4 and a stator 5. The pump 3 is fixed to the crank shaft 1, and the stator 5 is mounted to rotate on a fixed shaft 7 integral with a casing 11 for the multistage transmission geartrain apparatus 10 through a one-way clutch 6 which in turn is disposed so as to allow the stator 5 to rotate only in the same direction as the pump 3.
The multistage transmission geartrain apparatus 10 is provided with a center shaft 12 connected to the pump 3, which in turn is arranged such that its base end is fixed to the crank shaft 1 and its tip end penetrates and extends through a center portion of the multistage transmission geartrain apparatus, thus driving an oil pump P mounted on a side wall of the geartrain apparatus. Outside the center shaft 12 is mounted a hollow turbine shaft 13 supported rotatably by the side wall thereof, a base end of which is connected to the turbine 4 of the torque converter 2 and a tip end of which extends up to the side wall thereof. Mounted on the turbine shaft 13 is a planetary gear unit 14 which comprises a small-diameter sun gear 15, a large-diameter sun gear 16 disposed at a side of the small-diameter sun gear 15 away from the engine, a long pinion gear 17, a short pinion gear 18, and a ring gear 19.
At a side of the planetary gear unit 14 away from the engine are disposed a forward clutch 20 and a coast clutch 21 in series with each other. The forward clutch 20 is a clutch for forward driving and is to connect or disconnect a power transmission between the small-diameter sun gear 15 and the turbine shaft 13 through a first one-way clutch 22. The coast clutch 21 is to connect or disconnect a power transmission between the small-diameter sun gear 15 and the turbine shaft 13 in series with the forward clutch 20. Outside a radial direction of the coast clutch 21 is disposed a 2-4 brake 23 which is a band brake comprising a brake drum 23-1 connected to the large-diameter sun gear 16 and a brake band 23-2 suspended on the brake drum 23-1. Outside a radial direction of the forward clutch 20 and at a side of the 2-4 brake 23 is a reverse clutch 24 which is a clutch for reverse driving and is to connect or disconnect a power transmission between the large-diameter sun gear 16 and the turbine shaft 13 through the brake drum 23-1 of the 2-4 brake 23.
Outside a radial direction of the planetary gear unit 14 is disposed a low reverse brake 25 engaging or disengaging a carrier 14a for the planetary gear unit 14 with or from a housing case 10a for the multistage transmission geartrain apparatus 10. Between the 2-4 brake 23 and the low reverse brake 25 is disposed a second one-way clutch 26 in series with the low reverse brake 25, which is arranged so as to engage or disengage the carrier 14a for the planetary gear unit 14 with or from the housing case 10a for the multistage transmission geartrain apparatus 10. Disposed at a side of the planetary gear unit 14 close to the engine side is a 3-4 clutch 27 for connecting or disconnecting a power transmission between the carrier 14a therefor and the turbine shaft 13. At a side of the 3-4 clutch 27 close to the engine side is disposed an output gear 28 connected to the ring gear 19. The output gear 28 is mounted on an output shaft 28a.
In FIG. 1, reference numeral 29 denotes a lock-up clutch for connecting the turbine shaft 13 to the crank shaft 1 without a connection to the torque converter 2.
FUNCTIONS OF MULTISTAGE TRANSMISSION GEARTRAIN APPARATUS 10
The multistage transmission geartrain apparatus 10 has four forward drive speed ranges and one rearward drive speed range and is designed to provide a desired speed range by operating the clutches 20, 21, 24 and 27 as well as the brakes 23 and 25 in an appropriate combination. Table 1 below indicates relationships of the speed ranges with operation states of the clutches and brakes.
It is noted here that an actuator for the 2-4 brake 23 only is provided with two oil chambers at its apply side and at its release side and designed so as to couple or engage the 2-4 brake 23 only when an oil pressure is fed to the apply side oil chamber and when an oil pressure in the release side oil chamber is released and to uncouple or disengage the 2-4 brake 23 in the other conditions. The rest of actuators for the clutches and the brakes have each one oil chamber adapted to couple the clutch or brake only when an oil pressure is supplied to the corresponding oil chamber and to uncouple it when the oil pressure is released therefrom.
TABLE 1__________________________________________________________________________Speed BrakesRange Clutches Low One-Way ClutchPosi- Speed Forward Coast 3-4 Reverse 2-4 (23) Reverse First Secondtions Stages (20) (21) (27) (24) Apply Release (25) (22) (26)__________________________________________________________________________P --R -- ○ ○N --D 1st Speed ○ ○ ○ ○ 2nd Speed ○ ○ ○ ○ 3rd Speed ○ ○ ○ Δ ○ ○ 4th Speed ○ ○ ○ Δ2 1st Speed ○ ○ ○ ○ 2nd Speed ○ ○ ○ ○ 3rd Speed ○ ○ ○ Δ ○ ○1 1st Speed ○ ○ ○ ○ ○ 2nd Speed ○ ○ ○ ○__________________________________________________________________________ Note: The symbol ○ marks the state of coupling. The symbol Δ means the state of coupling without involving any powe transmission.
OUTLINE OF OIL PRESSURE CIRCUITS
An outline of the oil pressure circuits for the automatic transmission as shown in FIG. 1 will be described in conjunction with FIG. 2.
MANUAL VALVES
Referring to FIG. 2, a manual valve 41 is shown to provide six speed range positions "P", "R", "N", "D", "2" and "1" and comprises ports "a", "c", "e", "f", and "g". An oil pressure generated by the oil sucked from an oil reservoir tank 42 by a pump P is regulated by a pressure regulator valve 43 connected to an oil passage 101 and then fed as a line pressure to the ports "g".
When the manual valve 41 provides the speed range position "P", no port is communicated with the ports "g". At the speed range position "R" of the manual valve 41, only the ports "f" are communicated with the ports "f". No ports are communicated with the ports "g" when the manual valve 41 provides the speed range position "N". The ports "a" and "c" are communicated with the ports "g" at the speed range positions "D" and "2" of the manual valve 41 and the ports "a" and "e" are communicated with the ports "g" at the speed range position "1".
DUTY SOLENOID VALVES:
An oil pressure of the oil pumped from the oil reservoir tank 42 by the pump P is reduced to a predetermined pressure through an oil passage 102 by means of a solenoid reducing valve 44. The reduced oil pressure is then regulated by first, second, third and fourth duty solenoid valves 45A, 45B, 45C and 45D, respectively.
The first duty solenoid 45A converts the reduced oil pressure fed from the solenoid reducing valve 44 into a pilot pressure and supplies it to the pressure regulator valve 43 through an oil passage 103. The oil pressure fed from the solenoid reducing valve 44 is regulated by the second duty solenoid valve 45B and then supplied as a pilot pressure to a 3-4 pressure control valve 46 through an oil passage 104 and furthermore to a reverse pressure control valve 47 through an oil passage 104a branched from the oil passage 104. The oil pressure is fed to the third duty solenoid valve 45C and converted thereby into a pilot pressure that in turn is then fed to a servo pressure control valve 48 through an oil passage 105. The oil pressure regulated by the fourth duty solenoid valve 45D is fed as a pilot pressure to a lock-up control valve 49 through an oil passage 106.
The servo pressure control valve 48 is designed so as to regulate the oil pressure at a release side of an acutuator 23A for the 2-4 brake 23 through an oil passage 138 as will be described hereinbelow. The regulated oil pressure is then fed through an oil passage 107 to a coast control valve 50 as a pilot pressure. The duty solenoid valve 45C accordingly involves adjusting both the pilot pressure for the servo pressure control valve 48 and the pilot pressure for the coast control valve 50. The regulated oil pressure at the release side of the actuator 23A is also employed as a forward clutch pressure to be shifted by a forward control valve 51 through a branch oil passage 107a branched from the oil passage 107 in a manner as will be described hereinbelow.
ACTUATORS FOR CLUTCHES AND BRAKES
The actuators for the transmission clutches and the brakes other than the actuator 23A for the 2-4 brake 23 are of the type adapted each to be coupled only when the oil pressure is fed to the corresponding oil chamber. Accordingly, such actuators are indicated in FIG. 2 by the reference numerals provided on the corresponding clutches and brakes.
The actuator 23A for the 2-4 brake 23 comprises a cylinder 23a which in turn is divided by a piston 23b into an apply side oil chamber 23c and a release side oil chamber 23d. The piston 23b is disposed integrally with a piston rod 23e connected to the band brake 23-2 of the 2-4 brake 23. To the cylinder 23a is mounted a spring 23f in such a manner as urging the piston 23b in a downward direction as shown in FIG. 2. The actuator 23A allows the 2-4 brake 23 to be coupled or engaged with the 2-4 brake 23 only when the line pressure is introduced into the apply side oil chamber 23c and the oil pressure of the release side oil chamber 23d is released. In other words, even if the line pressure is fed to the apply side oil chamber 23c, the 2-4 brake 23 is in an uncoupled or disengaged state when the line pressure is introduced into the release side oil chamber 23d. A coupling force of the 2-4 brake 23 is to be adjusted by regulating the oil pressure of the release side oil chamber 23d by the servo pressure control valve 48 using the third duty solenoid valve 45C.
CONNECTION OF ACTUATORS FOR FRICTION COUPLING ELEMENTS WITH MANUAL VALVE 41
As shown in FIG. 2, the actuator 20A for the forward clutch 20 is connected through an oil passage 121 to the forward control valve 51 which in turn is communicated through oil passages 122 and 137 with the ports "a" of the manual valve 41.
The actuator 21A for the coast clutch 21 is connected through an oil passage 123 to the coast control valve 50 which in turn is connected through an oil passage 124 to a shift valve 53. The oil passage 124 is shifted by the shift valve 53 and connected to an oil passage 125 which in turn is connected to a coast exhaust valve 52. This coast exhaust valve is further connected through an oil passage 126 to the ports "c" of the manual valve 41.
The shift valve 53 can also connect the oil passage 124 to an oil passage 127 extending from the ports "e" of the manual valve 41 which in turn is communicated with the coast control valve 50, thus permitting a supply of line pressure to the coast control valve 50.
The actuator 27A for the 3-4 clutch 27 is connected through an oil passage 128 to the 3-4 pressure control valve 46 which in turn is connected through an oil passage 129 to a 2-3 shift valve 54. This 2-3 shift valve is connected to the ports "c" of the manual valve 41 through oil passages 130 and 126.
The actuator 25A for the low reverse brake 25 is connected to the ports "f" of the manual valve 41 through an oil passage 131 via a shift valve 55. The actuator 25A is also connected to the ports "e" thereof via the shift valve 55 which can shift the oil pressure in the oil passage 131 to an oil passage 132. This oil passage 132 is led to a 1-2 shift valve 56 which in turn is connected through an oil passage 133 to the low reducing valve 57. This low reducing valve 57 is then communicated with the ports "e".
The actuator 24A for the reverse clutch is connected through an oil passage 134 to the reverse pressure control valve 47 which in turn is connected to the ports "f" thereof via an oil passage 135.
For the actuator 23A of the 2-4 brake 23, the apply side oil chamber 23c thereof is connected through an oil passage 136 to the 1-2 shift valve 56 and then via the 1-2 shift valve 56 through an oil passage 137 to the ports "a" of the manual valve 41, on the one hand, and the release side oil chamber 23d is connected through the oil passage 138 to the servo pressure control valve 48 and then via the servo pressure control valve 48 through an oil passage 139 and the oil passage 137 to the ports "a" thereof, on the other hand. The pressure in the release side oil chamber 23d of the 2-4 brake actuator 23A is also fed to the coast control valve 50 through the oil passage 107 and to the forward control valve 51 through the oil passage 107 and the branch oil passage 107a.
SHIFT VALVES 54 AND 56
The 2-3 shift valve 54 regulates a supply or a release of a pilot pressure by turning the 2-3 solenoid 58 on or off. The pilot pressure to be regulated by the 2-3 shift solenoid 58 is determined by supplying an oil pressure from a branch oil passage 137a, as it is, to the 2-3 shift valve 54 or draining the oil pressure, the branch oil passage 137a being branched from the oil passage 137 extending from the ports "a" of the manual valve 41. The oil pressure is drained when the 1-2 solenoid 58 is turned on.
The 1-2 shift valve 56 regulates a supply or a release of a pilot pressure by the 1-2 solenoid 59. As the pilot pressure to be regulated by the 1-2 solenoid 59 is employed a line pressure from the oil passage 140 bypassing the manual valve 41. When the 1-2 solenoid 59 is turned on, the line pressure is drained to release the pilot pressure. The pilot pressure for the 1-2 shift valve 56 also contains a pilot pressure to be regulated for the 2-3 shift valve 54. That is, the pilot pressure regulated by the 2-3 solenoid 58 also acts as a pilot pressure on the 1-2 shift valve 56 through an oil passage 141.
The 1-2 shift valve 56 is operated by the pilot pressures regulated by the solenoids 58 and 59. Given the pilot pressure to be regulated by the 2-3 solenoid 58 being zero, that is, being drained as the 2-3 solenoid 58 is turned on, the 1-2 shift valve 56 is displaced to left in the drawings to communicate the oil passage 137 with the oil passage 136, when the 1-2 solenoid 59 is turned off and the pilot pressure is converted into a line pressure, thus enabling a supply of the line pressure to the apply side oil chamber 23c of the 2-4 brake actuator 23A. On the contrary, when the 2-3 solenoid 58 is turned off and the pilot pressure for the 2-3 shift valve 54 is converted into line pressure, the resulting line pressure acts on the 1-2 shift valve 56 which in turn is displaced to right in the drawings in order to block the oil passages 137 and 136, regardless of ON/OFF operation of the 1-2 solenoid 59.
COAST EXHAUST VALVE 52
As a pilot pressure for the coast exhaust valve 52 is used a pilot pressure regulated by the 1-2 solenoid 59. For this purpose, the pilot pressure regulated by the 1-2 solenoid 59 is fed to the coast exhaust valve 52 through an oil passage 142.
Table 2 below indicates the relationships of the speed range positions and speed stages with states of operation of the solenoid 58 and 59. It is noted herein that both the solenoid valves 58 and 59 can be turned off in the fourth speed stage in the speed range position "D".
TABLE 2______________________________________Speed Ranges And 1-2 Solenoid 2-3 SolenoidSpeed Stages (59) (58)______________________________________P ○R ○N ○ ○D 1ST ○ 2ND ○ ○ 3RD ○ 4TH ○2 1ST ○ 2ND ○ ○ 3RD ○1 1ST ○ 2ND ○ ○______________________________________ Note: The symbol ○ means that the solenoid is turned on (drained).
LOCK-UP CLUTCH 29
The lock-up clutch 29 is arranged such that it is at a stationary time in a state of being coupled by receiving a pressure from the torque converter 2 and that it is uncoupled when an oil pressure is introduced into the lock-up clutch 29. The lock-up clutch 29 is connected through an oil passage 151 to the lock-up control valve 49 which in turn is communicated through an oil passage 152 with the line pressure passage 101 bypassing the manual valve 41. This structure permits controlling a connection or disconnection of the lock-up clutch 29 or a connection thereof in a halfway state by regulating the pilot pressure of the lock-up control valve 49.
TORQUE CONVERTER 2
The torque converter 2 is communicated through an oil passage 153 with the lock-up control valve 49 which in turn is connected to a converter relief valve 60 through the oil passage 152, thus permitting a pressure in the torque converter 2 to be maintained always constant at the oil passage 152.
OPERATION OF VALVES IN THE OIL PRESSURE CIRCUITS
Shift Valves:
Shifting the speed stages in each of the speed range positions "D", "1" and "2" is effected basically by way of an appropriate ON/OFF operation of the shift valves 58 and 59 as have been indicated in Table 2 above. More specifically, engagement and disengagement of the 2-4 brake 23 is regulated, as shown in Table 1 above, by controlling an application or release of the oil pressure to or from the apply side oil chamber 23c of the actuator 23A for the 2-4 brake 23 by means of the 1-2 shift valve 56 via the 1-2 solenoid 59 or by controlling an application or release of the oil pressure to or from the release side oil chamber 23d thereof by means of the third duty solenoid 45C.
A control of an application or a release of the oil pressure to or from the 3-4 clutch 27 by means of the 2-3 shift valve 54 via the 2-3 solenoid 58 permits a regulation of coupling and uncoupling of the 3-4 clutch 27 as shown in Table 1 above.
Low Reducing Valve 57:
During the speed range position "1", the low reducing valve 57 regulates the oil pressure for coupling the low reducing valve 57 to be maintained at a constant low level.
Reverse Pressure Control Valve 47:
At the time when the speed range is selected from the position "N" to the position "D", the pilot pressure for the reserve pressure control valve 47 is regulated by the second duty solenoid 45B so that the oil pressure for coupling the reverse clutch 24 is regulated to thereby reducing a shock to be caused at that time.
Coast Control Valve 50:
This coast control valve 50 is to ensure a release of the coast clutch 21 during the fourth speed stage. As the pilot pressure for the coast control valve 50 may be used the oil pressure for coupling the 3-4 clutch 27 to be supplied through the oil passage 143 as well as the oil pressure from the release side oil chamber 23d of the 2-4 brake actuator 23A. This arrangement permits the coast control valve 50 to release the oil pressure for coupling the coast clutch 21 by receiving the coupling oil pressure of the 3-4 clutch 27 because the pressure in the release side oil chamber 23d thereof is released during the fourth speed stage where both the 3-4 clutch 27 and the 2-4 brake 23 are coupled. This prevents an internal lock of the planetary gear unit 14, which may be caused in instances where the 3-4 clutch 27 and the 2-4 brake 23 are coupled. Since the oil pressures coupling the 3 -4 clutch 27 and the 2-4 brake 23 are employed as the pilot pressure for the coat control valve 50, as have been described hereinabove, an internal lock at the fourth speed stage can be prevented for sure. This arrangement is also effective as a fail safe function for a secure prevention of an internal lock which may otherwise be coused when the solenoids 58 and 59 are both turned off during the fourth speed stage in instances where there is caused a deviation between a transmission signal and an actual state of the speed stage for the reason of sticking of the coast exhaust valve 52 or for other reasons.
Coast Exhaust Valve 52:
A basic engagement and disengagement of the coast exhaust valve 52 is controlled by the pilot pressure regulated by the 1-2 solenoid 59 as indicated in Tables 1 and 2 above.
The coast exhaust valve 52 ensures a prevention of the internal lock that may temporarily occur at a timing of operation of the 3-4 clutch 27 and the 2-4 brake 23 at the time of upshifting from the second speed stage to the third speed stage. While the 2-3 shift solenoid 58 is turned off to convert the pilot pressure into line pressure and the 1-2 shift valve 56 is held at the second speed stage, the coast exhaust valve 52 is turned on to convert the pilot pressure into line pressure by the pilot pressure (line pressure) of the 1-2 solenoid 59, releasing the oil pressure for coupling the coast clutch 21. Of course, this operation works in the midway of upshifting from the second speed stage to the third speed stage. After the upshifting to the 3rd speed stage was finished, the coast clutch 21 is coupled or engaged again by turning the 1-2 solenoid 59 on. A manner of this regulation will be described in detail hereinbelow.
Forward Control Valve 51:
At the time of shifting the speed range from the range "N" to the range "D", the servo pressure control valve 48 is regulated by the third duty solenoid 45C to adjust the oil pressure of the oil passage 107 and the branch oil passage 107a. If the oil pressure of the oil passage 107a does not reach a predetermined oil pressure, on the one hand, the forward control valve 51 is operated to supply an oil pressure to the forward clutch 20 so as to allow the oil passage 107a to reach the predetermined oil pressure. If the oil pressure of the branch oil passage 107a exceeds the predetermined oil pressure, on the other hand, the line pressure from the oil pressure 122 is supplied to the forward clutch 20 as it is. This arrangement reduces a shock at the time of shifting from the speed range "N" to the speed range "D".
3-4 Pressure Control Valve 46:
At the time of upshifting from the second speed stage to the third speed stage, the 3-4 clutch 27 is coupled at an appropriate pressure in order to prevent a transmission shock or a shock caused at the time of shifting the speed stages. This coupling is effected at an appropriate timing of releasing the 2-4 brake 23 by adjusting the pilot pressure by the second duty solenoid 45B.
At the time of downshifting from the third speed stage to the second speed stage, the oil pressure for coupling the 3-4 clutch 27 is released at an appropriate timing of coupling or engaging the 2-4 brake 23 by regulating the pilot pressure by means of the second duty solenoid 45B in order to prevent a shock to be caused at the time of the downshifting.
Servo Pressure Control Valve 48:
Regulation of the pilot pressure by means of the third duty solenoid 45C permits an adjustment of the oil pressure in the release side oil chamber 23d of the actuator 23A for the 2-4 brake 23 and an adjustment of the oil pressure for coupling the forward clutch 20. The above description on the forward control valve 51 in this section of the specification is incorporated as reference hereto.
When the speed stage is upshifted from the first speed stage to the second speed stage, the oil pressure for coupling is supplied to the apply side oil chamber 23c in the 2-4 brake actuator 23A by the 1-2 shift valve 56. At this time, a transmission shock can be reduced by an adjustment of the oil pressure in the release side oil chamber 23d thereof.
At the time of upshifting from the second speed stage to the third speed stage, the oil pressure for releasing is eventually fed to the release side oil chamber 23d of the 2-4 brake actuator 23A at a timing of coupling or engaging the 3-4 clutch 27 while adjusting the pressure in the release side oil chamber 23d thereof. This prevents a shock that may be caused at the time of upshifting from the second to the third speed stage. That is, although the oil pressure for coupling is supplied to the apply side oil chamber 23c thereof at both the second and third speed stages, the coupling or engagement and the uncoupling or disengagement of the 2-4 brake 23A is switched by shifting a supply and a release of the oil pressure to and from the release side oil chamber 23d thereof. Regulating the oil pressure to be fed to the release side oil chamber 23d thereof by the servo pressure control valve 48 permits a gradual engagement of the 2-4 brake 23, thus preventing a transmission shock which otherwise may be caused at the time of shifting the speed stages.
At the time of downshifting from the third speed stage to the second speed stage, while the oil pressure in the release side oil chamber 23d is adjusted, the oil pressure is eventually released to engage the 2-4 brake 23 at an appropriate timing of releasing the 3-4 clutch 27.
CONTROL AT THE TIME OF SHIFTING:
At the time of shifting between the second speed stage and the third speed stage, the 3-4 clutch 27 and the 2-4 clutch 23 are shifted between a coupled or engaged state and an uncoupled or disengaged state. At this time, shifting the speed stages is conveniently effected via a temporary state of the first speed stage as the lowest speed stage while the coast clutch 21 is uncoupled or disengaged. This can effectively prevent a transmission shock that might be caused at that time.
This will be set forth more in detail on condition that the coast clutch 21 is coupled in the course of shifting between the second speed stage and the third speed stage. At the time of downshifting from the third speed stage to the second stage, on the one hand, the fourth speed stage is temporarily established causing a shock on account of an internal lock if the timing of coupling the 2-4 brake 23 were too early. When the upshifting from the second speed stage to the third speed stage is in the progress, on the other hand, if the timing of coupling the 3-4 clutch 27 were too early, the fourth speed stage is temporarily established in this case, too, causing a shock to arise from an internal lock. Accordingly, if the coast clutch 21 were uncoupled at the time of shifting between the second and third speed stages prior to the coupling or uncoupling of the 2-4 brake 23 and the 3-4 clutch 27, a shock on account of such an internal shock can be effectively prevented.
Even if the coast clutch 21 were disengaged during the time of shifting between the second and third speed stages, a temporary state of the 4th speed stage as have been set forth hereinabove could be caused to arise. In this case, no shock will be caused on account of an internal lock because of the disengagement of the coast clutch 21, but there is the possibility that a shock could be caused to occur by engine braking. This is because, when the fourth speed stage is established temporarily, the number of revolutions on the engine side, viz., on the side of the turbine shaft 13 as an input shaft of the automatic transmission becomes extremely larger than that on the drive shaft side, viz., on the side of the output shaft 28, so that an engine braking action develops, reducing the number of revolutions on the engine side, thus causing a shock. Such an engine braking action can be prevented if a state of the first speed stage could be established in order to take the reverse relationship as performed by the fourth speed stage, that is, in such a manner as the number of revolutions on the input shaft side being smaller than that on the output shaft side.
A detailed description on the control at the shifting between the second speed stage and the third speed stage will be made with reference to the flowcharts indicated in FIGS. 3 and 4. In the following description, symbol "P" denotes a step. Although a transmission control is designed to be made by means of a microcomputer in this embodiment, it is known to use such a microcomputer for controlling the shifting of the speed stages so that a description on a system for the transmission control will be omitted below.
FIG. 3 indicates an instance of upshifting from the second speed stage to the third speed stage. In P1, it is discriminated whether or not the upshifting from the second speed stage to the third speed stage should be effected. If NO in P1, the flow returns and, if YES, the 2-3 solenoid 58 is turned off in P2 to suspend the draining by the 2-3 solenoid 58.
In P3, it is discriminated whether or not a predetermined period of time ΔT1 is elasped after the drain was suspended in P2. This discrimination in P3 is to ensure a state in which the shift valve 54 is retained at a position fixed in a leftward direction in FIG. 2 and the shift valve 56 is retained at a position fixed in a rightward direction. If NO in P3, this discrimation is repeated as it is and, if YES, the 1-2 solenoid 59 is turned off in P4 to suspend the drain by the 1-2 solenoid 59. It is then discriminated in P5 whether or not a predetermined period of time ΔT2 is elasped after the treatment in P4 was finished. This discrimination at P5 is to ensure a state of retaining the coast exhaust valve 52 at a position fixed in the leftward direction in FIG. 2, whereby the disengagement or uncoupling of the coast clutch 21 becomes ensured. If NO at P5, this discrimination is repeated as it was and, if YES, the flow advances to P6.
In P6, the draining by the third duty solenoid 45C is gradually suspended so that the oil pressure in the release side oil chamber 23d of the actuator 23A for the 2-4 brake 23 is gradually raised, thus releasing the coupling of the 2-4 brake 23 gradually. Thereafter, the flow proceeds to P7 in which the drain by the second duty solenoid 45B is gradually suspended, thereby coupling or engaging the 3-4 clutch 27 in a gradual manner.
At this time, with the relationship of the order of regulating the steps P6 and P7 under consideration, the 2-4 brake 23 and the 3-4 clutch 27 are both uncoupled and turned into a temporary state of the 1st speed stage. In this case, a manner of supplying the oil pressure to the apply side oil chamber 23c and the release side oil chamber 23d in the actuator 23A for the 2-4 brake 23 is different from the case shown in Table 1 above.
The flow then advances to P8 and it is discriminated therein whether or not a predetermined period of time ΔT4 has elasped in order to provide a time sufficient for allowing the 3-4 clutch 27 to be fully coupled and the 2-4 brake 23 to be fully uncoupled. Accordingly, if the discrimination at P8 is NO, this discrimination is repeated and, if YES, the flow proceeds to P9 and the draining by the 1-2 solenoid 59 is resumed to couple the coast clutch 21 again. This concludes the upshifting from the second speed stage to the third speed stage.
FIG. 4 indicates an instance of downshifting from the third speed stage to the second speed stage. The basic treatment is substantially the same as in FIG. 3. In P11, it is discriminated whether or not the current timing is appropriate for effecting the downshifting from the third speed stage to the second speed stage. If NO in P11, the flow returns to repeat this discrimination at P11 and, if YES, the flow proceeds to P12 and the drain of the 1-2 solenoid 59 is suspended thereby permitting the disengagement of the coast clutch 21. It is then confirmed in P13 whether there has been elapsed a predetermined period of time ΔT2 sufficient for allowing the coast clutch 21 to be uncoupled. The flow then proceeds to P14.
In P14, the draining by the second duty solenoid 45B is commenced gradually to release the coupling of the 3-4 clutch 27. The flow then proceeds to P15 and the draining by the third duty solenoid 45C is gradually commenced to release the oil pressure for releasing the coupling or engagement of the 2-4 brake 23 in a gradual manner. At this time, a temporary state of the first speed stage is established from the relationship of P14 with P15. Thereafter, it is discriminated at P16 whether a predetermined period of time ΔT4 has passed in order to provide a time enough to allow the oil pressure for releasing the coupling of the 2-4 brake 23 to be fully released. At P17, the draining by the 1-2 solenoid 59 is then resumed (engagement of the coast clutch 21 is resumed) and then a predetermined period of time ΔT5 is allowed to pass at P18. Then, at P19, the draining by the 2-3 solenoid 58 is effected and the 3-4 clutch 27 is uncoupled. This concludes the downshifting from the third speed stage to the second speed stage.
VARIANTS
FIG. 5 illustrates one of variants in the oil pressure circuits according to the present invention. In this embodiment, as shown in FIG. 5, the oil pressure circuit for the coast clutch 21 is modified from that as shown in FIG. 1.
Referring back to FIG. 2, the passage between the manual valve 41 and the coast exhaust valve 52 in the operating oil pressure supply passage for engaging or coupling the coast clutch 21 is shown to be composed of the oil passage 126 extending from the ports "c" of the manual valve 41. The oil passage 127 bypassing the coast exhaust valve 52 and the shifting valve 53 are further disposed in the embodiment as shown in FIG. 2.
Turning now to FIG. 5, the passage between the manual valve 41 and the coast exhaust valve 52 is shown to be composed of an oil passage 137 extending from the ports "a" of the manual valve 41 and a branch oil passage 137b branched from the oil passage 137. In the oil pressure circuit as shown in FIG. 5, the shifting valve 53 is not mounted, and the oil pressure in the oil passage 127 is arranged so as to allow the oil pressure therein to act on the coast exhaust valve 52 as a pilot pressure. The coast exhaust valve 52 which has received the pilot pressure from the oil passage 127 is energized in a direction in which the operating oil pressure from the branch oil passage 137b can be supplied to the coast clutch 21. At the speed range "1", the ports "e" of the manual valve 41 are communicated with the ports "g" thereof for supplying the line pressure, while at the speed ranges "2" and "D", the ports "g" are blocked as have been described in this respect on the manual valve 41 above. Accordingly, as shown in Table 1 above, even at first speed stage, the engagement of the coast clutch 21 is ensured in the speed range "1" while there is formed a state in which the coast clutch 21 is not coupled or engaged in the speed ranges "D" and "2". More specifically, the coast exhaust valve 52 is shifted to a state in which the oil pressure can be supplied for engaging the coast clutch 21 by receiving the pilot pressure controlled by the solenoid 59 for the 1-2 shift valve 56 at the second and third speed stages in the speed ranges "D" and "2" and at the second speed stage in the speed range "1". On top of this, the coast exhaust valve 52 is shifted to a state in which the oil pressure can be fed for engaging or coupling the coast clutch 21 by receiving the original pressure from the ports "e" of the manual valve 41 as pilot pressure at the first speed stage in the speed range "1".
The structure of the oil pressure circuits as shown in FIG. 5 has one of the advantages that the shifting valve 53 can be removed. Another advantage resides in that the operating oil pressure supply passage for the coast clutch 21 can be reduced to only one in common. This prevents a deviation in timings of operation of the coast clutch 21 compared with the case where the operating oil pressure is selectively supplied from different passages. A further advantage is in that the above two advantages can be gained without large modifications on a whole structure of the oil pressure circuit.
It is to be understood that the foregoing text and drawings relate to embodiments of the present invention given by way of examples but not limitation. Various other embodiments are possible within the spirit and scope of the present invention. | The multistage transmission gear mechanism is provided with a first and second coupling means for shifting speed stages, each being of a type operable hydraulically and adapted to allow four speed stages from first to fourth speed stages to be selected in accordance with a combination between a coupled state and an uncoupled state of the first and second coupling means. A third coupling means is further provided for ensuring engine braking.
The second coupling means is engaged or coupled by a first pilot pressure generated by a first solenoid at the second, third and fourth speed stages. The first coupling means is coupled by a second pilot pressure generated by a second solenoid at the third and fourth speed stages. The third coupling means is coupled at the second and third speed stages.
A third solenoid is provided for generating a third pilot pressure which prevails over the first pilot pressure and controls shifting the second coupling means at the third speed stage.
At shifting between the second and third speed stages, the second pilot pressure prevails over the first pilot pressure to being the second coupling means into a state of its shifting being controlled by the third pilot pressure. At this time, shifting the third coupling means is controlled by the first pilot pressure to avoid a temporary engagement of all the three coupling means, thus preventing a transmission shock. | 8 |
This is a continuation in part application of Ser. No. 11/900,583, filed Sep. 13, 2007 now U.S. Pat. No. 7,740,415.
BACKGROUND OF THE INVENTION
1. Technical Field
This device relates to automated digging machines that have been developed to engage, cut and remove manholes found in street environments. Such machines typically cut the interior casing of the manhole in preparation for removal, repair and replacement due to changes in street elevations associated with resurfacing or repair and replacement.
2. Description of Prior Art
Prior art devices of this type have relied on a variety of cutting and removal devices, see for example U.S. Pat. Nos. 4,924,951, 4,968,101, 5,470,131, 6,536,987, 6,709,064 and 6,755,481.
U.S. Pat. No. 4,924,951 claims a manhole cutter for cutting a fixed diameter circular groove of a fixed depth around the surface of a manhole. The cutter is of a continuous ring design with spaced sections having cutting teeth elements.
A vertical asphalt and concrete milling device is illustrated in U.S. Pat. No. 4,968,101 having a large circular cutting drum with continuous teeth along the bottom edge.
In U.S. Pat. No. 5,470,131 a method and apparatus for cutting circular slots in pavements extending about a manhole casing is disclosed in which a self-propelled core cutting device has an open drum shaped cutting blade which is rotated by a hydraulic drive means to engage and cut the surface about an existing manhole.
U.S. Pat. No. 6,536,987 discloses a quick manhole/manhole construction method and related device in which a cutting unit is positioned within the manhole and the cuts using a circular saw for removal thereof.
U.S. Pat. No. 6,709,064 is directed towards a method and device for detaching or cutting an embedded manhole frame that positions a circular cutting saw blade within the manhole so as to cut from the inside the existing hole casing for removal.
U.S. Pat. No. 6,755,481 claims a method for cutting asphalt or concrete around a manhole using a circular offset cutting blade.
SUMMARY OF THE INVENTION
An automatic manhole removing tool for use with a mobile power take-off that cuts and removes a manhole assembly from a street surface for replacement. The tool self-centers and secures within the manhole using adjustable blade elements to cut a circular groove about the manhole and therein remove same. An adjustable manhole engagement assembly provides multiple adjustable engagement arm pairs that engage the manhole frame aligning the cutting tool within the interior casing of the manhole to be removed.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the manhole removing device of the invention.
FIG. 2 is a top plan view thereof.
FIG. 3 is an enlarged partial top plan view of an adjustable cutting arm of the invention.
FIG. 4 is an enlarged side elevational view with portions broken away of a cutting blade of the invention.
FIG. 5 is a side elevational view illustrating a locking alignment assembly.
FIG. 6 is a top plan view of the locking alignment assembly.
FIG. 7 is a cross-section view on lines 7 - 7 of FIG. 6 .
FIG. 8 is a side elevational view with a portion broken away of the manhole removal device with an alternate cutting blade and alternate locking alignment device.
FIG. 9 is a top plan view of an alternate locking alignment assembly.
FIG. 10 is an enlarged side elevational view thereof with portions broken away.
FIG. 11 is an enlarged end elevational view.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings, an improved manhole removal tool 10 of the invention can be seen having a pair of vertically spaced and aligned main support frame disks 11 and 12 secured to a central drive shaft assembly 13 . The upper disk 11 has a reinforced plate 14 with a plurality of interconnection and guide brackets 15 extending between and securing the support frame disks 11 and 12 together. Multiple reinforcement gussets 16 are welded to the reinforcement plate 14 and central drive shaft assembly 13 . A drive and extraction shaft 13 A extends from the shaft assembly 13 . Pairs of oppositely disposed aligned cutting blade mounting arms 17 A, 17 B and 18 A and 18 B are slidably positioned between respective support frame disks 11 and 12 and the respective guide brackets 15 . Each of the mounting arms 17 A and 18 B are of a tubular construction having a plurality of longitudinally spaced and transversely aligned adjustable adjustment apertures A therein with a pair of spaced corresponding apertures A 1 in their respective upper and lower support frame disks 11 and 12 . Locking nut and bolt assemblies 19 are secured therethrough providing for incremental longitudinal adjustment of each of the mounting arms 17 A and 17 B and 18 A and 18 B extending from the respective guide brackets 15 between support frame disks 11 and 12 . Each of the mounting arms 17 A and 17 B and 18 A and 18 B have an apertured mounting flange 20 on the free end thereof.
Cutting blades 21 are secured to the mounting flanges 20 by multiple nut and bolt assemblies 19 A with of each of the blades extending downwardly therefrom with a plurality of hardened cutting teeth 22 which are welded in longitudinally spaced relation to one another on each of the arms oppositely disposed ends thereof as best seen in FIG. 4 of the drawings.
The mounting arms 17 A and 17 B and 18 A and 18 B determines the effective cutting diameter of the attached cutting blades 20 when driven circularly in respect of the diameter of a manhole MH to be removed as seen graphically in FIG. 1 of the drawings and will be described in greater detail hereinafter.
It will be seen that the respective support frame disks 11 and 12 have oppositely disposed reduced edge diameter portions 11 A and 12 A above and below the respective mounting arms 17 A, 17 B and 18 A and 18 B to provide additional adjustment clearance therefore when fully retracted therebetween.
Referring to FIGS. 1 and 2 of the drawings, an integrated leg support assembly 23 for the manhole removal tool 10 when not in use can be seen having multiple annular leg receiving sockets 24 affixed between the frame disks 11 and 12 . Each of the leg sockets 24 are aligned with access openings 25 in the disk 12 and evenly spaced between the respective adjustable cutting blade mounting arm pairs 17 A, 17 B and 18 A and 18 B hereinbefore described.
Tubular leg extension portions 26 of a reduced diameter are slidably secured within the respective sockets 24 by pins P through aligned receiving apertures A inwardly of the respective ends. Leg portion receiving platforms 27 are provided having a ground engagement end plate 28 secured on one end and are positioned and sized so as to telescopically receive the respective leg portions 26 which in combination provide a stable elevated integrated support structure for the manhole removal tool 10 when not in use.
Referring now to FIGS. 5 , 6 and 7 of the drawings, an improved alignment locking assembly 29 can be seen that will be positioned to receive a main support shaft 30 of the drive shaft assembly 13 .
The improved alignment and locking assembly 29 has a main support frame 31 with spaced parallel guide tube pairs 32 and 33 secured on a mounting platform 34 as best seen in FIG. 6 of the drawings. Apertured plates 35 and 36 extend between and are secured to the inner facing tubes 32 A and 33 A of the respective guide tube pairs 32 and 33 .
A pair of movable manhole engagement arm assemblies 37 and 38 are comprises of tubular elements 37 A, 37 B, 38 A and 38 B respectively and are slidably disposed from within respective guide tube pairs 32 and 33 extending in oppositely disposed relation to one another.
Each pair of said tubular elements 37 A, 37 B, 38 A and 38 B are secured to one another adjacent their respective free ends by reinforcing plates 39 and 40 with the plate 39 having a central aperture therein. A threaded adjustment rod 41 extends from and is secured to the respective apertured base plate 39 by a separate mounting plate 39 A. An indexed apertured adjustment disk 42 is threaded on the threaded rod 41 in spaced relation to the mounting plate 39 A. The threaded rod 41 extends through an aperture A in the plate 39 so as to allow rotational adjustment of the disk 42 therealong so as to be positioned against the plate 39 advancing the arm assembly 37 from within the respective guide tube pair 33 .
A locking disk engagement hook 43 is slidably mounted on the plate 39 for selective engagement through the apertured adjustment disk 42 . This allows for longitudinal fixed repositioning of the arm assembly 37 from within the hereinbefore described guide tube pair 33 as indicated in broken lines in FIG. 6 of the drawings.
The corresponding movable manhole engagement arm assembly 38 has a plurality of longitudinally spaced apertures A therein for registration insertion of a locking pin P through a correspondingly selectively aligned aperture A in the guide tube pair 33 so as to effectively lock the engagement arm assembly 38 in a preselected extended position relative to the guide tube pairs 33 as best seen again in FIG. 6 of the drawings.
The tubular elements 37 A, 37 B, 38 A and 38 B of the respective arm assemblies 37 and 38 each have an upstanding adjustable L-shaped manhole engagement tab 44 positioned inwardly from the respective free ends, as best seen in FIGS. 5 and 6 of the drawings. The adjustable engagement tabs 44 are vertically adjustable in height by alignment with registering apertures in adjacent mounting plates 45 positioned on the respective tubular elements with nut and bolt fasteners F as seen in broken lines in FIG. 5 of the drawings.
The engagement tabs 44 extend outwardly with a surface engagement tab portion 45 beyond corresponding perimeter end surface S of the respective tubular elements 37 A, 37 B, 38 A and 38 B which are positioned for engagement with the inner surface of the manhole MH indicated graphically in broken lines in FIG. 6 of the drawings.
The reinforcement plates 39 and 40 that extend between respective arm assemblies are adjacent the engagement tabs 44 with additional support imparted to the respective arm pairs by reinforcement gusset pairs 46 as will be well known and understood by those skilled in the art. Additionally, handles 47 and 48 are provided which are secured to and between the respective tubular elements 37 A, 37 B, 38 A and 38 B for transport and positioning thereof.
In use, the manhole removal tool 10 of the invention is connected to a mobile power equipment (not shown) like a backhoe or Bobcat type loader having hydraulic power take-off which is well known and understood by those skilled in the art. The effective diameter of the cut to be made about the manhole is determined by the multiple cutting blades 20 which are adjusted using the locking nut and bolt assemblies 18 to advance and retract the respective mounting arms 17 A, 17 B, 18 A and 18 B in equal increments.
Referring now to FIG. 8 of the drawings, an alternate offset cutting blade assembly 49 can be seen broken away in which the blade 50 has a right angular offset reinforced portion 51 with a depending surface engagement blade portion 52 extending therefrom. This allows for reduced diameter cuts which may be required in certain environments by reducing the effective diameter of the cutting blades by the proportional offset positioning of the blade 50 in association to that of the respective mounting arm.
In use, the alignment and locking assembly 29 is positioned within an open manhole MH with the movable manhole engagement arm assemblies 37 and 38 are adjusted and locked in place by advancement and rotation of the disk 42 on the corresponding threaded rod 41 with the corresponding perimeter end surfaces S of the arms frictionally engaging the inner surface of the manhole MH, as noted securing same thereto for removal once the surrounding pavement material has been continuously cut. The manhole removal tool is then positioned over the manhole MH and lowered with the drive shaft 13 A extending through a key-shaped opening in the best base plate 39 of the locking and alignment assembly 37 as seen graphically in FIG. 1 of the drawings. The drive shaft 13 A has multiple spaced key ways 52 therethrough with a selectively insertable single key tab 53 .
As the manhole removal tool is rotated by the power take-off (not shown) the respective supporting disks 11 and 12 having the multiple extended cutter assemblies 20 thereon will engage and cut into the street surface SS defining a circular cut of a greater diameter than that of the manhole MH to a predetermined depth. The manhole removal tool 10 then removes the manhole MH and surrounding surface material by retracting the tool 10 and the engagement of the drive shaft key lift tab 53 in non-alignment with the key opening so as to lift the locking and alignment assembly 29 , the manhole MH and associated material thereabout up and outwardly from the street leaving a uniform opening in the street which allows for rebuilding of the manhole MH to its proper height.
Referring now to FIGS. 9 and 10 of the drawings, an alternate alignment and locking assembly can be seen at 54 to address manhole configurations that require the alignment and locking assembly to be wedgeably engaged within the manhole casting.
A pair of oppositely disposed expanding arcuate engagement band assemblies 55 and 56 are adjustably secured to one another extending from the respective free ends of modified tubular extension arm assemblies 57 and 58 as will be described in detail hereinafter.
The arm assembly 57 has arm tubes 57 A and 57 B, each of which have cam roller mounting assemblies 58 A and 58 B on their free ends thereof. A transverse interconnecting support plate 59 with an upstanding apertured flange 60 extends between the tubes 57 A and 57 B adjacent the respective cam roller mounting assemblies 58 A and 58 B.
Correspondingly, the oppositely disposed arm assembly 58 has extending tubes 61 A and 61 B with their own cam roller mounting assemblies 62 A and 62 B extending from their respective free ends.
The arms assemblies 57 and 58 are slidably disposed from within corresponding spaced parallel guide tube pairs 63 and 64 secured to one another in spaced parallel relation with interconnecting ribs 65 and 66 extending therebetween defining a key way fitting 67 therebetween.
The respective cam roller mounting assemblies 57 A, 57 B, 62 A and 62 B have a U-shaped linkage arm 68 that is secured to the corresponding engagement band assemblies 55 and 56 so as to be vertically movable against the respective cam roller assemblies during engagement. The arm assembly 58 is movable from a first retracted position within the guide tube pairs 64 to a second fully extended position and locked by aligned fasteners F therethrough as best seen in FIG. 9 of the drawings.
The arm assembly 57 is incrementally advanced by engagement with an adjustment disk 69 which is rotatably positioned on a threaded rod 70 extending from the spacing rib 65 through the aperture in the flange 60 as hereinbefore described. It will thus be seen that by rotation of the disk 69 , it will advance and engage the flange 60 incrementally extending the arm assembly 57 outwardly from its respective guide tube pairs 63 thus advancing the interlinked band assembly 55 against the inner surface of a manhole MH during use. Once adjustment has been achieved of the arm assembly 57 an offset indexing bar 71 slidably positioned in a bracket on the flange 60 can selectively engages and locks the adjustment disk 69 by registration with the aligned annularly spaced apertured therewithin.
Referring to FIG. 9 of the drawings, the manhole engagement bands 55 and 56 each have a curved center band 55 A and 56 A with apertured ends 55 B and 56 B. Each of the bands accordingly have a pair of arcuately spaced frictional engagement plates 72 and 73 secured thereon for direct engagement with the inside surface of the manhole MH. The curved center bands 55 A and 56 A are adjustably secured together by interengaging threaded adjustment couplings 74 and 75 having apertured bifurcated end brackets 74 A and 75 A on the respective apertured band free ends 55 B and 56 B by pivoted fasteners F therethrough. The adjustable combination allows for manhole insertion and adjustment retention therewithin by expansion compression of the bands by the respective arm assemblies 55 and 56 as hereinbefore described.
Multiple retainment positioning tabs 76 are mounted on the outer surface S of the respective bands 55 A and 56 A allowing the alternate alignment and locking assembly 54 to be positioned initially in the manhole MH before the extension of the respective arm assemblies and interlinked pivoting engagement band assemblies 55 and 56 securely lock the assembly in place within the manhole.
The wedging action will accommodate manhole configurations without internal flanges which would be normally engaged by the primary alignment and locking assembly tubular arm assemblies 37 and 38 as hereinbefore described.
It will be evident from the above description that the alternate alignment and locking assembly 54 will provide centering guidance to the improved manhole removal tool 10 in which the drive shaft 13 A is extended through the key way 67 for guidance and then after surface cutting has occurred around the manhole MH, the repositioning of the drive shaft so as to engage the lift tab 53 within the key way 67 allows for removal of the manhole and associated cut-out of the street surface thereabout by elevation of the removal tool 10 by the mobile power equipment which it is attached (not shown) as previously described and disclosed.
It will thus be seen that a new and novel manhole removal tool 10 of the invention has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications will be made thereto without departing from the spirit of the invention. Therefore I claim: | A device to secure, cut and sequentially remove a manhole from a street environment. The manhole removing device is supported and rotatably driven hydraulically by a mobile operation equipment. A circular disk assembly has adjustable pavement cutters adjustably positioned from there within an inter-related manhole centering and a locking alignment and engagement plate assembly define a one-step cutting and removal of an existing manhole from the street for replacement. | 4 |
This application claims the benefit of U.S. Provisional Application No. 60/674,000, filed Apr. 25, 2005.
BACKGROUND OF THE INVENTION
1. Technical Field
This device relates to knitting needles which are typically elongated cylindrical elements with a pointed and opposing blunt ends used in the process of hand knitting in which yarn is manipulated in interlocking patterns to form integral panels of configured material that can be fashioned into clothing, for example.
2. Description of Prior Art
Prior art devices disclose a variety of knitting needle combinations; see for example U.S. Pat. Nos. 2,507,174, 4,553,410, 5,720,187 and 6,397,640.
In U.S. Pat. No. 2,507,174 a bend type knitting needle is shown having a pair of curved needles interconnected by multiple linked flexible connector.
U.S. Pat. No. 4,553,410 claims knitting needles with a flexible cord interconnect. The needles are of a larger diameter than the cord with a transition connection therebetween.
U.S. Pat. No. 5,720,187 discloses a knitting needle pair with an interconnected small diameter flexible cord therebetween.
U.S. Pat. No. 6,397,640 discloses a pair of knitting needles with elongated channels within from which extend interlinking cord extends.
SUMMARY OF THE INVENTION
A circular knitting needle assembly in which a pair of short, straight needle elements are secured to the oppositely disposed free ends of a flexible cord covered with a resilient synthetic fiber fabric defining a smooth continuous surface of a low frictional co-efficient. The flexible interconnection cord is of an equal diameter to that of the respective needles with an equilateral transition there between.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the knitting needle assembly shown in both solid and broken lines;
FIG. 2 is an elongated partial cross-sectional view of an end portion of the assembly with elements broken away for illustration;
FIG. 3 is an enlarged side elevational view of the knitting needle assembly with portions broken away; and
FIG. 4 is an enlarged side elevational view of one end portion of the assembly completed for use.
DETAILED DESCRIPTION OF THE INVENTION
A circular knitting needle assembly 10 can be seen in FIGS. 1 and 3 of the drawings having a pair of rigid preferably molded needle elements 11 and 12 having respective conical free ends 11 A and 12 A and opposing inner attachment distal ends 11 B and 12 B. The needle elements 11 and 12 are identical which are gripped by the knitter (not shown) during use and used together with yarn (not shown) to perform a singular task well known to those skilled in the art as knitting.
Each of the needle elements 11 and 12 have respective bore openings 13 and 14 formed centrally therein inwardly from their respective distal inner attachment ends 11 B and 12 B as best seen in FIG. 2 of the drawings. The bores 13 and 14 have continuous respective internal sidewalls 13 A and 14 A with a terminal annular end wall surface 13 B and 14 B. The sidewalls 13 A and 14 A have respective tapered end surface positioned at 13 C and 14 C.
A length of flexible resilient elongated cylindrical fabric cord 15 is provided and is covered with a resilient flexible synthetic fabric base material 15 A, such as or similar to Lycra brand having a tight fabric weave to define a smooth low friction contiguous outer surface. The so-configured covered cord 15 having oppositely disposed ends 15 A and 15 B is receivably secured within their respective bores 13 and 14 interconnecting the needle elements 11 and 12 together as best seen in FIG. 1 of the drawings. The covered cord 15 being of an annular dimension equal to that of the needle elements with the respective cord ends 15 A and 15 B secured within the respective bores 13 and 14 indicated by directional arrow in FIG. 2 of the drawings.
It will be noted that the respective tapered end opening portions at 13 C and 14 C and the sidewalls 13 A and 14 A assist in the insertion process of the cord ends 15 A and 15 B that compress during assembly.
Referring now to FIG. 4 of the drawings, the respective cords ends 15 A and 15 B are secured within their respective receiving knitting needle element bores 13 and 14 by inclusion of epoxy adhesive A within the respective bores during insertion.
Once completed, the interconnected needle elements 11 and 12 and covered cord 15 impart a continuous smooth surface which aids in the functionality of the needled assembly 10 by providing an integrated low friction surface. This covered cord 15 also provides a smooth protective transition between the distal needle ends 11 B and 12 B and the cord 15 as best seen at 16 A in dotted lines.
It will be evident that a variety of materials, natural and/or synthetic, may be used to form the needle elements 11 and 12 and it will also be evident from the above description that the interengaging covered cord 15 is preferably made of a fiber configuration or equivalent construction and materials well known within the art.
In this example chosen for illustration, a proportional length of the needle elements 11 and 12 to the interconnecting covered cord 15 are of a ratio of four to one, but be other ratios depending on the properties of the cord 15 material so chosen and the required use venues.
It will thus be seen that a new and novel knitting needle assembly 10 has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made thereto without departing from the spirit of the invention. | A knitting needle assembly for knitting tubular configurations having pairs of oppositely disposed rigid knitting needles interconnected by a flexible member of similar trans-dimensional properties. | 3 |
This patent stems from a continuation application of patent application entitled, MOTION PICTURE DISTRIBUTION SYSTEM, having Ser. No. 08/279,645, and filing date Jul. 25, 1994 now abandoned. The benefit of the earlier filing date of the parent patent application is claimed pursuant to 35 U.S.C. § 120.
BACKGROUND OF THE INVENTION
This invention relates to motion pictures, and more particularly to a motion picture distribution system and method.
DESCRIPTION OF THE RELEVANT ART
Film, as a distribution medium for the motion picture industry, has served the industry well for the past hundred years. The current method of motion picture distribution of shipping duplicate copies of the master copy of a feature property, plus trailers, teasers, cross-plugs, publicity clips, trailer derby prints, product reels, and promotional rough cuts to exhibitors is very expensive in light of modern recording and telecommunications technology. Utilizing electronic technology for distribution presents some technical problems inherent to the electronic standards which this invention proposes to overcome.
Duplication of positive-film copies from a negative-film master, in spite of continuous improvements over the years, can create a noticeable variance between any two duplicate copies. Electronic recording technology is precise and replicates any number of copies with exacting results at a considerable cost savings over film.
Several transmission systems exist which can assure scheduled delivery of a consistently high quality product throughout the world. Some are more economically feasible than others at present, but they utilize a set of standards within which this invention proposes to operate. Delivery by satellite has been proven by the CATV industry and holds great promise for international distribution. Common carrier networks have served the broadcast television industry for many years and, with the advent of fiber optic cable, show tremendous potential.
For domestic U.S. distribution the use of laser disks linked with courier delivery seems the most economical form of delivery at present. This, of course, depends upon the feasibility of electronic projection systems, which are rapidly approaching theatrical display quality, for exhibition.
The MUSE system of high definition television (HDTV) in Japan provides superior vertical and horizontal resolution in addition to excellent color reproduction. The extraordinary high cost of its unconventional equipment plus the extremely wide bandwidth required to deliver the image, however, seem to eliminate this system from consideration. Even scan compression does not improve this system, as that procedure introduces motion artifacts.
Several other HDTV systems exist but their standards are unestablished and untested, and the equipment for their transmission and recording is yet undemonstrated and unproved.
The standard electronic picture suffers from certain problems inherent in the methods used in recording and displaying the electronic image. National Television System Committee (NTSC) artifacts such as chroma crawl, edge flicker (15 Hz), and half-line flicker (30 Hz) have been accepted in the television industry in exchange for various trade-offs, but such artifacts are not acceptable to the motion picture industry. The 4:3 Academy aspect ratio of NTSC cannot carry the full width of wide-screen format motion-picture films.
Attempts to utilize video tape for shooting motion pictures, indeed, for making features for television have not been successful, in spite of the obvious cost savings. The electronic image compares unfavorably with film and presents archival storage problems. The recording format for video has improved enough about every ten years to establish a new standard, driving the old format into obsolescence.
Piracy of film properties through video transfer is a serious problem lacking a technological, preventative film-medium solution. The CATV experience with piracy of the signal of satellite television distribution represents an even greater threat for new-release motion picture distribution. While many methods for encoding have been attempted to prevent unpaid reception of satellite-transmitted signals, an entire industry has arisen for devices which capture and decode these signals so that individuals may view and record the programming without reimbursement to the distributors or the cable systems. This is totally unacceptable to the motion picture industry.
Many in the motion picture industry believe that the extremely long delay in international distribution of feature U.S. films may create the demand for pirated versions and that a system that delivers a timely, high quality product might eliminate the piracy problem.
NTSC standards prescribe 6 MHz of bandwidth per channel for television transmitters and receivers. To meet motion-picture quality standards, a wider bandwidth is required, yet it must fit within the format of laser-disk recording and it should follow the NTSC standards.
SUMMARY OF THE INVENTION
A general object of the invention is a process for transducing a motion picture into a high-quality, wide-screen image suitable for a direct-broadcast-satellite system (DBS) and fiber-optic transmission or laser-disk recording and playback which provides adequate pixel information capable of meeting image quality of 35 millimeter motion-picture distribution prints.
A further object is reduction or elimination of NTSC artifacts, such as half-line flicker (30 Hz), chroma crawl, and edge flicker (15 Hz), while operating within the NTSC standard as much as possible.
Another object of the present invention is a process for encoding standard NTSC horizontally-compressed RGB image inputs into a composite signal which eliminates chroma crawl, edge flicker, and differential phase error.
Another object of the present invention is a process for decoding the composite wideband video signal to present RGB outputs for driving a video display device.
Another object of the present invention is to provide a process for changing the vertical deflection of anamorphic RGB inputs to present the information in the same aspect ratio of the original signal as coded in the vertical interval of the wideband signal.
A still further object of the present invention is to provide a 12 MHz bandwidth tuner to reconstruct decoding of the encoded information.
The present invention, as embodied and broadly described herein, provides an improvement to a motion picture distribution system, thereby providing a high quality motion picture system which has compatibility with a pre-existing NTSC system. The present invention improves horizontal and vertical detail. The improvement to this television system includes a television camera having an anamorphic lens, an encoder, a receiver, and a decoder. The anamorphic lens is connected to the television camera. The television camera must be capable of producing at least 600 pixels per horizontal line an the standard NTSC scanning race. Preferably, the television camera system has a subcarrier frequency of 3.579545 MHz. Alternatively, the improvement to a motion picture distribution system can include a telecine with a spherical lens system, an encoder, a receiver, and a decoder.
The anamorphic lens compresses an entire viewing field into the NTSC standard four to three aspect ratio. The anamorphic lens generates a horizontally-compressed image, which passes through the television camera in compressed-image format. When transducing a horizontally-compressed image from film, a spherical lens system transmits the horizontally-compressed film image through the telecine capturing the horizontally-compressed image in standard television 4:3 format. The signal outputs of the television camera are defined herein to be a horizontally-compressed-image signal, and include a standard NTSC composite output, a standard NTSC component output, and standard NTSC primary color signal RGB outputs.
The encoder is coupled to the television camera or telecine. The encoder encodes the horizontally-compressed-image RGB outputs to a composite-wideband-video signal, i.e., a subcarrier-composite signal with increased bandwidth, with a subcarrier frequency of 7.159090 MHz. The composite-wideband-video signal may be direct broadcast, for example, through a satellite system, or recorded by a recording device which is adapted to the higher subcarrier frequency. Alternatively, the composite-wideband-video signal may be distributed in a 7.159090 MHz format to a cable television system or a fiber-optic system. The composite-wideband-video signal is capable of producing up to 1,000 pixels per scan line with a 12 MHz bandwidth.
Following the receiver, the decoder decodes the signal at the subcarrier-composite signal frequency to generate an RGB wideband signal to be displayed. If an NTSC-compatible television with RGB inputs were connected to the RGB outputs of the decoder then the receiver would display a wideband image in the correct aspect ratio.
The present invention also provides a method for improving the quality of a motion picture distribution system. The method provides compatibility with existing NTSC systems, and also provides an improved horizontal and vertical detail for a high quality motion picture system. The method comprises the steps of imaging with a television camera capable of capturing at least 600 pixels per horizontal line at the standard NTSC scanning rate, and generating a horizontally-compressed image with an anamorphic lens. The method includes the step of converting the horizontally-compressed image to a horizontally-compressed-image signal. The steps further include encoding the horizontally-compressed-image signal as a composite-wideband-video signal, and generating the subcarrier frequency within the external encoder from the television camera as a subcarrier-composite signal.
At the receiver, if an NTSC-compatible television camera were used, then the steps would include decoding the subcarrier-composite signal to generate a RGB signal to be displayed. Additionally, the NTSC-compatible television camera would ordinarily scan a picture of at least a quality similar to that provided 35 millimeter distribution print film quality.
If a high quality receiver were used, then the high quality receiver would detect using the subcarrier-composite signal directly, and receive the entire bandwidth of the encoded-horizontally-compressed-image signal.
Additional objects and advantages of the invention are set forth in part in the description which follows, and in part are obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention also may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention, and together with the description serve to explain the principles of the invention.
FIG. 1 is a system block diagram;
FIG. 2 shows how the horizontally-compressed images from the color camera are processed in the encoder for transmission or recording;
FIG. 3 is a block diagram of the decoder;
FIG. 4 illustrates how an anamorphic lens squeezes an image and how, in the prior art, an anamorphic lens unsqueezes the squeezed image;
FIG. 5 shows various aspect ratios commonly used in motion picture exhibition;
FIG. 6 explains how a coordinate 20:9 Vista Vision aspect ratio image is compressed and recorded on a 4:3 NTSC field;
FIGS. 7A and 7B depict an object captured in one field of a television image frame through a spherical lens in a distant nodal position to capture a certain field of view;
FIGS. 8A and 8B depict an object captured in two fields of a television image frame through an anamorphic system in a different nodal position necessary to capture the same field of view;
FIG. 9 compares the frequency spectrums for a standard NTSC 6 MHz signal and the composite wideband signal of this invention; and
FIG. 10 is a block diagram for generating an NTSC format from the wideband 7.159090 MHz information.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference now is made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals indicate like elements throughout the several views.
The present invention provides a novel process for transducing a motion picture into a high-quality, wide-screen image suitable for a direct-broadcast-satellite system (DBS) and fiber-optic transmission or laser-disk recording and playback. The pixel information meets image quality of 35 millimeter motion-picture distribution prints. NTSC artifacts, such as half-line flicker (30 Hz), chroma crawl, and edge flicker (15 Hz) are eliminated while operating within the NTSC standard as much as possible.
Broadly, a complementary anamorphic optical system is attached to a scanning television camera, or a spherical lens system is attached to a telecine, and the compressed image of the entire field is captured in the standard 4:3 format. The compressed image continues through the camera in the compressed-image format. The signal outputs of the camera or telecine include a standard NTSC composite output, a standard NTSC component output, and standard NTSC primary color signal RGB outputs.
An anamorphic system is used on a television camera in the same manner that an anamorphic system is used in filming motion pictures. The camera is positioned about one-half the distance to the subject, or with zoom lenses is brought to about one-half the focal distance. Moving the television camera closer effectively eliminates the NTSC image artifact known as half-line flicker (30 Hz) by doubling the distance node at which half-line flicker (30 Hz) occurs, and greatly increases vertical resolution because the anamorphic system stretches the vertical optical detail over a greater number of scanning lines.
Standard NTSC horizontally-compressed-image RGB inputs are encoded into a composite signal which eliminates three other video artifacts: chroma crawl, edge flicker, and differential phase error. Standard NTSC horizontally-compressed-image RGB inputs, generated either from television cameras or previously recorded signals, are input into an encoder producing a signal with increased bandwidth. This wider bandwidth signal may be broadcast directly, for example, through a satellite system, or recorded by a recording device adapted to the higher subcarrier clock frequency, or distributed in a 7.159090 MHz format to a CATV system or a fiber-optic system. This composite output is capable of producing up to 1,000 pixels per scan line with a 12 MHz bandwidth.
At the decoder, the composite wideband video signal is decoded to present RGB outputs for driving a video display device. The vertical deflection of anamorphic RGB inputs is transformed to present the information in the same aspect ratio of the original signal as coded in the vertical interval of the wideband signal. By degenerating the vertical deflection amplifier up to 50% of its normal operating height, the geometry area becomes proportional to the height of the screen.
The exemplary arrangement shown in FIG. 1 illustrates an overview of a motion picture distribution system according to the present invention. An anamorphic lens 52 of a selected aspect ratio is attached to a standard NTSC television camera 53, or a standard telecine 54 utilizing a standard spherical lens system is employed. The purpose of the anamorphic lens 52 is to map a wide-aspect-ratio field of view into an NTSC-aspect ratio. Thus, the anamorphic lens 52 modifies the conventional camera, e.g., by replacing the conventional lens, so as to produce a widescreen television signal corresponding to the increased aspect ratio, e.g., 5:3, of a widescreen high definition camera. When a telecine transduces a wide-screen motion picture, the motion picture is already horizontally compressed.
The television camera 53 or telecine 54 transmits horizontally-compressed-image RGB outputs to a wideband, harmonic encoder 56. The harmonic encoder 56 is explained in more detail below with reference to FIG. 2. The composite-wideband-video signal from the wideband, harmonic encoder 56 can be recorded by a recording device 58. The recording device 58 may be a recording or distribution means, such as a laser-disk recorder, capable of recording up to 8 MHz or greater bandwidth. The resultant recording medium 60, such as a laser disk, magnetic tape or digital storage device, may be delivered to an exhibitor.
Alternatively, the composite-wideband-video signal may be direct broadcast by a satellite system 62. The satellite system 62 would be capable of broadcasting up to 8 MHz or greater bandwidth, to a distributor or directly to the exhibitor. The exhibitor operates a 12 MHz tuner 64 which detects and processes the composite-wideband-video signal and records the composite-wideband-video signal on an audio and video wideband recorder/playback device 66, such as a commercial video-cassette recorder, using recording medium 68, such as a video cassette. As is practiced in the video recording arts, the information can be recorded on mass storage devices, optical recording/playback devices, and magnetic recording playback devices. As is also practiced in the video transmission arts, the signal can be transmitted via fiber optics or cable RF transmission.
In the case of the exhibitor who has received recording medium 60, a playback device 70, such as a laser disk player, samples and transmits the composite wideband video signal through a wideband harmonic decoder 72, explained in more detail below and in FIG. 3, to the display device 74. The display device 74 projects the resulting image onto a display screen 75.
In the case of the direct-broadcast, composite wideband signal, the recording medium 68 is sampled by a video and audio recorder/playback device 73 and transmitted through the wideband harmonic decoder 72 to the display device 74 for display of the image on the display screen 75.
In FIG. 2 the horizontally-compressed-image RGB signals from the color television camera 53 or telecine 54 are fed into a standard NTSC RGB matrix system 76, producing the signals Y, Q, and I. The Q signal is passed through a Q-bandpass filter 78, and the I signal is passed through an I-bandpass filter 83, limiting the bandwidth of the I and Q matrixed information, yet producing a bandwidth greater than the prevailing NTSC standard, allowing for greater color pixel detail.
Signal Y passes through delay line 82 increasing the standard NTSC Y-channel delay to be coincident with I and Q balanced modulator outputs. A standard NTSC synchronization-pulse generator 84 produces timing pulses and a subcarrier signal, framing synchronization for the harmonic encoder 56, and produces a sine wave which passes to a subcarrier doubler 86, and to modulator 91 and through 90° phase shift network 90 to modulator 92. The subcarrier doubler 86 increases the modulators' subcarrier rate to 7.159090 MHz, twice the NTSC standard of 3.579545 MHz. The subcarrier doubler 86 also phase inverts the chroma subcarrier into two fields, one 0°, and one 180°, alternatively, at the vertical field rate. Doubling the harmonic of the subcarrier rate changes the color field interlace from 4:1 to 2:1. These phase angles are fed to a phase invertor switch 88 synchronous to the vertical field rate which switches the 7.159090 MHz rate alternatively from 0° reference phase to 180° reference phase to the balanced modulators 91, 92 correcting the differential phase error in transmission which causes color contamination.
The signal R-Y output from modulator 91 and B-Y output from modulator 92 are added in the signal adder 94 to the delayed Y information to produce a composite-wideband-video signal which may be distributed by direct broadcast via a 12 MHz transmitter or recorded by a wideband, recording device.
The color subcarrier frequency is set to 7.159090 MHz and the brightness signal and chrominance signal are interleaved with each other. The frequency bandwidths of the brightness signal and the color difference signals are transmitted in the double-sideband mode. In this manner the brightness signal and chrominance signal have wider frequency bandwidths than those of the NTSC system, so that the horizontal resolution and color reproducibility can be improved materially. By choosing a color subcarrier frequency of 7.159090 MHz, i.e., the second harmonic of the standard NTSC subcarrier, equipment can be designed for the system of the present invention which are easily compatible with existing NTSC-type equipment through the addition of only a few circuits. To convert the typical NTSC encoder described above for use in the system of this invention, it is merely necessary to pass the incoming 3.579545 MHz color subcarrier frequency generated by the conventional equipment through a frequency multiplier which doubles the standard color subcarrier frequency. The resulting carrier signal is then applied to the B-Y modulator through a 90° phase shift circuit. The additional synchronization necessary for the timing of the invertor sequences at the receiving end is provided by a second synchronizing burst at the doubled color subcarrier frequency immediately following the burst produced by a burst generator, e.g. 3.579545 MHz. This second burst, 7.159090 MHz, is produced by a burst generator. The other reference points are at 15 MHz and at 3.579545 MHz which enables the equalizing circuitry to determine a truer frequency equalization curve. The two carrier signals which are modulated by the R-Y and B-Y signals, respectively, are both inverted, though at different rates. Typically, one carrier signal, usually the R-Y channel, may be inverted from line to line while the other is inverted from field to field.
If the source of the composite wideband video signal were the recording medium 60 in. FIG. 1, then the composite wideband video signal of the motion picture is sampled and transmitted by playback device 70 into the wideband harmonic decoder 72.
In FIG. 3 the composite wideband video signal from a playback device enters the wideband harmonic decoder, where the composite-wideband-video signal is input to a synchronization stripper 106, a 7.159090 MHz subcarrier filter 108, and a chroma-bandpass filter 114.
The synchronization stripper 106 strips the synchronization pulse from the composite-wideband-video signal to synchronize the VIT and synchronization information output, genlocking the decoder to the original synchronization timings.
The 7.159090 MHz subcarrier filter 108 removes the subcarrier from the signal, producing a Y signal. This Y signal, in combination with the VIT and synchronization information signal generated from VIT and synchronization generator 110, enters a Y delay line 112.
The chroma-bandpass filter 114 removes the I and Q color portion from the composite wideband video signal and is input to a Q filter 116 and to an I filter 118.
The Q filter 116 limits the signal with appropriate bandwidth for R-Y demodulation, becoming the Q signal. The I filter 118 limits the signal with appropriate bandwidth for B-Y demodulation, becoming the I signal.
The Q signal passes through the R-Y demodulator 120 creating the R-Y signal, and into the matrix decoder 122.
The I signal passes through the B-Y demodulator 124 creating the B-Y signal and into the matrix decoder 122.
A subcarrier oscillator 115 produces timing pulses and a subcarrier signal of 3.579545 MHz, and produces a sine wave which passes to a subcarrier doubler 117 and through 90° phase shift network 119 to the R-Y demodulator 120.
The R-Y signal and the B-Y signal combine with the Y signal in the matrix decoder 122 which outputs the RGB signals containing the wideband information for RGB reproduction in a display device 74.
In a system in which the display device 74 is a single-lens projector, the anamorphic source image can be corrected by passing the compressed image from the display device 74 through a complementary anamorphic lens attached to the display device 74, decompressing the compressed image, as is done routinely in the motion picture industry.
If the display device 74 were a multiple CRT-type projector, then the correction is induced by adjusting the vertical deflection driver in the projector as is done routinely in the motion picture industry.
This aspect ratio transformation reversal can be accomplished by a second anamorphic lens at the optical output of the projector. This is most suitable for an LCD type projector. Alternatively, for a CRT type projector, the aspect ratio transformation can be reversed electronically by adjusting the horizontal or vertical deflector amplifier gain in the projector.
Simultaneous to the generation of the horizontally-compressed-image RGB signals by the television camera 53 or telecine 54 in FIG. 1, an NTSC composite signal of a horizontally compressed image is also generated by the television camera. A pulse may be inserted into the vertical interval of the NTSC composite signal for a standard pan and scan routine which selects that portion(s) of the widescreen image which fits the NTSC standard 4:3 aspect ratio. The NTSC composite signal would then input to a real-time resampling chip to expand or reduce the image dimension using interpolation or decimation, geometrically correcting that part of the compressed image for standard broadcast or video recording.
The wide-screen image of subject 124 in FIG. 4 has been recorded in a horizontally compressed format, using an anamorphic lens 130, on the standard 4:3 aspect ratio optical plane 126. Various aspect ratios in which subject 124 could have been filmed are shown in FIG. 5.
In FIG. 6, subject 128 represents a coordinate image 20 horizontal units wide, i.e., 20 vertical columns, by 9 vertical units deep, i.e., 9 horizontal rows, approximately the aspect ratio of Vista Vision, 2.21:1. The image represented by subject 128 passes through anamorphic lens 130 and is transduced on optical plane 132 in a 4:3 format, with the 9 horizontal rows from subject 128 unchanged in optical plane 132, while the 20 vertical columns have been horizontally compressed by the anamorphic lens system into 12 units of width, resulting in an aspect ratio of 12:9 or 4:3.
In FIG. 7A, a ball 144 is centered in field of view 134 at a positioned distance 136 from a standard, spherical lens 138. The standard, spherical lens 138 focuses the scan lines, shown in FIG. 7B, of Field 1 and Field 2 of a television image frame 142. Field 1 and Field 2 are scanned 1/60 second apart from each other according to NTSC standards. The image of ball 144 has been partially scanned by Line N of Field 1. Precisely 1/60 second later, Line P and Line Q in Field 2 scan the field of view but do not scan any part of ball 144. The series of sequential field scans can continue with the image of ball 144 appearing alternately only in Field 1 of the image frame every 1/60 second, producing the effect known as line flicker to the human eye.
In FIG. 8A, a ball 148 is centered in the same field of view 134, positioned one-half the distance node 136 from a 2:1 anamorphic lens 140 which focuses the scan lines, shown in FIG. 8B, on Field 1 and Field 2 of a television image frame 146. The image of ball 148 represents the same ball depicted as in the image of ball 144 in FIG. 7A. The image of ball 148 is twice as large as the image of ball 144 because the 2:1 anamorphic lens 140 of the camera (not shown) is closer by a factor of 2, and the anamorphic lens 140 is elliptical by a proportion of 2:1 as a result of the anamorphic lens squeezing the horizontal dimension of the diameter in half but leaving the vertical dimension of the diameter unchanged, though doubled in size. Line P and Line Q of Field 2 and Line N of Field 1 all scan the image of ball 148, thus the image of ball 148 appears in both fields during each scan, removing the appearance of half-line flicker to the human eye.
In a situation where the camera position is fixed, the same effect would be obtained by attaching an anamorphic zoom lens to the television camera and doubling the focal length to achieve the same horizontal ratio.
FIG. 9 depicts the frequency spectrums for a standard NTSC 6 MHz signal having a subcarrier frequency of 3.579545 MHz and the composite wideband 12 MHz signal having a subcarrier frequency of 7.159090 MHz of this invention.
The above principle would apply if the television standard were PAL or SECAM.
FIG. 10 illustrates how the present invention may be used with an NTSC standard television camera. The television camera 53 or telecine 54 is connected to the encoder 56. The encoder 56 is coupled to the wideband harmonic decoder 72. The wideband harmonic decoder 72 is coupled to a decimation, scan and 3.579545 MHz NTSC encoding device 183. The television camera 53 or telecine 54, encoder 56 and wideband harmonic decoder 72 operate as previously described. The decimation, scan and 3.579545 MHz NTSC encoding device 183 performs additional functions which are discussed in the following paragraphs.
As shown in FIG. 10 the RGB signals come from the television camera 53 or telecine 54 to encoder 56. A communications channel recording medium or other device may be inserted between the encoder 56 and the wideband harmonic decoder 72. The output of the wideband harmonic decoder 72 is the RGB signals.
The decimation, scan and 3.579545 MHz NTSC encoding device 183 performs three additional functions: geometry correction, horizontal scanning, and re-encoding. The first objective of the decimation, scan and 3.579545 MHz NTSC encoding device is to convert the RGB signals from the wideband harmonic decoder 72 into a format that is compatible with the geometry and format of the standard NTSC signal. A problem arises in that in order to go back to the standard NTSC broadcast signal, the output of the signal from the wideband harmonic decoder 72 has to be corrected to remove the distortion from the anamorphic lens. The decimation, scan and 3.579545 MHz NTSC encoding device 183 corrects the geometry from the anamorphic lens, essentially converting the anamorphic aspect ratio back to a four to three aspect ratio. This can be done by vertically removing pixels from the signal output from the wideband harmonic decoder 72.
The horizontal scanning function of the decimation, scan and 3.579545 MHz NTSC encoding device 183 encodes into a vertical interval information for the standard NTSC, PAL or SECAM audience. More particularly, since the signal from the anamorphic lens requires a wider screen than does a normal NTSC signal, a technical director can direct the scan device to select any four to three portion of the wide screen image for viewing on a standard NTSC, PAL or SECAM receiver. For example, if two people were being interviewed on a screen, in a wide screen scenario both can be observed; in the narrower screen NTSC, PAL or SECAM scenario, however, the technical director can select which subject he wishes to observe through the generation of electronic codes. This function of the decimation, scan and 3.579545 MHz NTSC encoding device is standard to the film industry but represents a new addition to the television industry.
The re-encoding function of the decimation, scan and 3.579545 MHz NTSC encoding device 183 re-encodes the signal output from the wideband harmonic decoder 72 back into a 3.579545 MHz composite NTSC signal for displaying the visual image using an NTSC-compatible television receiver.
It will be apparent to those skilled in the art that various modifications can be made to the motion picture distribution system of the instant invention without departing from the scope or spirit of the invention, and it is intended that the present invention cover modifications and variations of the motion picture distribution system provided they come within the scope of the appended claims and their equivalents. | An improvement to a motion picture distribution system providing a high quality motion picture system compatible with pre-existing NTSC systems and improving horizontal and vertical detail. The improvement includes a television camera having an anamorphic lens, an encoder coupled to the television camera, and a decoder at a receiver. The anamorphic lens can have an aspect ratio of two to one, and compresses an entire motion picture viewing field into the NTSC-standard, four to three aspect ratio, to produce a horizontally-compressed image. The horizontally-compressed image is output from the television camera as a horizontally-compressed-image signal. The encoder encodes the horizontally-compressed-image signal as a composite-wideband-video signal having increased bandwidth, and generates a subcarrier-composite signal. The composite-wideband-video signal may be directly broadcast to a receiver or recorded by a recording device for subsequent transfer to a receiver, if the receiver is NTSC-compatible, the decoder generates a decoded-subcarrier-composite signal for use by the NTSC-compatible receiver. If the receiver includes a high quality system, then the high quality system uses the subcarrier-composite signal directly, demodulating the entire bandwidth of the composite-wideband-video signal to generate a motion picture image having a quality similar to a 35-mm film distribution print. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 164,086, filed July 19, 1971, now U.S. Pat. No. 3,875,215.
BACKGROUND OF THE INVENTION
The compounds of the present invention are substituted phenoxyalkyl quaternary ammonium compounds. Various ether phenoxyalkyl quaternary ammonium compounds have been described by Hey, Brit. J. Pharmacol. 7, 117 (1952); Hey and Willey, Brit. J. Pharmacol. 9, 471 (1954) and U.S. Pat. No. 2,895,995; and by Jones et al., Biochem. J. 45, 143 (1949).
SUMMARY OF THE INVENTION
This invention is directed to quaternary ammonium salt compounds, and to a method and composition utilizing such compounds. More particularly, the invention is concerned with quaternary ammonium salt compounds corresponding to the formula: ##SPC1##
Wherein Y represents amino, loweralkylamino or diloweralkylamino; R 1 and R 2 represent lower alkyl; R 1 and R 2 independently taken together represent an aliphatic hydrocarbon moiety of from 4, to 5, to 6 carbon atoms, which can be substituted with zero, one, or two lower alkyl substituents, R 1 , R 2 and the quaternary nitrogen forming a 5, 6 or 7-membered ring; R 3 represents lower alkenyl, phenacyl, mono-, di or trihalophenacyl, lower alkynyl, substituted lower alkyl, substituted lower alkenyl or substituted lower alkynyl in which such moieties are substituted with one substituent selected from halogen, phenyl, halophenyl, dihalophenyl, trihalophenyl, nitrilo, hydroxy, carboxyalkyl and keto; or R 1 , R 2 and R 3 taken together represent a quinuclidine residue; X 1 and X 2 both represent halogen; A - represents a stoichiometric equivalent quantity of a pharmaceutically-acceptable anion; n represents one of the integers 2, 3 or 4; HX represents a stoichiometric equivalent quantity of a pharmaceutically-acceptable acid; and m represents one of the integers 0 and 1. The quaternary ammonium salt compounds are crystalline solids which are soluble in water, and of varying degrees of solubility in organic liquids such as dimethyl formamide, esters, halohydrocarbons, alcohols and the like.
In the present specification and claims, the term "halogen" is employed with respect to the moieties X 1 , X 2 and R 3 of the above formula to designate one of the halogens chlorine, bromine and iodine, and the term "lower alkyl" is employed to designate lower alkyl of from 1, to 2, to 3, to 4, to 5, to 6 carbon atoms, the term "carboxyalkyl" is employed to designate such moieties containing from 2, to 3, to 4, to 5 carbon atoms. The terms "lower alkenyl" and "lower alkynyl" are employed to designate such moieties containing from 2, to 3, to 4, to 5, to 6 carbon atoms. The terms "pharmaceutically-acceptable anion" and "pharmaceutically-acceptable acid" as herein employed, refer to non-toxic anions or acids employed in quaternary ammonium salt compounds or acid-addition salts thereof. The terms include the acidic or anionic moieties which have no substantial toxicity or detrimental pharmacological effect when a quaternary ammonium salt compound including such an anion is administered to animals at dosages consistent with good pharmacological activity and acids of such moieties. Such pharmaceutically-acceptable anions include non-toxic inorganic anions such as the chloride, bromide, iodide, sulfate, nitrate, bisulfate or phosphate, or organic anions such as the acetate, propionate, succinate, malate, fumarate, glutamate, salicylate, maleate, tartrate or citrate anions, organic sulfonate anions such as the camphorsulfonate, methanesulfonate, benzenesulfonate or toluenesulfonate anions. The methanesulfonate, benzenesulfonate, chloride and bromide anions are particularly useful in the preparation, purification and use of the quaternary ammonium salts of the invention and are preferred pharmaceutically-acceptable anions.
The compounds of the invention are useful in the study of drug effects upon cardiac activity in animals, and have been found to be particularly useful as antiarrhythmic agents. The compounds can be employed in combatting cardiac arrhythmias in animals by administering an antiarrhythmic amount of one or more of the quaternary ammonium salt compounds to an animal. In such use, the compounds are administered internally to the animal to introduce the compound into the animal's cardiovascular system. The compounds can be administered parenterally by intraperitoneal, subcutaneous or intravenous injection, for example, and typically by intravenous injection. In contrast to many known quaternary ammonium compounds, the quaternary ammonium salt compounds of the invention can also be administered to animals via the gastrointestinal tract, typically by oral administration. The compounds have excellent antiarrhythmic activity both therapeutically, in administration to an animal suffering from a cardiac arrhythmia, and prophylactically to protect an animal against the occurrence or recurrence of arrhythmias, typically in an animal subject to arrhythmias.
The terms "arrhythmic", "cardiac arrhythmia" and "arrhythmia" as employed herein refer to irregular cardiac activity characterized by irregular beating of the heart, that is, non-rhythmic heart beat. Such arrhythmias involve substantial departures from the regular, substantially sinus (sinusoidal) normal heart beat. Arrhythmias are generally beyond the normal increased, but still substantially regular, heart beat rate resulting from physical activity. The term is inclusive of the conditions described by terms such as ventricular fibrillation, ventricular tachycardia, atrioventricular nodal beats, auricular flutter, auricular fibrillation or premature ventricular contractions. The terms "arrhythmic animal" and "arrhythmic mammal", as employed in the present specification and claims, mean and refer to animals suffering cardiac arrhythmias. Such arrhythmias can be the result of physiological or pathological conditions. They can also be brought about by physical conditions such as electrical stimulation or physical injury or they can result from pharmacological effects such as the administration of compounds such as digitalis or similar compounds such as ouabain, acetyl strophanthidin, deslanoside C or digitoxin; epinephrine; ergot; chloroform; cyclopropane and the like having cardiac stimulant and arrhythmia-inducing activity or side effects.
In the practice of the method of the invention, a quaternary ammonium salt compound is normally incorporated in a pharmaceutical carrier and the resulting composition is administered internally to an animal. In the present specification and claims, "pharmaceutical carrier" refers to known pharmaceutical excipients which are substantially non-toxic and non-sensitizing at dosage levels consistent with good antiarrhythmic activity. The active ingredient is preferably administered parenterally in the form of liquid injectable solutions or suspensions, and orally in the form of solid compositions which can be prepared by known techniques such as tableting and encapsulation. Suitable pharmaceutical carriers which can be employed for formulating the solid compositions include starch, lactose, glucose, sucrose, gelatin, powdered licorice, malt, rice flour, chalk, silica gel, hydroxyethyl cellulose, hydroxypropyl cellulose, magnesium carbonate, magnesium stearate, carboxymethyl cellulose, and the like and compatible mixtures thereof. The quaternary ammonium compounds can also be formulated as liquid compositions including syrups, elixirs, suspensions and emulsions for oral administration. Among the liquid pharmaceutical carriers which can be employed for orally-administered compositions are ethanol, water, saline, glucose syrup, syrup of acacia, mucilage of tragacanth, propylene glycol, polyethylene glycols, peanut oil, wheat germ oil, sunflower seed oil or corn oil and the like and compatible mixtures thereof. Orally-ingestible compositions can include emulsifying agents such as lecithin, sorbitan trioleate, polyoxyethylene sorbitan monooleate and natural gums such as gum acacia and gum tragacanth, and suspending agents such as polyethylene oxide condensation products of alkylphenols or fatty acids or fatty alcohols, or cellulose derivatives such as carboxymethyl cellulose or hydroxypropylmethyl cellulose. The compositions can also contain sweetening agents such as sucrose, or saccharin, flavoring agents such as caramel, coloring materials, preservatives and the like.
Injectable compositions adapted for parenteral administration such as intramuscular, subcutaneous or, preferably, intravenous injection can be prepared with pharmaceutical carriers which are liquid parenterally-acceptable vehicles, i.e., liquid pharmaceutical carriers which are adapted for use in formulating parenteral preparations and which are substantially non-toxic and non-irritating when administered parenterally at dosages consistent with good antiarrhythmic activity. Representative liquid parenterally-acceptable vehicles include pyrogen-free water, normal saline solutions, Ringer's Injection, Lactated Ringer's Injection, dextrose solutions, ethanol, propylene glycol, liquid polyethylene glycols, fixed vegetable oils such as corn oil, peanut oil or cottonseed oil, ethyl oleate, isopropyl myristate and the like. The injectable compositions can also contain other materials such as preservatives, buffers and the like. Preferred injectable compositions comprise a sterile solution of the quaternary ammonium salt compound in the parenterally-acceptable vehicle. The compositions can be formulated by using conventional procedures such as are described in Remington's Pharmaceutical Sciences, 13th Ed., Chapter 36, Mack Publ. Co., Easton, Pa. (1965).
The selection of the exact pharmaceutical carrier to be employed in any given circumstance can be carried out by routine and conventional range finding operations to arrive at formulations having the desired characteristics of physical form, ease of administration in a desired route, storage stability, etc.
The antiarrhythmic amount of the quaternary ammonium salt compounds to be administered to an animal can vary depending upon such factors as whether or not the animal is suffering from an arrhythmia at the time of administration, the type and severity of arrhythmia exhibited, the method and frequency of administration, the exact anti-arrhythmic effect to be produced, the particular quaternary ammonium salt compounds employed and the species, size, weight, age and physical condition of the particular animal being treated. In general, when the animal is actively exhibiting arrhythmia, it is preferred to administer the compound at an antiarrhythmic dosage rate sufficient to bring about a complete conversion of the arrhythmia to normal sinus cardiac activity. In such operations, the active compound is preferably introduced directly into the cardiovascular system of the animal to provide an antiarrhythmic concentration of the quaternary ammonium salt compound in the cardiovascular system, particularly at the heart. In a convenient procedure, the compound is administered by intravenous injection at an initial antiarrhythmic dosage less than that required to fully convert the arrhythmia to normal rhythm, and the heartbeat of the animal is monitored as the amount of compound administered is gradually increased over a period of minutes until an antiarrhythmic amount sufficient to fully convert the arrhythmia to rhythmic cardiac activity has been administered. It is then preferred to supply the compound in periodic maintenance antiarrhythmic dosages, such administration being either by the same parenteral route, or by administration of larger antiarrhythmic dosages by another route such as orally. The maintenance antiarrhythmic dosage and mode of administration are selected to provide a more-or-less continuous antiarrhythmic concentration of the quaternary ammonium salt compound in the cardiovascular system, such concentration being sufficient to inhibit further arrhythmia. In general, the quaternary ammonium compound can be administered intravenously in initial dosages of from about 0.1 or less to about 15 or more milligrams per kilogram of animal body weight, providing initial antiarrhythmic concentrations in the cardiovascular system. Maintenance dosages can vary widely depending upon a variety of factors such as the time and frequency of administration, the exact compound or compounds employed, the condition, size, age and species of the animal, the route of administration selected, the type of dosage form employed, the type and cause of the arrhythmia, and the length of time during which a maintenance dose is desired. In cases in which there is little or no likelihood of recurrence of arrhythmia once conversion has been brought about, the maintenance dosage can comprise a continuation of the initial intravenous antiarrhythmic dosage for a relatively brief period. When recurrence of arrhythmia is likely, the maintenance dosage can comprise repeated oral administration of an antiarrhythmic amount of the compounds over extended periods. Maintenance dosages can be administered by single or multiple doses provided that the compounds are administered in an antiarrhythmic amount sufficient substantially to alleviate cardiac arrhythmia.
A preferred group of the quaternary ammonium salt compounds comprises the compounds corresponding to the above formula I wherein R 1 and R 2 are both methyl or both ethyl, wherein Y is amino and wherein X 1 and X 2 are both bromine or both chlorine. It is also generally preferable that the moieties R 1 and R 2 together contain from 2 to 6 carbon atoms; that the moiety R 3 contain from 3 to 7 carbon atoms and that R 1 , R 2 and R 3 together contain from 5 to 9 carbon atoms. Other preferred groups of compounds include those wherein Y is amino, R 3 is lower alkenyl or lower alkynyl of 3 to 4 carbon atoms or those wherein R 3 is substituted lower alkyl, lower alkenyl or lower alkynyl of from 2 to 4 carbon atoms substituted with a single bromo, chloro, keto or nitrilo substituent, and those wherein R 3 is benzyl, monohalobenzyl and dihalobenzyl. A further preferred group comprises the compounds corresponding to the above formula wherein n is 2, Y is amino, X 1 and X 2 are bromine, R 1 and R 2 are methyl, and R 3 is lower alkenyl or lower alkynyl of 3 or 4 carbon atoms, and A - is chloride or bromide anion. This latter group of quaternary ammonium salts thus corresponds to the formula ##SPC2##
wherein m, HX and A - have the significance set out above with respect to formula I and R 3 is lower alkenyl or lower alkynyl of 3 or 4 carbon atoms, preferably 2-propynyl, allyl or 2-methylallyl. The preferred compounds of Formula Ia provide excellent antiarrhythmic results of long duration when administered orally or parenterally in relatively low dosages and are particularly preferred for combatting cardiac arrhythmias.
PREPARATION OF THE COMPOUNDS
The quaternary ammonium salt compounds of the invention can be prepared by the reaction of a tertiary amine compound corresponding to formula II ##EQU1## with a substituted organic alkylating agent corresponding to formula III
R'''' -- B III
In the above formulae II and III, one of the substituent moieties R',R", R'", and R"" represents a substituted phenoxyalkyl moiety corresponding to formula IV ##SPC3##
wherein X 1 , X 2 , Y and n all have the significance set out above with respect to formula I; and each of the remaining substituent moieties R', R", R'" and R"" represents a different individual one of the moieties R 1 , R 2 and R 3 as set out above with respect to formula I and B represents a pharmaceutically-acceptable strongly anionic moiety such as halide, alkyl or aryl sulfonate, sulfate or phosphate. Thus the substituted phenoxyalkyl moiety of formula IV can be provided as a substituted phenoxyalkylamine or as a substituted phenoxyalkyl halide, and the R 1 , R 2 and R 3 moieties similarly can be provided by a tertiary amine compound of formula II or by a substituted organic compound of formula IV. Representative tertiary amines which can be employed as starting materials include N-methyl-N-ethyl-N(2-propynyl) amine; dimethyl phenethylamine; N,N-diethyl-N-4-chlorobutylamine; N-2-butenyl dimethylamine; N-allyl-pyrrolidine; picoline, lutidine; quinuclidine; 3,5-dibromo-β-dimethylamino-p-phenetidine; 3,5-diiodo-β-(N-3-nitrilopropyl-N-ethyl)amino-p-phenetidine; 3-chloro-5-bromo-4-[2-(N-2,4,5-trichlorobenzyl-N-methyl amino)propoxy]-N-butyl aniline; N,N-diethyl-N-(2-methylallyl) amine; N-butyl-N-[ 3-(2,5-diiodophenyl)propyl]-N-[3-(2,6-dichloro-4-aminophenoxy)propyl]amine; 3,5-dichloro-4-[3-(N-3-nitrilopropyl-N-methylamino)propoxy]-N,N-dimethylaniline; 3,5-dibromo-4-[β-N-(3-butynyl)-N-methyl amino ethoxy]-N-ethylaniline; N-[β(2-bromo-4-amino-6-iodophenoxy)-ethyl]-N-(2-methylallyl)-N-ethylamine; N-allylpiperidine; 3,5-dichloro-β-(N-isopropyl-N-methyl)amino-p-phenetidine; and 3,5-dibromo-β-(N-3-ketobutyl-N-methyl)amino-p-phenetidine. Representative substituted organic compounds can include propargyl bromide, propargyl chloride, 3,5-dibromo-4-(2-bromoethoxy)aniline; 3,5-dichloro-4-(3-bromopropoxy) N,N-dimethylaniline, β-cyanoethyl tosylate; 1-(2-bromo-6-chlorophenoxy)-(2-bromoethane); propenyl chloride, chlorohexane, methyl bromide, ethylene dibromide, benzyl bromide, 3,4,5-trichlorophenethyl bromide, chloroacetone, 1,4-dichloro-2-butene, butyl bromide, 1-chloro-2-methyl propane, 1-chloro-3-cyanopropane, 1,1,3-trichloropropane, 1-bromo-4-phenylbutane, and 3,4,5-trichlorophenacyl bromide.
The reaction proceeds when the reactants are contacted and mixed, preferably in the presence of an inert organic liquid such as acetonitrile or dimethyl formamide as a reaction medium. In preparing the quaternary ammonium compounds of the invention, the substituted halophenoxyalkyl amine compound of formula II and the organic compound of formula III are selected from such compounds in which the R', R", R'" and R"" moieties are such as to provide the R 1 , R 2 and R 3 moieties desired in the quaternary product. The reaction proceeds readily at temperatures of from about 10° to about 100°C., and is preferably carried out at a temperature from about 25° to about 70°C. The exact proportions of the reactants to be employed are not critical, however the formation of one molar proportion of the quaternary ammonium salt product requires one molar proportion of each of the tertiary amine and substituted organic reactants, and the reactants are preferably employed in such proportions. The reaction of the tertiary amine and organic compound proceeds with the evolution of heat and the production of a quaternary ammonium salt product wherein the anionic moiety is the anionic moiety B of the organic compound of formula III. In those cases in which the product separates as a precipitate in the reaction mixture, the product can be separated by conventional procedures such as filtration, decantation, centrifugation. In cases in which the product does not precipitate from the reaction mixture, the quaternary ammonium salt can be separated by other conventional procedures such as evaporation under reduced pressure, cooling of the reaction mixture and scratching or seeding to induce crystallization, dilution with organic liquids such as ethyl acetate, benzene or butyl acetate or the like. The product can be purified by conventional procedures such as recrystallization and washing.
The anionic moiety A - of the quaternary ammonium salts corresponding to formula I can be varied by conversion of one salt to another by conventional procedures for anion exchange. The exchange can be carried out, for example, by the methathetic reaction of one of the quaternary ammonium salts of the invention with the desired anion in the presence of a cation which forms a methathesis reaction product with the anionic moiety to be replaced, and methathesis reaction product being insoluble in the reaction medium employed for the metathetic reaction. In a convenient procedure a quaternary ammonium halide of the invention is prepared as described above using a reactant corresponding to formula III wherein A is halogen, such as chlorine or bromine. The quaternary ammonium halide is dissolved in aqueous ethanol at room temperature and the solution is mixed with an aqueous solution of an acid supplying the desired anion, e.g., sulfuric acid. The haldie is removed as hydrogen halide by fractional distillation and the methathesis quaternary ammonium salt product is separated and purified by conventional procedures. Alternatively, different anionic moieties can be introduced into the quaternary ammonium salt compounds of formula I by passing an aqueous solution of a compound of formula I through an anion-exchange resin saturated with the anion desired in the product.
In the preparation of the quaternary ammonium salts of the invention wherein R 1 , R 2 and R 3 represent a quinuclidine, pyridine, picoline or lutidine residue, the substituted phenoxyalkyl moiety is conveniently supplied as a substituted phenoxyalkyl halide. The tertiary amine reactant is a substituted nitrogen-containing heterocyclic amine such as quinuclidine, pyridine, α-picoline, 3,4-dimethyl pyridine or the like. The quaternization reaction is conveniently carried out under substantially the conditions described above.
The pharmaceutically-acceptable acid addition salt form of the quaternary ammonium compounds, that is, those quaternary ammonium salts of formula I wherein m is 1, are prepared according to conventional procedures for forming acid addition salts of primary, secondary or tertiary amines. In a convenient procedure, a quaternary ammonium salt corresponding to formula I wherein m is 0 is taken up in a minimal amount of a lower alkanol and the mixture is treated with an excess of the desired pharmaceutically-acceptable acid in ether or dioxane. The salt is separated and purified by conventional procedures.
In a convenient procedure for the preparation of the quaternary ammonium salts of the invention wherein R 1 and R 2 represent lower alkyl, the tertiary amine reactant employed is a substituted 3,5-dihalophenoxy alkylamine corresponding to the above formula II wherein R' and R" represent the R 1 and R 2 lower alkyl moieties as described above with respect to formula I and R'" represents a substituted phenoxyalkyl moiety corresponding to the above formula IV. Such tertiary amine starting materials can be prepared readily by the reaction of a substituted phenoxyalkyl halide with a dialkyl amine by the procedures described in U.S. Pat. No. 3,389,171 or by analogous procedures. The substituted organic compound reactant employed is a compound of formula III above wherein R"" represents R 3 as described with respect to formula I and B represnts halo, alkyl sulfonyl or aryl sulfonyl. In such procedure, the substituted halophenoxyalkylamine is dispersed in an inert organic liquid such as dimethylformamide or acetonitrile, and an equimolar proportion of the organic compound of formula III is added gradually and mixed therewith. The reaction mixture is maintained at a temperature within the reaction temperature range for a period of 1 to 36 hours. In those cases in which the product does not separate from the reaction mixture, the product can be conveniently separated by diluting the reaction mixture with several volumes of ethyl acetate. In those cases in which a crystalline product is not obtained upon dilution with ethyl acetate, the product can be crystallized by treating the ethyl acetate mixture with excess pharmaceutically-acceptable acid, trituration, or crystallization from other organic liquids such as methanol, ethanol, or isopropanol. The product can be purified by conventional procedures such as recrystallization and washing.
DESCRIPTION OF PREFERRED EMBODIMENTS
The following examples are illustrative of the invention.
EXAMPLE 1
3,5-Dibromo-β-dimethylamino-p-phenetidine (25.4 grams; 0.075 mole) is dissolved in 200 milliliters of acetonitrile at room temperature. 2-Methylallyl chloride (6.9 grams; 0.075 mole) is rapidly added dropwise to the solution with stirring, during which time a temperature rise of 3°-4° C. is observed. The reaction mixture is heated at a temperature of 55°-65°C. for 4 hours with continued stirring. Formation of a precipitate is observed in the mixture, beginning about 15 minutes after addition of the 2-methallyl chloride and continuing through the heating period. The reaction mixture is then cooled in an ice bath and filtered. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl-(2-methylally)ammonium chloride product is collected as a filter cake, dried in air and found to melt at 185°-186°C. The product is dissolved in hot isopropanol and the solution treated with activated carbon and filtered. The solution is cooled, whereupon a crystalline solid precipitate forms, and filtered. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl]-dimethyl(2-methylallyl)ammonium chloride product is collected as a filter cake, dried under reduced pressure, and found to melt at 181°-182°C. The structure of the product, corresponding to the formula: ##SPC4##
is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 39.35, 4.98 and 6.64 percent, respectively, as compared with the theoretical contents of 39.2, 4.94 and 6.54 percent, respectively, calculated for the named structure.
EXAMPLE 2
3,5-Dibromo-β-dimethylamino-p-phenetidine (16.9 grams; 0.05 mole) is dissolved in 50 milliliters of dimethyl formamide at a temperature of about 25°C. To this solution is added dropwise with stirring ethyl bromoacetate (9.2 grams; 0.055 mole). During the addition the mixture warms spontaneously to a temperature of about 49°C., and the mixture is cooled to 27°C. prior to addition of the final 2 grams of ethyl bromoacetate. A precipitate forms in the reaction mixture after the addition is complete, and 50 milliliters of additional dimethyl formamide is added. The mixture is stirred for one hour, then held over night at room temperature. The crystalline solid product is collected as a filter cake by suction filtration of the mixture and the filter cake is recrystallized from boiling ethanol. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(ethyl carboxymethyl) ammonium bromide is obtained as a light tan crystalline solid, melting at 187°-188°C. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 33.5, 4.3 and 5.6 percent, respectively, as compared with the theoretical contents of 33.3, 4.2 and 5.6 percent, respectively, calculated for the named structure. The structure of the product is confirmed by infrared spectroscopy and nuclear magnetic resonance analysis.
A second crop of the product is obtained by diluting the dimethyl formamide reaction mixture filtrate with excess ethyl acetate, and collecting the resulting precipitate by filtration. This crop of the product is dried, crystallized from acetonitrile and found to have nuclear magnetic resonance and infrared spectra consistent with the assigned structure, and in excellent agreement with the spectra obtained with the first crop.
EXAMPLE 3
3,5-Dibromo-β-dimethylamino-p-phenetidine (20.3 grams; 0.06 mole) and 2-chlorobenzyl chloride (9.7 grams; 0.06 mole) are dissolved in 200 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 35° C. for about 1 hour and then at ambient temperature overnight with continued stirring. Formation of a precipitate is observed in the mixture, beginning about one hour after initial contacting of the reactants. The reaction mixture is filtered, and the [2-(4-amino-2,6-dibromophenoxy)-ethyl]dimethyl(2-chlorobenzyl)ammonium chloride product is collected as a filter cake, dried in air, and recrystallized from isopropanol. The purified [2-(4-amino-2,6-dibromophenoxy)-ethyl]dimethyl(2-chlorobenzyl)ammonium chloride product is found to melt at 172°-173°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 41.3, 4.3 and 5.8 percent, respectively, as compared with the theoretical contents of 40.9, 4.0 and 5.6 percent, respectively, calculated for the named structure.
EXAMPLE 4
3,5-Dibromo-β-dimethylamino-p-phenetidine (16.9 grams; 0.05 mole) is dissolved in 35 milliliters of dimethyl formamide and the solution is cooled in an ice-bath to a temperature of about 10°C. To this solution is added dropwise with stirring propargyl bromide (6.5 grams; 0.055 mole). During the addition the mixture warms spontaneously to a temperature of about 18°C., and the mixture is cooled to 10°C. prior to addition of the final amounts of propargyl bromide. The mixture is allowed to warm to room temperature then heated at a temperature of 45°C. for 1 hour and diluted with ethyl acetate, whereupon the crystalline solid product separates. The product is separated by filtration of the mixture, recrystallized once from a mixture of isopropanol and ethanol and recrystallized a second time from a mixture of ethanol and ethyl acetate. The [2-(4-amino-2,6-dibromo-phenoxy)ethyl]dimethyl(2-propynyl)ammonium bromide product is obtained as a yellow crystalline solid melting at 166°-168°C. The product is found by combustion analysis to have carbon, hydrogen and bromide contents of 34.5, 3.8 and 52 percent, respectively, as compared with the theoretical contents of 34.2, 3.8 and 52.5 percent, respectively, calculated for the named structure. The structure of the product is confirmed by infrared spectroscopy and nuclear magnetic resonance analysis.
EXAMPLE 5
3,5-Dibromo-β-dimethylamino-p-phenetidine (25.4 grams; 0.075 mole) is dissolved in 200 milliliters of acetonitrile at room temperature. Chloroacetone (7.0 grams; 0.075 mole) is rapidly added dropwise to the solution with stirring, during which time a slight temperature rise is observed. The reaction mixture is heated at a temperature of 55°-65°C. for 4 hours with continued stirring, then cooled in an ice bath and filtered. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(acetonyl)ammonium chloride product is collected as a filter cake, dried in air, and recrystallized from isopropanol. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(acetonyl)ammonium chloride product is obtained as a tan crystalline solid melting at 181°-182°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 36.1, 4.6 and 6.4 percent, respectively, as compared with the theoretical contents of 36.3, 4.5 and 6.5 percent, respectively, calculated for the named structure.
EXAMPLE 6
3,5-Dibromo-β-dimethylamino-p-phenetidine (16.9 grams; 0.05 mole) is dissolved in 35 milliliters of dimethyl formamide at a temperature of about 25°C. Allyl bromide (6.7 grams; 0.055 mole) is added dropwise to the solution with stirring. During the addition the mixture warms spontaneously to a temperature of about 32°C. The mixture is then held overnight at room temperature. The mixture is diluted with a large excess of ethyl acetate, whereupon a yellow amorphous solid separates. The solid product is separated by decantation, washed with ethyl acetate and crystallized by trituration with isopropanol. The product is recrystallized once from hot isopropanol and a second time from an ethanol-ethyl acetate mixture. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(allyl)ammonium bromide product is obtained as a yellow crystalline solid melting at 157.5°-159°C. The product is found by combustion analysis to have carbon, hydrogen and bromide contents of 33.8, 4.2 and 52.0 percent, respectively, as compared with the theoretical contents of 34.0, 4.2 and 52.2 percent, respectively, calculated for the named structure. The structure of the product is confirmed by infrared spectroscopy and nuclear magnetic resonance analysis.
EXAMPLES 7-14
In procedures similar to those employed in Examples 1-6 above, 2,6-dibromo-β-dimethylamino-p-phenetidine is quaternized with appropriate organic alkylating reactants to produce quaternary ammonium salt compounds of the invention. The compounds correspond to formula I above wherein m is zero, Y is amino, n is 2, X 1 and X 2 are both bromo and R 1 and R 2 are methyl. The compounds obtained, identified by the R 3 and A - moieties, and the organic reactants reacted with the said phenetidine compounds are set out in the following table.
__________________________________________________________________________Ex. R.sub.3 A.sup.- Melting Alkylating Point °C. Reactant__________________________________________________________________________7 2-hydroxyethyl bromide 228°-229° ethylenebromohydrin8 3,4-dichlorophenacyl bromide 212°-214° 3,4-dichlorophenacyl- bromide9 phenethyl bromide 209°-210° β-bromoethylbenzene10 3-chloropropen-2-yl chloride 168°-169° 1,3-dichloropropene11 benzyl bromide 198°-199° benzyl bromide12 4-chlorobenzyl chloride 187°-188° 4-chlorobenzyl chloride13 2,4-dichlorobenzyl chloride 172°-173° 2,4-dichlorobenzyl chloride14 3,4-dichlorobenzyl chloride 158.5°-160° 3,4-dichlorobenzyl chloride__________________________________________________________________________
EXAMPLE 15
3,5-Dichloro-β-dimethylamino-p-phenetidine (15 grams) and 2-methylallyl chloride (5.6 grams) are dissolved in 140 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 60°-65°C. for 32 hours and then cooled. The reaction mixture is filtered, and the [2-(4-amino-2,6-dichlorophenoxy)ethyl]dimethyl(2-methylallyl)-ammonium chloride product is collected as a filter cake, washed with acetonitrile and dried. The purified [2-(4-amino-2,6-dichlorophenoxy)ethyl]dimethyl(2-methylallyl)-ammonium chloride product is found to melt at 189°-191°C.
EXAMPLE 16
3,5-Dibromo-β-diethylamino-p-phenetidine (14 grams; 0.038 mole) and 4.85 grams of allyl bromide are dissolved in 140 milliliters of acetonitrile. The mixture is heated with stirring at a temperature of 60°-65°C. for 4 hours, stirred at room temperature overnight, then heated at 60°-65°C. for about 18 hours and cooled. The crystalline product is separated by filtration of the mixture and the [2-(4-amino-2,6-dibromophenoxy)ethyl]diethyl(allyl)ammonium bromide product is obtained as a crystalline solid melting at 205°-207°C.
EXAMPLE 17
3,5-Dibromo-4-(3-dimethylaminopropoxy)aniline (5 grams) and 1.8 grams of allyl bromide are mixed with 30 milliliters of acetonitrile. Crystal formation and a slight temperature rise is observed. The reaction mixture is heated at a temperature of 50°-60°C. for 4 hours with stirring, then held overnight and filtered. The [3-(4-amino-2,6-dibromophenoxy)propyl]dimethyl(allyl)ammonium bromide product is collected as a filter cake, dried in air, and obtained as a buff colored crystalline solid melting at 167°-169°C.
EXAMPLE 18
3,5-Dibromo-β-dimethylamino-p-phenetidine (13.5 grams; 0.04 mole) is dissolved in 150 milliliters of ethyl acetate at room temperature. Cyanomethyl benzenesulfonate (8 grams; 0.04 mole) is added dropwise to the solution with stirring. The reaction mixture is held overnight at room temperature. The reaction mixture is filtered. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-nitriloethyl)-ammonium benzenesulfonate product is collected as a filter cake. The product is taken up in hot acetonitrile and the solution is filtered. The hot filtrate is cooled, whereupon a crystalline solid precipitate forms, and filtered. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-nitriloethyl]ammonium benzenesulfonate product is collected as a filter cake, air dried, and found to melt at 173.5°-175°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 40.6, 3.93 and 7.87 percent, respectively, as compared with the theoretical contents of 40.39, 3.96 and 7.85 percent, respectively, calculated for the named structure.
EXAMPLE 19
3,5-Dibromo-β-dimethylamino-p-phenetidine (25.4 grams; 0.075 mole) is dissolved in 300 milliliters of acetonitrile at room temperature. Allyl methanesulfonate (10.2 grams; 0.075 mole) is rapidly added to the solution with stirring. The reaction mixture is heated at a temperature of 35°-45°C. for 5 hours with continued stirring. Formation of a precipitate is observed in the mixture, beginning about 10 minutes after addition of the allyl methanesulfonate and continuing through the heating period. The reaction mixture is cooled and filtered. The [2-(4-amino-2,6-dibromophenoxy)-ethyl]dimethyl(allyl)ammonium methanesulfonate product is collected as a filter cake, dried, and recrystallized from n-propanol. The product is found to melt at 202°-203°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 35.35, 4.65 and 6.13 percent, respectively, as compared with the theoretical contents of 35.45, 4.68 and 5.91 percent, respectively, calculated for the named structure.
EXAMPLE 20
α,3,5-Tribromo-p-phenetidine (20.2 grams) is dissolved in 150 milliliters of acetonitrile, then mixed with a solution of 6 grams of quinuclidine in 100 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 50°C. for 4 hours and then cooled, and held for 48 hours at ambient temperature. The reaction mixture is filtered, and the [2-(4-amino-2,6-dibromophenoxy)-ethyl] quinuclidinium bromide product is collected as a filter cake, washed with acetonitrile and dried. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl] quinuclidinium bromide product is found to melt at 239°-241°C. The product corresponds to the formula: ##SPC5##
EXAMPLE 21
3,5-Dibromo-β-pyrrolidino-p-phenetidine (15 grams) and allyl bromide (5.25 grams) are mixed in 50 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 60°-70°C. for 4 hours and then cooled. The reaction mixture is diluted with ethylacetate, and the [2-(4-amino-2,6-dibromophenoxy)ethyl] allyl pyrrolidinium bromide product is collected by decantation. The product is taken up in isopropanol, mixed with excess hydrogen bromide in isopropanol and the mixture is cooled and filtered. The 1-[2-(4-amino-2,6dibromophenoxy)ethyl]-1-allyl pyrrolidinium bromide hydrobromide product is found to melt at 211°-213°C.
EXAMPLE 22
In a procedure similar to that described in Example 21, 1-[2-(4-amino-2,6-dibromophenoxy)ethyl]-1-allyl piperidinium bromide hydrobromide, melting at 207°-209°C., is prepared by reacting 17 grams of 3,5-dibromo-β-piperidino-p-phenetidine and 5.75 grams of allyl bromide in 50 milliliters of acetonitrile.
EXAMPLE 23
3,5-Dibromo-β-hexamethyleneamino-p-phenetidine (16.8) grams) and allyl bromide (5.47 grams) are dissolved in 70 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 60°C. for 2 hours and then cooled. The reaction mixture is filtered, and the [2-(4-amino-2,6-dibromophenoxy)ethyl]-1-allylhexahydroazepinium bromide product, corresponding to the formula ##SPC6##
is collected as a filter cake, washed with acetonitrile and dried. The purified product is found to melt at 177°-179°C.
EXAMPLE 24
In a procedure similar to that described above in Example 20, β,3,5-tribromo-p-phenetidine and 3-picoline are reacted together to prepare 1-[2-(4-amino-2,6-dibromo-phenoxy)ethyl]-3-picolinium bromide, melting at 218°-220°C.
EXAMPLE 25
In a procedure similar to that of Example 17, 3,5-dibromo-4'-(4-dimethylaminobutoxy) aniline is reacted with allyl bromide to prepare [4-(4-amino-2,6-dibromophenoxy)-butyl]dimethyl(allyl) ammonium bromide as a pale yellow crystalline solid melting at 184°-186°C.
In procedures similar to those described above in Examples 1-25, the following quaternary ammonium salt compounds are prepared:
1-[3-(4-ethylamino-2,6-dibromophenoxy)propyl]-1-allyl-2-methyl pyrrolidinium bromide hydrobromide;
[4-(4-dimethylamino-2,6-dichlorophenoxy)butyl]-dibutyl(3-butynyl)ammonium methanesulfonate;
1-[2-(4-amino-2,6-diiodophenoxy)ethyl]-3,4-dimethyl pyridinium bromide hydrobromide;
[3-(4-hexylamino-2,6-dichlorophenoxy)propyl]dimethyl-(4-nitrilobutyl)ammonium chloride;
[2-(4-amino-2,6-dibromophenoxy)ethyl]diethyl(3-butenyl)ammonium p-toluenesulfonate;
[2-(4-amino-2,6-diiodophenxoy)ethyl]dimethyl[4-(3,4-dichlorophenyl)butyl]ammonium chloride;
1-[3-(4-ethylamino-2,6-dichlorophenoxy)propyl]-1-(2-propynyl)-hexahydroazepinium chloride hydrochloride; and
[2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(3-keto butyl)ammonium benzenesulfonate.
The following examples further illustrate the invention, particularly as to the use of the compounds in controlling cardiac arrhythmias.
EXAMPLE 26
Ventricular tachycardia is produced in dogs in a method similar to the method of Lucchesi and Hardman (J. Pharmacol. Exptl. Therap., 132, 372, 1961) by the administration of ouabain. In such operations, a dog is anesthetized by the intravenous administration of pentobarbital sodium at a dosage rate of 30 milligrams per kilogram. A femoral artery is cannulated with polyethylene tubing for measurements of blood pressure. A femoral vein is similarly cannulated for administration of ouabain and administration of the test compound. Hypodermic needle electrodes are employed for recording electrocardiograms. In such operations, ouabain is administered intravenously by infusion at a constant rate via the cannulated femoral vein. The infusion rate is 35 micrograms of ouabain per kilogram of animal body weight per hour. Within 1 to 1.5 hours following the start of the infusion, a ventricular tachycardia is seen to develop.
After ventricular tachycardia is observed, a test compound is administered intravenously by administration of varying amounts of a composition comprising 50 milligrams of the test compound as a sterile solution in 10 milliliters of water containing 0.9 percent sodium chloride. Each dose is administered slowly over a period of 15 to 30 seconds. The compound is administered at an initial dosage rate of 0.25 milligram of test compound per kilogram of animal body weight. Blood pressure and electrocardiogram are observed for 5 minutes after administration. When a complete conversion from the arrhythmic condition to normal sinus rhythm is not observed within the 5 minute period, a second dose of 0.50 milligram of the test compound per kilogram is administered by a similar procedure and blood pressure and heartbeat are similarly observed for 5 minutes. When complete conversion of the ventricular tachycardia to normal sinus rhythm is not observed, the dosage is increased two-fold every five minutes until complete conversion is obtained. The animal is then observed and the duration of the period of normal cardiac rhythm produced by administration of the test compound is recorded as the duration of antiarrhythmic activity. The termination of the period of normal activity is marked by the reappearance of ventricular tachycardia or fibrillation as indicated by the electrocardiogram observations. The antiarrhythmic dosage of test compound sufficient to bring about a complete conversion of the cuabain-induced tachycardia, and the duration of the period of normal cardiac activity are set out below.
______________________________________Cmpd. of Conversion Dose DurationEx. No. (Milligrams per Kilogram) in Minutes______________________________________1 0.5 152 1 2.6 2 3.53 1 12.54 0.5 245 1 116 1 67 1 258 16 109 2 3.510 1 311 1 8.512 1 9.513 0.5 414 2 1415 0.5 4.516 2 6.517 1 618 1 419 1 17.5 2 39.020 0.5 121 2 1.522 1 6.523 0.5 3.3 1 7.524 0.5 3825 2 26______________________________________
EXAMPLE 27
The procedure of Example 26 is repeated, employing the compound of Example 1, [ 2-(4-amino-2,6-dibromophenoxy)-ethyl]-dimethyl(2-methylallyl)ammonium chloride, as a test compound. In these operations two groups of three dogs each are administered the test compound intravenously at anti-arrhythmic dosage rates of 1 and 2 milligrams per kilogram after ectopic ventricular rhythms have been established by continuous infusion of cuabain. Complete conversion of the arrhythmias to sinus rhythm is observed in all the dogs, with mean durations of sinus rhythm of 12.7 and 26.5 minutes, respectively, being observed in the groups administered 1 and 2 milligrams of the test compound, respectively, per kilogram.
EXAMPLE 28
[2-(4-Amino-2,6-dibromophenoxy)ethyl]dimethyl-(2-methylallyl)ammonium chloride is employed to alleviate multifocal ventricular arrhythmias induced by administration of n-hexane and epinephrine. In these operations, dogs are anesthetized by intravenous administration of 30 milligrams of pentobarbital sodium per kilogram. Transient ventricular arrhythmias are induced by a modification of the method of Garb and Chenowith, J. Pharmacol. Exp. Ther. 94; 12 (1948) in which the heart is sensitized by intratracheal injection of 0.04 milliliter of n-hexane per kilogram, followed in 15 seconds by rapid intravenous administration of 1-epinephrine bitrate at a dosage rate of 10 micrograms per kilogram. Such procedure produces a transient arrhythmia lasting about 10 seconds. Duration of protection by a test compound is evaluated by repeating the n-hexane and epinephrine challenge periodically and monitoring electrocardiogram and arterial blood pressure. In such operations the above-named quaternary ammonium compound is found to give excellent protection against the arrhythmias when administered intravenously at a dosage rate of one milligram per kilogram, the duration of antiarrhythmic effect lasting about 1 hour. When the same compound is administered at a dosage rate of 2 milligrams per kilogram, the duration of protection is found to be greater than 2 hours.
In similar operations, dosages of 5 to 10 milligrams per kilogram are found to be required to obtain similar antiarrhythmic effects when the known antiarrhythmic agent, quinidine sulfate, is employed as a test compound.
In other operations carried out by procedures similar to that described by Bacaner, American Journal of Cardiology, 21, 504 (1968); the intravenous administration of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl) ammonium chloride to electrically paced dogs is found to provide substantial increases in the threshold for electrically induced ventricular fibrillation.
EXAMPLE 29
An experimental occlusion of the anterior descending coronary artery is produced in dogs according to the method of Harris, Circulation 1, 1318 (1950). Following surgery the animals are given a penicillin-streptomycin preparation and allowed to recover for 18-24 hours. The animals are given 3 milligrams per kilogram of morphine sulfate as an analgetic and sedative to allow handling. Electrocardiograms are recorded both before and after administration of [2-(2-amino-2,6-dibromophenoxy)ethyl]dimethyl-(2-methylallyl)ammonium chloride to the test animals. The incidence of abnormal complexes (premature ventricular contractions and atrioventricular nodal beats) per minute is recorded as a percentage of total beats per minute. In one such operation the test compound is administered by intravenous infusion at rates of 1, 2, 2 and 2 milligrams per kilogram at intervals of 10 to 15 minutes. A marked decrease in heart beat rate is observed with a concomitant decrease in percentage of abnormal beats per minute following the first infusion. Following the last infusion of test compound the heartbeat rate is observed to have decreased from a rate of over 160 beats per minute prior to the first infusion to about 90-100 beats per minute. The incidence of ectopic beats at this time has decreased from a pre-treatment level of 100 percent abnormal beats per minute to below 60 percent, reaching zero (100 percent normal beats) within about 10 minutes after the last infusion. The lower heartbeat rate and low incidence of abnormal beats (generally 0 to 20 percent of the total beats per minute are abnormal) is found to persist for 2 hours following the last infusion of test compound, at which time the experiment is terminated.
In similar operations, the same test compound is infused at dosages of 1, 2 and 4 milligrams per kilogram at intervals over a forty minute period. Prior to infusion the incidence of abnormal beats is 100 percent. Within about eight minutes following the last infusion, a substantially complete conversion to sinus rhythm is obtained. The incidence of abnormal beats is found to remain at zero with occasional brief periods of slight arrhythmia (2-5 percent abnormal beats) for 2.5 hours following the last dosage of the test compound, when recording is terminated. Resumption of recording 215 minutes later indicates that significant anti-arrhythmic effects are still exhibited.
In a similar operation the [2-(2-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl)ammonium chloride is administered orally in gelatin capsules. The test compound is administered in multiple dosages of 30, 30 and 50 milligrams per kilogram over a period of 150 minutes. Periods of reduced frequency of abnormal heart beats are noted beginning 10 minutes after administration of the first dosage of test compound, the second and third doses providing further and more consistent antiarrhythmic effects. Beginning about 25 minutes after the last dose of the test compound is administered the electrocardiogram shows periods in which less than 10 percent of the beats are abnormal interspersed with occasional periods of arrhythmia. Antiarrhythmic effects continue to be observed until the recording is terminated 140 minutes after the last dose of test compound.
EXAMPLE 30
[2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl-(allyl)ammonium bromide is administered to mice intravenously and orally. The animals are thereafter sacrificed and blood and heart tissue analyses are carried out to ascertain the concentration of test compound present. In such operations mice intravenously administered the test compound at a rate of 6 milligrams per kilogram are found to have blood levels of 27 micrograms of test compound per milliliter 10 seconds after injection, 2.1 micrograms per milliliter 3 minutes after injection. Analysis of heart tissue indicates a concentration of 5.5 micrograms of test compound per gram of tissue 10 minutes after injection. Similar analyses are carried out with animals administered 6 milligrams of test compound per kilogram orally. Thirty minutes after oral administration, blood and heart levels of 1.1 and 5.1 micrograms, respectively, of test compound per milliliter of blood or gram of heart tissue, respectively, are found.
Similar operations carried out by administration of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl)-ammonium chloride to rabbits similarly indicate oral absorption of the test compound. Significant blood and heart levels of test compound are detected with both oral and intravenous administration.
EXAMPLE 31
An aqueous solution of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl (2-methylallyl)ammonium chloride is administered orally to several groups of male and female Sprague-Dawley derived rats and male and female Swiss mice (Cox strain). The compound is administered as single oral dosages in varying amounts, and the animals are held to assess toxicity twenty-four hours after administration of the compound. In such operations, the quaternary ammonium compound is found to have an LD 50 of 758 milligrams per kilogram (mg/kg) in the male rats; 725 mg/kg in the female rats, 560 mg/kg in the male mice, and 550 mg/kg in the female mice.
EXAMPLE 32
35 Grams of [2-(4-amino-2,6-dibromophenoxy)ethyl]-dimethyl (2-methylallyl)ammonium bromide is dissolved in 2 liters of sterile normal physiological saline solution. The solution is filtered and filled into 10 cubic centimeter (cc) syringes calibrated to permit injection of the parenteral preparation in 0.5 cc increments. The syringes are individually packaged in containers adapted to maintain sterility and sterilized. The parenteral dosage units are each adapted for parenteral administration of the active compound in increments of about 8.75 milligrams each to a total of 175 milligrams.
Similar parenteral preparations are prepared using 25 grams of [2-(4-amino-2,6-dibromophenoxy)ethyl](ethyl)methyl-(allyl) ammonium methane sulfonate in 1.5 liters of Lactated Ringer's Injection; 40 grams of 1-[2-(4-amino-2,6-diiodophenoxy)ethyl) (2-methylallyl)3,4-dimethylpyrrolidinium bromide hydrobromide in sterile distilled water containing 0.4 percent chlorobutanol preservative; and 10 grams of [3-(4-diethylamino-2,6-dichlorophenoxy)propyl]dimethyl(2-propynyl)-ammonium chloride in 1 liter of Dextrose Injection.
EXAMPLE 33
100 Parts of [3-(4-amino-2,6-dichlorophenoxy)-propyl]dibutyl(3-butynyl)ammonium methanesulfonate and 35 parts of lactose are mixed well with 751 parts of starch. The mixture is filled into gelatin capsules in the amount of 0.4 grams per capsules are suitable for oral administration.
EXAMPLE 34
Tablets are prepared from a granulation comprising 50 parts by weight of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl)ammonium chloride, 100 parts lactose, 3.5 parts magnesium stearate, 170 parts starch, 50 parts microcrystalline cellulose, one part of a polyoxyethylene sorbitan monooleate surface active dispersing agent and 0.4 part of F.D.&C. approved color. The granulation is screened and compressed into tablets weighing about 0.287 gram each to prepare a composition in dosage unit form adapted for oral administration to animals. The dosage units are adapted to be employed in maintenance antiarrhythmic therapy to inhibit recurrence of arrhythmias in animals subject thereto, and prophylactically to animals in preparation for exposure to physical or chemical conditions creating a risk of cardiac arrhythmia. The tablets are administered to animals at the rate of one or two tablets (containing 50 milligrams of active antiarrhythmic agent) per day. | Quaternary ammonium compounds such as [2-(4-amino-2,6-dibromophenoxy)ethyl[dimethyl (allyl) ammonium bromide are prepared by the reaction of a tertiary amine such as 3,5-dibromo-β-dimethylamino-p-phenetidine with a substituted organic compound such as allyl bromide. The quaternary ammonium compounds are useful in alleviating or inhibiting cardiac arrhythmias when the quaternary ammonium compounds, or compositions comprising the same are administered to animals. | 2 |
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